Tooling element and methods for forming and using same

A method for forming a composite structure, the method comprising:

• providing at least one tooling element comprising:
• a flexible sleeve defining an interior cavity, the flexible sleeve comprising a sealable access port extending through the flexible sleeve from the interior cavity to an exterior of the flexible sleeve;
• and
• vacuum-packed tooling particulate disposed within and filling the interior cavity of the flexible sleeve, providing the at least one tooling element including the steps of:
• inserting a rigid support sheet into the interior cavity of the flexible sleeve, in contact with the flexible sleeve, to form and support a tooling face of the flexible sleeve;
• packing the flexible sleeve with the tooling particulate, subsequent to inserting the rigid support sheet, by inserting the tooling particulate into the interior cavity of the flexible sleeve through a sealable access port;
• and
• removing air from the interior cavity of the flexible sleeve through the sealable access port to form the tooling element as a rigid tooling structure;
• supporting at least one composite component by positioning the at least one tooling element in contact with the at least one composite component;
• and
• curing the at least one composite component to form the composite structure.