Complex, hollow composite parts present a unique manufacturing challenge. Internal tooling, generally referred to as cores, are used to create the hollow features in composite structures when a smooth internal surface finish and seam-free construction are required. Some tooling can be easily removed from the composite part’s design geometry, but any configuration that traps a tool inside requires sacrificial tooling or a more complex, collapsible or inflatable tool. Current sacrificial tooling technology uses eutectic salts, ceramics, cast urethanes or similar materials.
