Low-cost resin infusion mould tooling for carbon fibre composites manufacture

This article describes the research to date carried out under the BAE Systems/Engineering and Physical Sciences Research Council (EPSRC)-funded programme 'Flapless Aerial Vehicle Integrated Interdisciplinary Research' (FLAVIIR), aimed at developing innovative technologies for the low-cost manufacture of next-generation Unmanned Aerial Vehicles. The aim of the researchers in FLAVIIR was to develop low-cost innovative tooling technologies to enable the affordable manufacture of complex composite aerospace structures. The advances in tooling technology were achieved through the application of rapid prototyping, tooling and manufacture technologies to provide rapidly configured and reconfigurable tool concepts, for low-cost resin infusion moulding. This article introduces three tooling innovations: reconfigurable tooling concept, variable cavity tooling, and porous cavity tooling.