SAMPE Journal - July/August 2021 - 36
FEATURE / 3D PRINTECH TECHNOLOGY
Figure 3. Test tool dimensions (1,106mm x 368mm x 533mm).
Vacuum integrity would be validated with room
temp drop tests over ten minutes (< 25.4 mmHg in
10 min, < 33,8 mbar in 10 min). During the cure,
vacuum is monitored, and several 176°C (350°F)
leak checks were ran during the testing. Leak
checks during every thermal cycle were not ran
since the majority of the testing was ran over night.
Geometry would be validated with a Creaform
Laser Scanner after every 20 cycles.
Tool and Equipment Used
A U-shaped tool with two flat flanges and complex
contour was used for the testing. The tools is
minimally reinforced and built to Airtech design
standards for a tool of this size. Finished face sheet
is two printed beads and is 35.6 mm (1.4 in) thick,
nominally. Reinforcement headers are 20.3 mm
(0.8 in) thick with a contact area of approximately
63.5 mm (2.5 in). Overall tool dimensions were
selected due to autoclave sizing. The tools and its
dimensions can be seen in Figure 3.
Post NC machining, the tool was hand finished
to better than 0.8 Ra (32 Ra) finish. This surface
finish was achieved prior to the application
of sealer. Sealer selected was Chemlease MPP
2180 and the tool was coated with four coats to
manufacturer recommendation. Sealer selected
for the testing was Marbocoat TRE 45 ECO with
2 coats being applied. Materials for seal and
release were selected because of availability.
Standard recommended process by Airtech for
sealing printed mold tools is 4 coats of MPP2180,
3 coats of Zyvax Sealer GP, and 2 coats of Zyvax
Release Ease 2.0. With all of them being applied
per the manufacturer recommendations. Airtech's
Huntington Beach, CA autoclave was used for the
thermal cycling and elevated leak checks. Due to
tool weight, a cart is needed. Available space and
autoclave dimensions are shown in Figure 4.
Dimensional analysis was completed with
a Creaform Laser Scanner. Using the scanner
an optimized mesh was created and then best
fit to tool. The critical surfaces for the analysis
was the U-shaped portion of the tool, with the
other surfaces considered excess. The accuracy
or repeatability for the scanner is ±0.0381 mm
(±0.0015 in).
Figure 4. Tool loaded in autoclave for testing.
36 | SAMPE JOURNAL | JULY/AUGUST 2021
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SAMPE Journal - July/August 2021
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