# US 5,707,477 A · Model and method for fabricating same

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- Number: US 5,707,477 A
- Document ID: US5707477A
- Status: Granted
- Kind: A
- Application number: 08/518,097
- Filed: 1995-08-22
- Granted: 1998-01-13
- Earliest claimed: 1995-08-22
- Assignees: The Boeing Company
- Inventors: David J. Cloud
- Web page: https://patentgrep.com/patent/US5707477A

## CPC

- B32B 3/12: characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
- B22C 7/00: Patterns; Manufacture thereof so far as not provided for in other classes
- B32B 3/08: characterised by added members at particular parts {(layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18)}
- B32B 3/266: {characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12}
- B32B 15/20: comprising aluminium or copper {(B32B15/016 and B32B15/017 take precedence)}
- B32B 27/38: comprising epoxy resins
- B29C 33/40: Plastics, e.g. foam or rubber
- B29C 2033/385: {by laminating a plurality of layers}
- B32B 2266/0271: Epoxy resin
- Y10T 428/1234: Honeycomb, or with grain orientation or elongated elements in defined angular relationship in respective components [e.g., parallel, inter- secting, etc.]
- Y10T 428/24149: Honeycomb-like
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B22C: FOUNDRY MOULDING (moulding refractory materials in general B28B)
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A method for fabricating a model includes the steps of stacking successive layers of aluminum honeycomb core to a desired height to form a block, machining the block to within a desired tolerance of the desired final contour, applying a layer of modeling material such as syntactic epoxy to the outer surface of the block, and machining the layer of modeling material to the desired contour. The result is a model from which a mold or composite parts can be fabricated, using high temperature and pressure processes if desired.

## Claims

### Claim 1

A method for fabricating a model comprising in sequence the steps of:
stacking successive layers of aluminum honeycomb core to form a stack of a desired height;
machining at least a portion of said stack to within a desired tolerance of a desired contour;
applying a layer of modeling material to at least a portion of the outer surface of said stack; and,
machining said layer of modeling material to the desired contour.

### Claim 2 (depends on 1)

The method of claim 1 wherein said modeling material comprises a syntactic epoxy.

### Claim 3 (depends on 2)

The method of claim 2 wherein said aluminum honeycomb core comprises perforated aluminum honeycomb core.

### Claim 4 (depends on 3)

The method of claim 3 further comprising, after the step of applying the layer of epoxy, the step of curing the epoxy.

### Claim 5 (depends on 4)

The method of claim 4 wherein said step of applying a layer of epoxy comprises the steps of
forming patties of said epoxy;
applying said patties to said outer surface of said stack;
forming said patties into a continuous layer; and
applying hand pressure to seat said epoxy into the aluminum honeycomb core.

### Claim 6 (depends on 4)

The method of claim 4 further comprising sealing the outer surface of said layer of epoxy after curing.

### Claim 7 (depends on 6)

The method of claim 6 further comprising the step of fabricating a mold on the surface of said model.

### Claim 8 (depends on 6)

The method of claim 6 further comprising the step of fabricating a composite part on the surface of the said model.