Technology Overview

Innovations

2Phase Technologies is developing a new class of material formulations that can undergo a reversible room-temperature transition - going from liquid-like to solid with no change in volume. 2Phase personnel have extensive experience in materials science and composites, and are now engaged in combining the transition material technology with 'universal' tooling concepts for the composites industry.

Reformable tooling can take the contour of any shape pressed against it. Prototype tooling can be prepared in five minutes or less and can be repeatedly transformed into different contours for different parts. The tooling can take a splash or negative that can be turned into a positive on another reconfigurable tool. It can be 350°F capable, can be given a CTE to match any materials system, and will be capable of use under vacuum and up to100 psi.

Brief on Transition Material Properties

2Phase has patents pending on its unique approach to formulating liquid-solid materials systems. A transition material can take on the properties of nearly any particulate fill material used in its formulation. It can have the stiffness, temperature resistance and CTE of hard tooling materials or the elastomeric properties of 'soft' tooling.

Transition materials will be tailored to a user's exact specification to include CTE and mechanical properties. In a liquid state these materials are formed around a master model, part or tool. The materials are then transformed instantly at room temperature to a solid state with no change in volume.

Since the change is accomplished at ambient temperature, a 'splash' can be taken from any stable material, such as foam block, wood, the part to be replicated, or a rapid-prototyped part from stereolithography (STL), fused-deposition modeling (FDM), laminated object manufacturing (LOM), or any machined or hand-worked material.

Concept tests of 'quasi-stable' transition materials have also been made, showing that the development of 'toolable' transition materials are possible, with the material being progressively sculpted to shape. When transition materials with three properties are developed (liquid, solid, quasi-stable state), the option will exist to go directly from 3D CAD to a formed pattern or tool without resorting to rapid prototyping, machining or hand fabrication of patterns.

Early tests have been made on tailoring the physical properties of these materials and utilizing them for both dimensional capture ('splash' tools) and the creation of male and female molding tools. Light fill can be used to create large-scale universal splash tools - including sectional tools - that can be manually transported and positioned, with 'limpet' application under partial vacuum to conform the liquid-stage tool to a surface before transition to the solid stage.

In like manner a variety of 'melt-out' mandrels can be produced for wide-ranging applications as tool inserts. In the future the prospective user will be free to specify a desired set of physical properties, such as a CTE matching that of the composite structure to be produced. The materials should be tailorable so that properties including CTE's and dimensional stability match those of all current tool materials. Potentially infinite variations of the physical and chemical properties, including tailored CTE, stiffness, elastic properties and temperature resistance are possible.

Tooling Applications

The company's innovative transition materials, tooling designs and application concepts will provide for the creation of a wide variety of instantly formable and reconfigurable tools. The materials can be contained permanently within elastic membrane elements or can be transferred in a liquid-like state from flexible containment to holding tanks and back.

We expect these materials to open up realms of free thinking about tool design as dedicated engineers begin working with them (see Concept Demonstrator below). Though our perspective is at present limited, we advance the following concepts:

  • Modification of tool - add or subtract contours; blend two shapes into one; form controlled-thickness offset; instantly create matched-tool set.
  • Transfer from positive to negative repeatedly with no loss of accuracy.
  • Reinforcement - make patterns over properly sized plug; lay, form and consolidate preforms between male & female tools; apply light tack-release forces to develop patterns w/ actual materials.
  • Rapid hard-shell forming - thermoform and heat-cure prepregs in one operation.
  • Form over honeycomb or core material; foam between skins & cure under pressure.
  • Scale complex parts up or down by transferring dimensions.
  • Perform a wide variety assembly tooling functions, holding, positioning, clamping & pressing operations.
  • Use in rapid field repair tooling kits - patch tools can be formed quickly without the use of chemicals and temperature controlled materials.

Potential tooling forms, in either hard or soft tooling, include:

  • 'Splash' tooling of any scale, including segmented exterior and separable mandrel elements. These can be tools that are pressed against a surface by partial vacuum, or they can be internally pressurized to capture interior contours.
  • Open Molds of any size, including multi-part designs. These can be suitable for VIP, VARTM and 'Light RTM' applications, with permanent bags or caps being formed by matched tooling (see below). These can be temperature-controlled with liquid lines or heater elements embedded beneath the tool surface.
  • Collapsible mandrels & core tools will be offered for hollow body forming. When pressure and temperature capable these will be available for filament-winding applications.
  • Trapped tooling can be fabricated in one piece without multi piece jigsaw puzzle metal tooling. This reduces not only tooling cost but also tool assembly and disassembly.
  • Rapid prototype tooling of multiple part configurations can be made from one tool, vastly reducing cycle time in prototyping or fabrication on R&D parts or materials.
  • Matched tooling for pressure forming and thermoforming. Temperature-controlled tools will be available.
  • Closed molds with two or more mating components will be available, as will a variety of internal mandrels for use in conjunction with these molds. While initially offering 'light' pressure molds, continuing transition material development will provide RTM-capable tooling and eventually injection-mold tooling.
  • Autoclave tooling: 2Phase is looking for partnering companies to accelerate this development.
  • Bonding fixtures can be formed to fit individual parts contours and part to part variations to ensure that pressure can be applied uniformly over entire surfaces and eliminate dis-bonds.
  • NDI inspection part holding fixtures can be formed.

Concept Demonstrator and Follow-on Systems

2Phase has developed a concept demonstrator for the composites industry offered to all interested parties under license. This demonstrator was produced by a partnering company with an extensive background in aerospace and commercial composites tooling development and fabrication

For more information please contact us.