Reusable mold forming tool

Abstract

Embodiments of the disclosure provide methods, apparatus, and articles for making a plurality of molds described by CAD data in machine readable form using a reusable mold-forming device. Various embodiments include configuring a plurality of adjustable actuators fixed to a base of a mold-forming device, where the top surface of the adjustable actuators takes the form of the mold required to make the part described by the CAD data. The adjustable actuators may then be readjusted to form another mold surface.

1 . A method for making a plurality of molds, comprising:
 configuring a plurality of adjustable actuators of a mold-forming device to a first plurality of positions for forming a first mold, using first CAD data of the first mold;   forming the first mold using the mold-forming device;   reconfiguring the plurality of adjustable actuators of the mold-forming device to a second plurality of positions for forming a second mold, that is separate and distinct from the first mold, using second CAD data of the second mold; and   forming the second mold using the mold-forming device.   
   
   
       2 . The method of  claim 1 , further comprising generating the data for positioning the plurality of adjustable actuators of the mold-forming device, the data describing a mold form. 
   
   
       3 . The method of  claim 1 , further comprising locking the plurality of adjustable actuators in specified positions. 
   
   
       4 . The method of  claim 3 , wherein the locking further comprises continuing locking the plurality of adjustable actuators in specified positions while the mold-forming device receives no power. 
   
   
       5 . The method of  claim 1 , further comprising receiving electronic feedback from the at least one of the adjustable actuators, wherein the plurality of adjustable actuators include an electronic feedback system attached to each actuator, providing verification feedback of the current positions of the adjustable actuators. 
   
   
       6 . The method of  claim 5 , wherein the verification feedback of the adjustable actuators is compared to input CAD data for the mold being formed. 
   
   
       7 . The method of  claim 1 , further comprising locating the mold-forming device on a mobile platform. 
   
   
       8 . The method of  claim 7 , wherein the mold-forming device on the mobile platform further comprises physical connectors allowing a plurality of mobile platforms to be joined. 
   
   
       9 . The method of  claim 1 , wherein the configuring further comprises computing positions of each of the plurality of adjustable actuators based upon a thermal expansion. 
   
   
       10 . The method of  claim 1 , wherein the configuring further comprises computing positions of each of the plurality of automatic adjustable actuators based upon a composite part spring-back. 
   
   
       11 . The method of  claim 1 , wherein the configuring further comprises computing positions of each of the plurality of adjustable actuators, based upon a thickness of the material to be formed into a mold. 
   
   
       12 . The method of  claim 1 , further comprising disposing a flexible caul plate upon the upper surface of the plurality of adjustable actuators. 
   
   
       13 . The method of  claim 1 , further comprising providing an interconnect socket allowing the mold-forming device be coupled with a plurality of mold-forming devices, allowing data communications to transfer through the interconnect socket. 
   
   
       14 . The method of  claim 1 , further comprising providing a data communication interconnect socket to the mold-forming device for receiving data at the mold-forming device. 
   
   
       15 . An apparatus for forming a mold comprising:
 a plurality of adjustable actuators each including an upper surface adapted to receive a material to be formed into a mold;   a base unit supporting the plurality of actuators; and   a module operatively coupled to the plurality of adjustable actuators and adapted to:
 configure the plurality of adjustable actuators to a first plurality of positions for forming a first mold, using first CAD data of the first mold, 
 facilitate forming the first mold, 
 reconfigure the plurality of adjustable actuators to a second plurality of positions for forming a second mold, that is separate and distinct from the first mold, using second CAD data of the second mold; and 
 facilitate forming the second mold. 
   
   
   
       16 . The apparatus of  claim 15 , wherein the module is further adapted to generate the data for positioning the plurality of adjustable actuators, the data describing a mold form. 
   
   
       17 . The apparatus of  claim 15 , wherein the module is further adapted to lock the plurality of adjustable actuators in specified positions. 
   
   
       18 . The apparatus of  claim 15 , wherein the module is further adapted to lock the plurality of adjustable actuators in specified positions while the mold-forming device receives no power. 
   
   
       19 . The apparatus of  claim 15 , wherein the base unit is further located on a mobile platform. 
   
   
       20 . The apparatus of  claim 19 , wherein the mobile platform further comprises physical connectors allowing a plurality of mobile platforms to be joined. 
   
   
       21 . The apparatus of  claim 15 , wherein the module further comprises an interconnect socket allowing coupling with a plurality of modules, allowing data communications to transfer through the interconnect socket. 
   
   
       22 . An article of manufacture comprising:
 a storage medium; and   a plurality of programming instructions stored on the storage medium and configured to program a mold-forming device to
 configure a plurality of adjustable actuators of a mold-forming device to a first plurality of positions to form a first mold, using first CAD data of the first mold; 
 form the first mold using the mold-forming device; 
 reconfigure the plurality of adjustable actuators of the mold-forming device to a second plurality of positions to form a second mold, that is separate and distinct from the first mold, using second CAD data of the second mold; and 
 form the second mold using the mold-forming device.