Method for making composite parts having complex shapes

Abstract

A method for making parts ( 6 ) having a complex geometrical shape, the geometrical shape including e.g. various bends, branching, deflectors, sections or thickness, that includes the steps of: forming a core part ( 1 ) having a geometry substantially similar to that of the target shape, except for the outer thickness, using a three-dimensional creation method; wrapping at least a portion of the core part with fibres previously or subsequently impregnated with resin until the final dimensions of the target shape are reached; and curing the resin.

1 . Method for making composite tubular parts ( 6 ) having complex shapes, characterized in that it comprises steps of :
   100 —creating a core part ( 1 ) having a geometry substantially similar to the desired shape, except for the outer thickness, by a three-dimensional creation method, said geometric shape comprising in particular at least one of the following elements: on the outside of the tube:   bend, branch, variable cross-section; or inside the tube: deflector, separation,  105 —assembling the core part ( 1 ) with at least one tool ( 2 ,  3 ,  4 ), installed at one of the end cross-sections of said core part,     110 —wrapping at least one portion of said core part ( 1 ) with fibers ( 5 ) previously or subsequently impregnated with resin, until the final dimensions of the desired shape are obtained,     120 —hardening the resin, and extracting said tools from the complete part ( 6 ).   
     
     
         2 . Method according to  claim 1 , characterized in that the three-dimensional creation method is a laser fusion method (SLS). 
     
     
         3 . Method according to  claim 1 , characterized in that the core part ( 1 ) is realized in a very high temperature thermoplastic resin. 
     
     
         4 . Method according to  claim 3 , characterized in that the very high temperature thermoplastic resin is a PEEK (poly-ether-ether-ketone) type. 
     
     
         5 . Method according to  claim 1 , characterized in that hardening of the resin is obtained by a phase of polymerization or consolidation of said resin. 
     
     
         6 . Method according to  claim 1 , characterized in that the core part ( 1 ) is wrapped using a layup method for the core part ( 1 ) using fabric or tapes pre-impregnated with resin. 
     
     
         7 . Method according to  claim 1 , characterized in that the core part ( 1 ) is wrapped using a resin transfer molding method. 
     
     
         8 . Method according to  claim 1 , characterized in that in step  100  of creating the core part ( 1 ), at least one portion of the surface of said core part ( 1 ) intended to receive the fibers ( 5 ) is roughened to boost mechanical binding with the fibers' impregnation resin.