WO2004069526A1 - Method for fast prototyping of large parts in composite material without molds - Google Patents
Method for fast prototyping of large parts in composite material without molds Download PDFInfo
- Publication number
- WO2004069526A1 WO2004069526A1 PCT/IT2003/000067 IT0300067W WO2004069526A1 WO 2004069526 A1 WO2004069526 A1 WO 2004069526A1 IT 0300067 W IT0300067 W IT 0300067W WO 2004069526 A1 WO2004069526 A1 WO 2004069526A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- production
- prototypes
- thin film
- composite material
- create
- Prior art date
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/56—Coatings, e.g. enameled or galvanised; Releasing, lubricating or separating agents
- B29C33/68—Release sheets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
- B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
- B29C70/342—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using isostatic pressure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
Definitions
- the invention concerns a method for making prototypes in composite material with shapes obtained by automatic milling on light material. It has the aim to drastically reduce costs and time to create prototype parts.
- the method allows to obtain one or more prototypes without the requirement of creating a mold.
- Prototypes are made to verify technical characteristics, design and functional correctness, feasibility of production and assembly and can be used subsequently to create mold to be utilized in production lines.
- Prototypes are particularly important for production of composite material parts and products.
- fast prototyping it is meant all the advanced technologies that can turn an idea of a product into the prototype, in a very short time compared to traditional manual product development.
- Prototypes obtained using traditional fast prototyping techniques have usually mechanical properties of lower quality compared to final production parts and are usually employed only for design validation and dimensional and assembling compatibility testing. These technologies accompanied by high costs per unit of volume are applicable only in specialty fields such as precision mechanics and large production lines in order to spread the elevated cost over very large number of pieces.
- the prototyping here described overcomes the above limitations and makes it possible to obtain in a few days a prototipe starting from the CAD phase without the requirement of manual labour and without the creation of a mold.
- the prototype can be made of the material and with the same mechanical properties of the final piece and thus used for functional tests
- Prototyping systems consist of the creation of the negative of the required shape in any soft homogeneous material which can be machined, such as light metals, wood, MDF, plastic resins, plastic polymeric foams, PVC foams, etc.; the shape is molded from these materials by CNC machining from a 3D CAD drawing.
- the shapes created on soft materials are not suited, however, for the production of a piece, but a number of additional phases are required to harden the surface, pre- finishing, finishing and application of detaching substance, in order to obtain a false mold able to support the deposition of the composite material components.
- the invention described here a thin film is employed to avoid the intermediate phases.
- the film is characterized by a very high elongation ratio, that is it can be stretched without damage up to many times its original area.
- the film is made adhere to the 3D shape created by machining very closely.
- the part is then created directly on the film using the standard composite material techniques.
- the prototype obtained following the above procedure is very low cost calculated to be four to five times lower compared to the currently employed fast prototyping techniques.
- the system can be used for "one-off models as well as the basis to make a mold for production, this latter step using traditional methods.
- the method does not require specialized labour to sculpt dummies, expertise which is very costly and difficult to find nowadays.
- the fast prototyping system consists of the creation of negative shape of the desired part made of a low cost soft and homogeneous material, such as wood, MDF, plastic resins, plastic or polymeric foams, PVC foams, etc., that can be machined; this shape is then generated by CNC milling from a 3D CAD drawing.
- a low cost soft and homogeneous material such as wood, MDF, plastic resins, plastic or polymeric foams, PVC foams, etc.
- the shape is inserted in a vacuum pumped container and covered with a thin film of high degree of elongation material, that is capable of withstanding stretch up to several times its original area.
- the film is made adhere to the machined shape in order to stretch it to follow closely the surface.
- the composite material is formed using the traditional techniques for composite material parts, that is:
- the thin film to be used for the fast prototyping process is chosen so that the surface of the material is smoothed, and it depends on the porous nature of the material as well as roughness deriving from CNC machining; it therefore acts as a surface pre-finish.
- the thin film composition can be chosen to not stick to material used for making the prototype; in this case the film acts as a detaching compound.
- the thin film can be chosen to permanently stick to the material used for making the prototype, in this case the film will be the outer skin of the prototype itself.
- the prototype created with the method described here has the same mechanical properties of the production parts which can be obtained with traditional production methods for composite materials.
- the prototype can in some cases, depending on the material chosen for the machining phase, display a varying roughness, which can be constrained within a maximum thickness by changing material for machining, film material and machining precision; the prototype can be made to have a roughness below the gel-coat layer thickness.
- the final finish of the prototype is then, when required, limited to fine sanding using traditional techniques.
