Modeling and characterization of fused deposition modeling tooling for vacuum assisted resin transfer molding process

The material extrusion additive manufacturing process, i.e., fused deposition modeling (FDM), as opposed to traditional subtractive manufacturing, offers a superior way of manufacturing tooling components in terms of great design flexibility, rapid tooling development, material requirement reduction and significant cost savings. However, it is always challenging to design a tool structure with minimized material and labor cost while maintaining satisfactory tooling performance. In the current study, a comprehensive finite element model was developed for ULTEM 9085 FDM tools subjected to applied pressure and elevated temperature for vacuum assisted resin transfer molding (VARTM) process. Both solid-build and sparse-build tools were studied. Material properties of the tools were obtained from solid coupon testing at elevated temperatures. The thermo-mechanical behavior of tools during the VARTM process was investigated using the finite element model. The ULTEM tools were manufactured using Stratasys Fortus 400mc FDM machine. Thermal cycling of the tools was performed at elevated temperatures (180 °F and 250 °F). Dimensional analysis and surface roughness of the tools were evaluated after thermal cycling. This study on the performance of FDM tooling for VARTM composite manufacturing process can be extended to other composite manufacturing processes.