Modular tooling for multi-spar torsion box

A method to assemble modular tooling to form a multi-spar torsion box, the method comprising:

• receiving information defining a selected predefined height for the module tooling, wherein the selected predefined height is selected from a plurality of predefined heights;
• providing a mandrel module including a hollow beam geometry which comprises a first base, a second base opposite to the first base, and two walls extending between said first base and said second base;
• selecting at least one spacer module from a plurality of spacer modules, wherein the spacer modules include spacer modules having common widths and different heights, wherein the selection of the at least one spacer module is made to stack one or more of the spacer modules and the mandrel module to the selected predefined height;
• coupling the mandrel module to the selected at least one spacer module;
• stacking the selected at least one spacer module and the mandrel module to form a modular tooling assembly stack, wherein the modular tooling assembly stack has a height corresponding to the selected predefined height;
• and
• forming multi-spar torsion box using the modular tooling assembly stack.

A modular tooling kit configured to manufacture multi-spar torsion box, the modular tooling comprising:

• a hollow beam mandrel module having a first base, a second base opposite to the first base, and side walls extending between the first and second bases;
• and
• a plurality of spacer modules each configured to couple with the mandrel module and each of the spacer modules having a width common to a width of the mandrel module and a height differing from at least one of the other spacer modules;
• wherein the mandrel module is stacked with a selected at least one of the spacer modules to form a modular tool stack having a height corresponding to one of a plurality of predefined web height of the multi-spar torsion box, and
• wherein the modular tool stack is configured to form a multi-spar torsion boxing having at least one web with a height corresponding to the predefined web height.