Tool arrangement for compacting a composite preform assembly comprising a support structure preform and an array of component preforms each extending from the support structure preform and spaced apart along the support structure preform. The tool arrangement comprises a support tool defining a lay-up surface for laying up the support structure preform; a plurality of component moulds, each component mould comprising a pair of blocks configured to cooperate with one another to receive and compact a respective component preform extending from the support structure therebetween, each block having a compaction surface for engaging the component preform and a driving surface.

Systems and methods are provided for forming composite parts. One embodiment is an apparatus that includes a forming tool. The forming tool includes a body, which includes an exterior that defines a shape for forming a laminate that will be cured into a composite part. The body also includes elements of phase change material that provide rigidity to the body below a threshold temperature, and that exhibit a phase change above the threshold temperature causing the body to become pliable. Further, the body includes flexible material that encloses the elements of phase change material.

An additively manufactured mandrel is disclosed, including a plurality of separable segments arranged to form a main body having a first end and a second end, each separable segment connected to adjacent segments. A first plug connected to the first end, and a second plug connected to the second end of the main body are configured to support the main body during a composite curing process.

A substantially air-tight triple seal arrangement along a seam between first and second tool segments comprises inner, middle and outer seals forming first and second substantially air tight vacuum chambers.

The invention relates to a process for producing complex, mould-foamed rigid foam materials, more particularly of poly(meth)acrylimide (P(M)I) cores, preferably of polymethacrylimide (PMI) cores, which may be employed, for example, in carmaking or aircraft construction. A feature of the process is that through use of a particulate core during foam, it is possible to achieve an additional weight saving relative to foam materials or sandwich materials of the prior art.

A molded a product includes a body including a hollow interior region and a plurality of openings in communication between an interior region and an exterior of the body. The body is formed from a resilient material that enables the product to stretch and retract to an original shape without tearing or breaking when removing a first part of a core of a mold from a first portion of the interior region through a first opening of the plurality of openings and a second part of the core of the mold from a second portion of the interior region through at least one of the first opening and a second opening of the plurality of openings, the first and second parts of the core of the mold being larger than each of the plurality of openings.

Methods and apparatuses for electromagnetic support tooling for use in composite part curing are described. In one example, a support tooling, such as a mandrel, includes an elastomeric housing that has ferromagnetic components. The mandrel also has electro-magnetic coils positioned within the elastomeric housing and operable to generate magnetic fields to repel or attract the ferromagnetic components of the elastomeric housing to the electro-magnetic coils. When the ferromagnetic components of the elastomeric housing are repelled by the electro-magnetic coils, the elastomeric housing has a rigid surface state. When the ferromagnetic components of the elastomeric housing are attracted to the electro-magnetic coils, the elastomeric housing is collapsed.

Methods and apparatuses for electromagnetic support tooling for use in composite part curing are described. In one example, a support tooling, such as a mandrel, includes an elastomeric housing that has ferromagnetic components. The mandrel also has electro-magnetic coils positioned within the elastomeric housing and operable to generate magnetic fields to repel or attract the ferromagnetic components of the elastomeric housing to the electro-magnetic coils. When the ferromagnetic components of the elastomeric housing are repelled by the electro-magnetic coils, the elastomeric housing has a rigid surface state. When the ferromagnetic components of the elastomeric housing are attracted to the electro-magnetic coils, the elastomeric housing is collapsed.

An illustrative embodiment of the present disclosure provides a method of manufacturing a composite structure. A composite material having a closed cross-section or a partially closed cross-section is cured to form the composite structure, wherein the composite material is in contact with a foam mandrel assembly when curing begins. A supportive foam mandrel in the foam mandrel assembly is collapsed during curing.

A reusable countertop mold in accordance with the present invention includes at least one mold sheet, but generally a plurality of mold sheets are required to extend about a predetermined portion of a periphery of a floor mounted cabinet. The mold sheet is dimensioned and configured to ultimately form a countertop having a predetermined configuration with predetermined dimensions. The mold sheet includes a relatively thin base portion and a wall portion perpendicular to the base portion. The reusable countertop mold further includes a plurality of fastener recesses in an inner side portion of the base portion, the recesses ultimately allowing fasteners to pass through a countertop substrate and into the floor mounted cabinet, after the base portion has been inserted between the countertop substrate and the cabinet. After a countertop forming material has hardened upon the countertop substrate and the mold sheet, the base portion of the mold sheet is slidably removed from between the countertop substrate and the cabinet, thereby allowing the reusable countertop mold to be reused for another countertop forming project.