Nevada Composites

Green-Aero^SM -- The Next Generation in Rapid-Tooling

Green-Aero^SM Tooling

• Based on ceramic microspheres in a water-soluble refractory binder
• Available as custom single-sided tooling or custom washout mandrels

• Rapid: tooling in as little as one day
• Lightweight: ≈0.4 g/cc (≈24 lb/cu.ft.)
• Inexpensive: tool cost is ≤ 5% of Invar tools
• Low, constant CTE: ≤ 5x10^-6/K (≤2.8 µin/in/F)
• Low thermal mass: due to its very low density
• Versatile: washout mandrels or single-sided tools
• Accurate: as molded ± 0.38mm (0.015"); as machined ± 0.13 mm (0.005")
• Reliable: uniform, reproducible; easily repaired
• Tailorable: tool properties adjustable; can incorporate co-cured features




Mandrels with precision-located features machined from blocks of Green-Aero^SM tooling

• Warm-water washout: even after high-T cure of up to 370°C/700°F, 1400 kPa/200 psi
• Master or mold sees room T only: and only rough vacuum




1.2-meter (4-foot) hat stiffeners molded using wooden mold

• Straightforward multi-tool production: suitable for rate manufacturing
• Scalable: tools can be assembled from blocks or units to achieve large sizes
• Green: all steps are environmentally benign