Reconfigurable shape memory polymer support tooling

A method of forming a composite part on an SMP apparatus composed of shape memory polymer (SMP) and having a first surface and a second surface opposite the first surface, the method comprising:

• placing a support apparatus proximate to at least one surface of the SMP apparatus, wherein the support apparatus comprises:
• an adjustable, rigid structural member having mechanically adjustable cross-sectional dimensions, wherein the rigid structural member is adjustable between a first configuration and a second configuration, wherein at least one of the cross-sectional dimensions of the rigid structural member is greater in the second configuration than in the first configuration, and
• a plurality of shape memory polymer (SMP) support components comprising shape memory polymer, each spaced apart from each other and fixed to an outer surface or end portion of the adjustable rigid structural member, wherein the SMP support components are configured to transition between a rigid state and a malleable state and to be independently deformable in the malleable state when mechanical force is applied thereto, wherein the SMP support components are configured to be in the rigid state at a temperature below Tg and to begin changing to the malleable state at a temperature above Tg;
• triggering the SMP support components from the rigid state into the malleable state;
• actuating the rigid structural member to increase in at least one cross-sectional dimension, such that the SMP support components are pressed against at least one surface of the SMP apparatus;
• triggering the SMP support components from the malleable state to the rigid state while the SMP support components are pressed against the at least one surface of the SMP apparatus, thus providing a rigid load path between the SMP apparatus and the rigid structural member;
• and
• applying uncured composite material to a surface of the SMP apparatus opposite of the at least one surface of the SMP apparatus in contact with the SMP support components.

A support apparatus configured for providing structural support for forming composite parts, the support apparatus comprising:

• an adjustable, rigid structural member having mechanically adjustable cross-sectional dimensions, wherein the rigid structural member is adjustable between a first configuration and a second configuration, wherein at least one of the cross-sectional dimensions of the rigid structural member is greater in the second configuration than in the first configuration;
• a plurality of shape memory polymer (SMP) support components comprising shape memory polymer, each spaced apart from each other and fixed to an outer surface or end portion of the adjustable rigid structural member, wherein the SMP support components are configured to transition between a rigid state and a malleable state and to be independently deformable in the malleable state when mechanical force is applied thereto, wherein the SMP support components are configured to be in the rigid state at a temperature below Tg and to begin changing to the malleable state at a temperature above Tg;
• and
• an SMP apparatus made of SMP material having a first surface and a second surface opposite the first surface, wherein the second surface is configured to have uncured composite material applied thereto, wherein at least some of the plurality of SMP support components are pressed against the first surface of the SMP apparatus when the rigid structural member is in the second configuration, such that the SMP support components provide a structural load path from the SMP apparatus to the rigid structural member.