SAMPE Journal - November/December 2016 - 7

Feature Article
Practical use of DForm® Fabric Tooling
Prepreg-Epoxy and BMI
J. P. Grigson and K. T. James
Cytec Industrial Materials, Tulsa, OK
Abstract
This paper looks at the development of a new tooling prepreg format that combines the performance of its class leading legacy tooling prepreg
portfolio LTM®, CYFORM® and Duratool®, in a configuration that permits circa four times faster lay-up of material. In this paper we will explore
in more detail how DForm® Fabric Tooling prepreg material compares with conventional tooling prepregs, reviewing time saving opportunities,
skill needs, and other key focus points attributable to laying up with a simple highly conformable tile format. Some examples of tools in service
are included to demonstrate tool surface quality, through thickness quality microsections and cross sectional thickness. In addition, this paper will
review and address some frequently tabled tool design and service questions, such as methods of placing metal bushings and inspection balls into
a DForm® fabric tool (often used for location purposes), spring back (angular rotation), female radii, and tool cycling history expectations.
Introduction
Cytec Industrial Materials developed this new format
of prepreg (DForm®) as an enabling technology for the
manufacture of composite tooling. The manufacture
of accurate, high temperature capable / long cycle
history tooling to support the production of successful
composite structural parts is too often deemed to be
too time consuming for the part manufacturing staff
or considered too risky and hence not undertaken in
the first place. This paper provides an introduction to
this new innovative format and how it addresses part
success which is often directly attributable to correct
tooling choices.
Intended Audience
The information in this paper is targeted at dedicated tool
manufacture shops, composite part manufacturers and
engineers challenged with a tooling need to successfully
execute a composite project. The substantially reduced
build time and skills needed when utilizing DForm® to
realize a fresh look at composite tooling.
Perceived Major Challenges to Creation of a Successful Tool for
Composite Parts
This paper attempts to address some of the perceived
challenges, namely;
* Skill levels necessary to fabricate the tool
* Existing knowledge base and concerns
about successful outcome

* Available time for existing workforce to dedicate
to tool building
* Accuracy demands
* Durability in service
* Acceptable surface finish
* Availability of materials to execute project
What is DForm® Fabric Tooling Prepreg
DForm®
Dform® is a highly conformable tile that utilizes short
fibers to facilitate compliancy in conventional woven
tooling fabrics. In addition the layers are then assembled
into a thick easily formable composite compound that is
mid-plane symmetric with anisotropic properties.
DForm® simply improves the laydown times by taking
established tooling prepregs and re-presenting them in
a user friendly fast deposition format. No fundamental
changes are made to legacy Cytec tooling matrices,
FV% (Fiber Volume) or the fabric architecture that are all
established and proven.
DForm® Matrix Options
Table 1 provides basic overview of matrix nomenclature
and typical in service expectations. Both matrix
options are initially cast, however the unique tough
properties of this BMI matrix chemistry have enabled
subsequent machining possibilities often utilized by tool
manufacturers to hone in fine tolerance.

Table 1. Provides a basic overview of matrix nomenclature.

SAMPE Journal, Volume 52, No. 6, November/December 2016

Table of Contents for the Digital Edition of SAMPE Journal - November/December 2016