FORMING CELL FOR TUFF THERMOSET PART FABRICATION

• Jiro Guillen, Mechanical Engineering, University of Delaware
• Matthew Yezek, Mechanical Engineering, University of Delaware

• Shashank Sharma, CCM, University of Delaware

In this work, a forming cell is being developed to manufacture TuFF (Tailored Universal Feedstock for Forming) based parts for scalable manufacturing and is a collaborative initiative with Joby Aviation. The materials being used are TuFF based thermoset prepreg system developed at the Center for Composite Materials (CCM) known for its ability to form due to the short fiber-based design, and a Bi-Axial Stretch Formable nature thereby having the ability to be used in high curvature applications. The forming cell comprises of a top and bottom mold, along with a custom designed material holding frame to load material in the forming cell for fabrication of part. In this work, several parameters for forming are being developed to determine the feasibility and optimum forming limits and parameters for a rib part used in Joby Aviation’s aircraft. Preliminary trials are being done to finalize material limits and development of critical parameters including temperature and pressure during the forming process. Initial assessment of the materials includes mechanical testing of the TUFF based prepreg systems to develop parameters and criteria for material forming limits to be used in the forming cell. Once the initial material testing is complete, the forming cell will be used to produce parts based on the initial parameters followed by process optimization based on quality of parts produced and findings.