Permanent tooling for composite coil spring compression molding

Tooling for use in forming a variable taper component, the tooling comprising:

• an inner mandrel comprising:
• a master insert defining:
• opposed tapered edge faces, each tapered edge face defining at least one locking feature;
• a first surface having a variable taper and a plurality of recesses configured to receive at least a portion of the variable taper component;
• and
• a tapered second surface opposite the first surface;
• a plurality of interlocking pieces arranged about the master insert, each interlocking piece defining:
• opposed tapered edge faces, one of the opposed tapered edge faces defining at least one locking feature and another of the opposed tapered edge faces defining at least one receiving feature to engage the at least one locking feature of an adjacent interlocking piece;
• a first surface defining a variable taper and a plurality of recesses configured to receive at least a portion of the variable taper component;
• and
• a tapered second surface opposite the first surface;
• and
• an outer mandrel disposed around the inner mandrel, the outer mandrel defining a corresponding plurality of recesses configured to receive at least a portion of the variable taper component,
• wherein a maximum width of each of the interlocking pieces and the master insert is smaller than a minimum width of end portions of the variable taper component, and a central portion of the variable taper component is wider than the end portions.