AM Tooling & Internal Structures

Previous FSAE aerodynamic wings were manufactured using traditional machined foam and polymer features to create a defined shape. With these types of tools the internal structure has to be removed after cure, and once removed are left with a hollow structure. A slit is placed on the rear facing edge to allow access for the internal supporting structure to be installed. The traditional method consists of multiple steps, and this capstone hopes to reduce these steps. This project was meant to assist in the students learning about additively manufactured (AM) tooling and topology optimization structures within a composite aerodynamic wing. The AM sub-structure could be used for multiple purposes; to support in tooling for composite layup, curing of the composite wing, and structure to support on the car. The process aimed to help reduce manufacturing time and create an opportunity for students to understand the interaction between composites and polymers.

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