Low cost prototype tooling

Utilizing off the shelf urethane and epoxy materials, UCAR Composites Inc. (UCI) has successfully developed RapidMold(TM), a new low-cost tooling concept. RapidMold(TM) tooling systems combine low cost, shorter turnaround time and accuracies derived from direct N/C machining. Teals utilizing RapidMold(TM) tooling systems can be tailored for use at room temperature or to a maximum of 176.7 (0) C (350 (0) F) with linear coefficients of thermal expansion ranging from 12.6 x 10(-6) mm/mm K (7.0 in./in (0) F) to 28.8 x 10(-6) mm/mm K (16 x 10(-6) in/in (0) F). Conventional composite curing molds, fiber winding mandrels, master models, assembly fixtures, stretch form dies and trim and drill fixtures can easily be adapted to the RapidMold(TM) tooling system concept. Fabricated from a steel eggcrate backup structure, large sizes can be fabricated with minimal distortion. Fabrication details and examples will be shown to highlight this new method.