Conventional tooling for composite manufacturing is expensive and requires long lead times. 2Phase Technologies, Inc. has created Reconfigurable Tooling Systems (RTS (TM)) that can quickly produce low-cost, lightweight tooling usable in most composite fabrication processes. These systems are based upon a new class of state-change materials that can be cycled from a liquid-like state to a solid state at room temperature with no change in dimensions. This paper describes the use of the tooling and tooling systems for part fabrication, replication, and repair, as well as the production of trapped tooling for applications including filament-winding of structures with precision-located features. This reconfigurable tooling technology enables a completely new approach to many composite manufacturing and repair operations, permitting designs and innovations that previously were difficult or impossible.

Rapid low-cost, reusable tooling systems are being adapted to the repair of composite parts. Capturing a shape within minutes and hardening within hours, repair tooling can be created quickly, as needed, without the storage needs, delays, or cost of traditional tooling. Tools can be used repeatedly in conventional processes or quickly reconfigured.

A new reconfigurable tooling system (RTS) has been developed for single-sided layup of epoxy-matrix prepreg materials. The system uses a new class of materials that can be reversibly transformed from a liquid-like state to a solid state at room temperature with no change in volume. With this system a tool can be created within minutes from a master model, a rapid prototype model or an existing part, and the tool can then be used to manufacture a part using conventional layup and cure processes. If specifications change or the part becomes obsolete, the tool can be partially or completely reconfigured and reused. An engine valve cover was manufactured using the tooling system, and characteristics were measured and found identical to those for the same part manufactured with conventional tooling. This demonstration part confirmed that the system could assume complicated shapes and provide a tooling surface for the conventional fabrication of fiber-reinforced parts with a high degree of dimensional accuracy. In addition, the ability of the technology to extend to high temperatures was confirmed by temperature cycling experiments.