Method and material efficient tooling for continuous compression molding

A continuous compression molding fabrication line for performing a continuous process for forming a part using a lay-up of composite laminate plies, the continuous compression molding fabrication line comprising:

• a pre-forming zone configured to receive sheet members of composite material, the pre-forming zone further configured to align and apply pressure to the sheet members;
• a consolidation station configured to receive preformed sheet members from the preforming zone, the consolidation station comprising a heater that heats the preformed sheet, followed by a plurality of tool dies individually mated with tool members having outer surfaces engaged by the plurality of tool dies and configured to compress heated preformed sheet members, followed by a cooling zone comprising a cooler configured to cool compressed heated preformed sheet members, and wherein the consolidation station has a first length;
• and
• tooling around which the sheet members are attached, the tooling initially connected to the pre-forming zone, the tooling configured to be drawn through the pre-forming zone and then through the consolidation station, the tooling further configured to reduce an amount of material required to manufacture the part, wherein the tooling is configured to reduce the amount of material required to manufacture by having:
• a body having first and second ends,
• the body including a recessed area,
• the first and second ends of the body extending beyond the recessed area;
• and
• a second length of the second end being greater than or equal to the first length of the consolidation station through which the tooling is configured to pass during operation of the continuous compression molding fabrication line.

A continuous compression molding fabrication line for performing a continuous process for forming a part using a lay-up of composite laminate plies, the continuous compression molding fabrication line comprising:

• a pre-forming zone configured to receive sheet members of composite material, the pre-forming zone further configured to align and apply pressure to the sheet members;
• a consolidation station configured to receive preformed sheet members from the preforming zone, the consolidation station comprising a heater that heats the preformed sheet, followed by a plurality of tool dies individually mated with tool members having outer surfaces engaged by the plurality of tool dies and configured to compress heated preformed sheet members, followed by a cooling zone comprising a cooler configured to cool compressed heated preformed sheet members, and wherein the consolidation station has a first length;
• and
• tooling around which the sheet members are attached, the tooling initially connected to the pre-forming zone, the tooling configured to be drawn through the pre-forming zone and then through the consolidation station, the tooling further configured to reduce an amount of material required to manufacture the part, wherein the tooling is configured to reduce the amount of material required to manufacture by having:
• a body having opposite first and second ends, the body being elongate,
• the body having at least one recess,
• the first and second ends of the body extending respectively beyond opposite ends of the at least one recess and having outside surfaces forming an extension of a profile of the part when the lay-up is compressed into a shape of the part, and wherein a second length of the second end is greater than or equal to the first length of the consolidation station through which the tooling is configured to pass during operation of the continuous compression molding fabrication line.

A continuous compression molding fabrication line for performing a continuous process for forming a part using a lay-up of composite laminate plies, the continuous compression molding fabrication line comprising:

• a pre-forming zone configured to receive sheet members of composite material, the pre-forming zone further configured to align and apply pressure to the sheet members;
• a consolidation station configured to receive preformed sheet members from the preforming zone, the consolidation station comprising a heater that heats the preformed sheet, followed by a plurality of tool dies individually mated with tool members having outer surfaces engaged by the plurality of tool dies and configured to compress heated preformed sheet members, followed by a cooling zone comprising a cooler configured to cool compressed heated preformed sheet members, and wherein the consolidation station has a first length;
• and
• tooling around which the sheet members are attached, the tooling initially connected to the pre-forming zone, the tooling configured to be drawn through the pre-forming zone and then through the consolidation station, the tooling further configured to reduce an amount of material required to manufacture the part, wherein the tooling is configured to reduce the amount of material required to manufacture by having:
• an elongate body having a leading end, a central section, and a trailing end, in which a second length of the leading end of the tool is greater than or equal to the first length;
• and
• at least one recess positioned within the central section,