Tool comprising eutectic material, method of making the tool and method of using the tool

A method of making a molding tool by additive manufacturing, the method comprising:

• i) forming a first layer of eutectic alloy, the forming comprising depositing the eutectic alloy in liquid form and then cooling to form a solid eutectic alloy;
• ii) forming an additional layer of the eutectic alloy on the first layer, the forming of the additional layer comprising depositing the eutectic alloy in liquid form and then cooling to form the solid eutectic alloy;
• and
• iii) repeating ii) one or more times to form a structure comprising a tool body having a tooling surface, the tool body comprising the eutectic alloy.

A method of making a composite part, the method comprising:

• laying up a moldable composite material on a molding tool, the molding tool comprising a eutectic alloy having a melting temperature;
• heating the moldable composite material to a first temperature that is below the melting temperature of the eutectic alloy to form a green body;
• heating the green body to a second temperature to form a composite part, the second temperature being above the melting temperature of the eutectic alloy so as to melt the molding tool to form a liquid molding tool alloy;
• and
• removing at least a portion of the liquid molding tool alloy from the composite part.