Patent ID: 8088317

Claim:
A method of producing a composite part of an aircraft, comprising in sequence: manufacturing a low-temp male mold from a material selected from the group consisting of a soft plastic and a foam, the material permanently deforming at or below an upper limit temperature that is no greater than 180° F., using computer numerically controlled machining; adding a plurality of composite layers to the male mold to create a female tool and at least partially curing the female tool at a primary cure temperature below the upper limit temperature, while at least a portion of the female tool is coupled to at least a portion of the male mold; separating at least the portion of the female tool from the portion of the male mold; curing the female tool at a secondary cure temperature above the upper limit temperature; depositing a first composite material on the female tool, in a freestanding fashion, to create the composite part; and hand touching up the composite part to meet a specification.