TABLE OF CONTENTS The purpose of the bond tool is to transfer the autoclave heat and pressure during cure to yield a dimensionally accurate part. Tooling for composite fabrication is a major up-front non-recurring cost. It is not unusual for a large bond tool to cost as much as $500 000 $1 000 000. Unfortunately, if the tool is not designed and fabricated correctly, it can become a recurring headache, requiring continual maintenance and modifications, and, in the worst-case scenario, replacement. Tooling for composite structures is a complex discipline in its own right, largely built on years of experience. It should be pointed out that there is no single correct way to tool a part. There are usually several different approaches that will work, with the final decision based largely on experience of what has worked in the past and what did not work.
There are many requirements a tool designer must consider before selecting a tooling material and fabrication process for a given application. However, the number of parts to be made on the tool and the part configuration are often the overriding factors in the selection process. It would not make good economic sense to build an inexpensive prototype tool that would only last for several parts when the application calls for a long production run, or vice versa. Part configuration or complexity will also drive the tooling decision process. For example, while welded steel tools are often used for large flat pasts, such as wing...
