Rapid tooling using meltable substrate and electrodeposition

A method of manufacturing an aircraft assembly tool, the method comprising:

• forming a soluble substrate into a model that corresponds with a shape of the aircraft assembly tool and that includes one or more hollow segments exposed through an outer surface of the model, and wherein the soluble substrate is integrated with an electrically conductive material;
• electrodepositing metal onto the outer surface of the model to form a metal frame having the shape of the aircraft assembly tool, the metal frame having one or more holes corresponding with the one or more hollow segments of the model;
• and
• dissolving the model to remove the soluble substrate and the electrically conductive material from the metal frame via the one or more holes to form a hollow metal tool having the shape of the aircraft assembly tool.

A method for forming a tool comprising:

• shaping a substrate into a model for the tool;
• integrating a conductive material with the substrate at an outer surface of the model;
• electrodepositing metal onto the outer surface of the model to form a metal shell of the tool;
• removing the substrate and the conductive material from a weep hole of the metal shell;
• and
• filling the metal shell with additional metal to form the tool.