- the figure depicts the method to create the prototype.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
Abstract
Description
Claims
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2003209701A AU2003209701A1 (en) | 2003-02-10 | 2003-02-10 | Method for fast prototyping of large parts in composite material without molds |
PCT/IT2003/000067 WO2004069526A1 (en) | 2003-02-10 | 2003-02-10 | Method for fast prototyping of large parts in composite material without molds |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
PCT/IT2003/000067 WO2004069526A1 (en) | 2003-02-10 | 2003-02-10 | Method for fast prototyping of large parts in composite material without molds |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2004069526A1 true WO2004069526A1 (en) | 2004-08-19 |
Family
ID=32843861
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/IT2003/000067 WO2004069526A1 (en) | 2003-02-10 | 2003-02-10 | Method for fast prototyping of large parts in composite material without molds |
Country Status (2)
Country | Link |
---|---|
AU (1) | AU2003209701A1 (en) |
WO (1) | WO2004069526A1 (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP2388131A1 (en) * | 2010-05-20 | 2011-11-23 | Siemens Aktiengesellschaft | Method of moulding a wind turbine blade using a release film, and said film |
FR3015339A1 (en) * | 2013-12-24 | 2015-06-26 | Plastic Omnium Cie | PREFORMING PLASTIC ASSISTED SEMI-PRODUCT OF MEMBRANES |
Citations (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0036391A2 (en) * | 1980-03-17 | 1981-09-23 | Herbert Schreiber | Process for preparing fibre-reinforced plastic articles, prepreg to be used in the process and the article so prepared |
DE3206905A1 (en) * | 1982-02-26 | 1983-10-27 | Weigel, Angela | Process for producing reinforced components by means of a vacuum and substrate surfaces; autolaminate method |
US4478771A (en) * | 1981-03-12 | 1984-10-23 | Herbert Schreiber | Method of manufacturing fibre-reinforced plastic articles, a prepreg for the manufacture of fibre-reinforced plastic articles and a fibre-reinforced plastic article |
DE3319204A1 (en) * | 1983-05-27 | 1984-11-29 | Weigel, Angela | Process for producing laminated moulds and components using a vacuum |
US4562033A (en) * | 1982-07-24 | 1985-12-31 | Rolls-Royce Limited | Method of manufacturing articles from a composite material |
DE3727926A1 (en) * | 1986-08-27 | 1988-03-10 | Dornier Gmbh | Process for producing moulded parts |
JPH05177704A (en) * | 1992-01-07 | 1993-07-20 | Mitsubishi Paper Mills Ltd | Shaping release material and production thereof |
US5304339A (en) * | 1990-05-23 | 1994-04-19 | Le Comte Adolf | Method for manufacturing a large-sized object of fiber reinforced synthetic resin |
EP1038656A1 (en) * | 1999-03-02 | 2000-09-27 | LS Technologies, Inc. A Pennsylvania Corporation | Vacuum resin impregnation process |
WO2001041993A2 (en) * | 1999-12-07 | 2001-06-14 | The Boeing Company | Double bag vacuum infusion process and system for low cost, advanced composite fabrication |
-
2003
- 2003-02-10 AU AU2003209701A patent/AU2003209701A1/en not_active Abandoned
- 2003-02-10 WO PCT/IT2003/000067 patent/WO2004069526A1/en not_active Application Discontinuation
Patent Citations (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0036391A2 (en) * | 1980-03-17 | 1981-09-23 | Herbert Schreiber | Process for preparing fibre-reinforced plastic articles, prepreg to be used in the process and the article so prepared |
US4478771A (en) * | 1981-03-12 | 1984-10-23 | Herbert Schreiber | Method of manufacturing fibre-reinforced plastic articles, a prepreg for the manufacture of fibre-reinforced plastic articles and a fibre-reinforced plastic article |
DE3206905A1 (en) * | 1982-02-26 | 1983-10-27 | Weigel, Angela | Process for producing reinforced components by means of a vacuum and substrate surfaces; autolaminate method |
US4562033A (en) * | 1982-07-24 | 1985-12-31 | Rolls-Royce Limited | Method of manufacturing articles from a composite material |
DE3319204A1 (en) * | 1983-05-27 | 1984-11-29 | Weigel, Angela | Process for producing laminated moulds and components using a vacuum |
DE3727926A1 (en) * | 1986-08-27 | 1988-03-10 | Dornier Gmbh | Process for producing moulded parts |
US5304339A (en) * | 1990-05-23 | 1994-04-19 | Le Comte Adolf | Method for manufacturing a large-sized object of fiber reinforced synthetic resin |
JPH05177704A (en) * | 1992-01-07 | 1993-07-20 | Mitsubishi Paper Mills Ltd | Shaping release material and production thereof |
EP1038656A1 (en) * | 1999-03-02 | 2000-09-27 | LS Technologies, Inc. A Pennsylvania Corporation | Vacuum resin impregnation process |
WO2001041993A2 (en) * | 1999-12-07 | 2001-06-14 | The Boeing Company | Double bag vacuum infusion process and system for low cost, advanced composite fabrication |
Non-Patent Citations (1)
Title |
---|
PATENT ABSTRACTS OF JAPAN vol. 017, no. 595 (M - 1503) 29 October 1993 (1993-10-29) * |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP2388131A1 (en) * | 2010-05-20 | 2011-11-23 | Siemens Aktiengesellschaft | Method of moulding a wind turbine blade using a release film, and said film |
US9005381B2 (en) | 2010-05-20 | 2015-04-14 | Siemens Aktiengesellschaft | Method of moulding a wind turbine blade |
FR3015339A1 (en) * | 2013-12-24 | 2015-06-26 | Plastic Omnium Cie | PREFORMING PLASTIC ASSISTED SEMI-PRODUCT OF MEMBRANES |
WO2015097397A3 (en) * | 2013-12-24 | 2015-08-20 | Compagnie Plastic Omnium | Membrane-assisted preforming of plastic semi-finished product |
Also Published As
Publication number | Publication date |
---|---|
AU2003209701A1 (en) | 2004-08-30 |
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