Fabrication of an additive manufactured mould for the production of a drone engine cover using the infusion composites process

Abstract

Metal moulds have historically been employed in the fabrication of composite components. The primary drawbacks associated with this method of mould fabrication include the substantial time investment required and the significant expense, which necessitates amortisation only when manufacturing large quantities of a component. As an alternative, we propose the utilisation of moulds fabricated by fused deposition modelling (FDM) technique. The primary benefit of this technology is their accessibility, which facilitates their localised manufacturing in a significantly reduced timeframe. This renders them well-suited for the fabrication of moulds for composite components in limited production runs. Moreover, the utilisation of biodegradable materials derived from renewable sources during manufacturing processes enables the creation of moulds in a more sustainable manner. In this case study, the computer-aided design (CAD) process and manufacture of a mould using FDM for the production of a cover for a drone engine is presented. The design phases and requirements are outlined, and the challenges encountered during the process are discussed. The infusion process is conducted using sustainable materials such as flax and bio-epoxy resin. The final result of this process is the engine casing, which is composed of the aforementioned materials as part of the Sustainable Industrial Design of Textile Structures for Composites European project (SustDesignTex). In conclusion, the utilisation of FDM technology facilitates the manufacture of polylactic acid (PLA) moulds for small series of parts in a more accessible and economical way compared to costly conventional methodologies. The most notable result of the study was that the curing of the resin should not exceed 40°C, as exceeding this temperature results in mould deformations, shortening its lifespan.