# US 2019/0376199 A1 · Rapid tooling using meltable substrate and electrodeposition > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2019/0376199 A1 - Document ID: US20190376199A1 - Status: Published application - Kind: A1 - Application number: 16/004,696 - Filed: 2018-06-11 - Published: 2019-12-12 - Earliest claimed: 2018-06-11 - Assignees: The Boeing Company - Applicants: The Boeing Company - Inventors: Thomas K. Tsotsis - Web page: https://patentgrep.com/patent/US20190376199A1 ## CPC - C25D 1/02: Tubes; Rings; Hollow bodies - B64F 5/10: Manufacturing or assembling aircraft, e.g. jigs therefor - C25D 1/10: Moulds; Masks; Masterforms - C25D 5/10: Electroplating with more than one layer of the same or of different metals (for bearings C25D7/10) - C25D: PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR - B64F: GROUND OR AIRCRAFT-CARRIER-DECK INSTALLATIONS SPECIALLY ADAPTED FOR USE IN CONNECTION WITH AIRCRAFT; DESIGNING, MANUFACTURING, ASSEMBLING, CLEANING, MAINTAINING OR REPAIRING AIRCRAFT, NOT OTHERWISE PROVIDED FOR; HANDLING, TRANSPORTING, TESTING OR INSPECTING AIRCRAFT COMPONENTS, NOT OTHERWISE PROVIDED FOR ## Abstract Systems and methods are provided for rapidly producing complex aircraft assembly tools using a meltable substrate and electrodeposition. One embodiment is a method that includes forming a meltable substrate into a model that corresponds with a shape of the aircraft assembly tool, wherein the meltable substrate is integrated with an electrically conductive material. The method also includes 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 at least one hole. The method further includes melting the model to remove the meltable substrate and the electrically conductive material from the metal frame via the hole to form a hollow metal tool having the shape of the aircraft assembly tool. ## Claims ### Claim 1 A method of manufacturing an aircraft assembly tool, the method comprising: forming a meltable 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 meltable 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 melting the model to remove the meltable 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. ### Claim 2 (depends on 1) The method of claim 1 further comprising: forming the meltable substrate into the model via additive manufacturing, wherein the additive manufacturing forms the outer surface of the model with an amount of the electrically conductive material integrated with the meltable substrate that is sufficient for the electrodepositing of the metal. ### Claim 3 (depends on 1) The method of claim 1 wherein: the meltable substrate is integrated with the electrically conductive material via dissolution. ### Claim 4 (depends on 1) The method of claim 1 further comprising: depositing additional metal into the hollow metal tool via the one or more holes to form the aircraft assembly tool. ### Claim 5 (depends on 1) The method of claim 1 further comprising: forming the one or more hollow segments via additive manufacturing. ### Claim 6 (depends on 1) The method of claim 1 further comprising: forming the one or more hollow segments via machining. ### Claim 7 (depends on 1) The method of claim 1 wherein: the meltable substrate includes wax. ### Claim 8 (depends on 1) The method of claim 1 wherein: the electrodepositing includes repeatedly submerging the model in an electrolytic bath until an outer dimension of the metal frame matches an outer dimension of the aircraft assembly tool. ### Claim 9 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. ### Claim 10 (depends on 9) The method of claim 9 further comprising: forming the soluble substrate into the model via additive manufacturing, wherein the additive manufacturing forms the outer surface of the model with an amount of the electrically conductive material integrated with the soluble substrate that is sufficient for the electrodepositing of the metal. ### Claim 11 (depends on 9) The method of claim 9 wherein: the soluble substrate is integrated with the electrically conductive material via dissolution. ### Claim 12 (depends on 9) The method of claim 9 further comprising: depositing additional metal into the hollow metal tool via the one or more holes to form the aircraft assembly tool. ### Claim 13 (depends on 9) The method of claim 9 further comprising: forming the one or more hollow segments via additive manufacturing. ### Claim 14 (depends on 9) The method of claim 9 further comprising: forming the one or more hollow segments via machining. ### Claim 15 (depends on 9) The method of claim 9 wherein: the soluble substrate includes a soluble polymer. ### Claim 16 (depends on 9) The method of claim 9 wherein: the electrodepositing includes repeatedly submerging the model in an electrolytic bath until an outer dimension of the metal frame matches an outer dimension of the aircraft assembly tool. ### Claim 17 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. ### Claim 18 (depends on 17) The method of claim 17 further comprising: removing the substrate and the conductive material from the metal shell by melting the substrate and the conductive material integrated therein through the weep hole. ### Claim 19 (depends on 17) The method of claim 17 further comprising: removing the substrate and the conductive material from the metal shell by dissolving the substrate and the conductive material integrated therein through the weep hole. ### Claim 20 (depends on 17) The method of claim 17 further comprising: integrating the conductive material with the substrate by printing one or more layers forming the outer surface of the model with a combination of the substrate and the conductive material.