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Introduction
As the world moves faster and parts are developed via computer aided design, the old
methods of building masters (plugs) and pulling parts has become too slow and costly.
Designers want to go from a CAD file to a composite part as fast as possible.
Touchstone is currently developing several processes to apply tooling surfaces to CFOAM carbon foam that are suited for prototype tools designed to
make less than ten parts. It is an inexpensive process that can be manufactured quickly.
1. BLOCK AND MACHINE: First, panels of CFOAM are bonded together and
machined to within 0.004" of the desired final geometry of the tool.
2. FILL AND CURE: The filler coat is then applied to the surface of the machined
foam with a squeegee and adds no measurable thickness when applied and
prepared properly. The picture below shows a tool that has been filled. An oven cure
in excess of 350° F is typically performed. A second coating of filler materials could
be applied and oven cured if required.
Another optional process for applying a different filler material is to apply it very
liberally over the entire surface of the machined tool, cure it at room temperature
within an hour while the tool is on the mill, and then re-machining the tool to the
finish dimensions. This eliminates hand work and the filler provides a very hard
surface.
3. PRIMER COATING: After the filler material has been completely smoothed,
consistent with the CFOAM carbon foam surface by hand or via machining, a primer
coating is applied by either spraying or rolling. The primer used is typically part of a
two part epoxy paint that has use temperature of 400° F (204° C). The primer coating
fills any remaining porosity in the filled CFOAM surface.
After the primer coat is applied, the surface is ready for the second coat of the two part epoxy paint.
Below are two examples of completed rapid prototype tools with both coats of the two part epoxy paint system. The tool on the left shows the masking
paper on the edges. The paint system adds approximately 0.004” to the surface of the tool.
To date, the rapid prototype tooling surfaces used at Touchstone have been used to successfully cure composite parts when the tool was vacuum
bagged to a flat table, or the entire tool was envelope bagged.
Touchstone has a development plan to expand the robustness of the rapid prototype surfaces for autoclave processes and to achieve a vacuum integral
surface.
What We Offer
In addition, Touchstone can manufacture a rapid prototype tool and pull a part. If the part is acceptable, Touchstone can machine away the
prototype surface and replace it w ith a durable rate tool surface.
We also supply CFOAM carbon foam either in panels or machined to shape for our customers to build their own tools.
Although our customers are always trying something new, we will provide the best advice we can offer and we do offer on-site consulting and
assistance in dev eloping new composite tooling specifically for your special needs.
For more information about our Rapid Composite Tooling, please call or email us for a prompt response.
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