Reconfigurable Tooling Systems for Depot Level Parts Repair

Just as it takes a tool to manufacture a part it takes a tool, often an identical tool to repair the part. Reconfigurable tooling systems consist of a state-change material that can be cycled from a liquid-like state to a solid state resembling a ceramic in order to make a tool from an existing part or master model. The state change is accomplished at room temperature without any change in volume. The resulting tool can be used with conventional repair techniques consisting of furnaces, autoclaves, etc., to accomplish the repair of the part or it can be combined with integrated heating and vacuum to become a complete system for parts repair.

Often in a facility, only a limited number of parts can be repaired because of the need to maintain an inventory of unique tools for each part. With a reconfigurable tooling system, a unique repair tool can be created for each use utilizing either a master model or an identical good part. The time to create the tool is on the order of minutes. With the repair complete, the tooling bed can be returned to its liquid-like state within minutes to be used again for another repair.

A project is proposed with the following objectives: 

• Develop reconfigurable tooling systems for fiber reinforced composite parts capable of creating tooling that will accommodate part geometries up to 4’ x 4’ with depth of draw up to 18 inches.
• Provide for integrated heating and vacuum in the processing of repair parts. 
• Demonstrate that the reconfigurable tooling systems can be deployed successfully at a depot level repair facility

NCMS Contact: Steve Hale, (734) 995-2195, stevenh@ncms.org