04.02.

2011 Rapid Prototype Composite Tooling

Rapid Prototype Composite Tooling Using CFOAM® Carbon Foam

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.

At Touchstone Research Laboratory, there has been a breakthrough in the development of

inexpensive, off-the-shelf coatings providing dimensionally stable, low coefficient of
thermal expansion (CTE), large (and small) rapid prototypes of carbon fiber reinforced
plastics.

Rapid Prototype Composite Tooling Using CFOAM Carbon Foam

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.

The “rapid prototype” surfacing concept begins with the

application of a filler material to the top layer of the
foam. The filler material has high use temperatures,
suitable compressive strengths, and is easily machined or
sanded. The purpose of the filler material is to fill the
CFOAM pore structure in order to create the base for a
tool surface that will maintain vacuum integrity during
vacuum bagging on the surface.

High-temperature epoxy paint is then applied to the filled

foam surface in a carefully controlled manner in order to
manage the final tolerance that takes into account the
paint thickness. This system can be seen in the
photomicrographs below.

Steps in Making a Rapid Prototype Tool Using CFOAM Carbon Foam

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

We currently offer rapid prototype tools built to order.

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.

Telephone: 304.547.5800 email: CFOAMnfo@trl.com

Voice: (304) 547-5800

Fax: (304) 547-5802
Email: CFOAMinfo@trl.com

CFOAM® is a registered trademark of Touchstone Research Laboratory, Ltd.

CFOAM® products may be covered under the following patents with more patents pending:
6,656,238 - 6,656,239 - 6,689,470 - 6,749,652 - 6,814,765 - 6,833,011 - 6,833,012 -
6,849,098 - 6,860,910 - 6,861,151 - 6,869,455 - 6,899,970 - 7,192,537 - 7,247,368

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