Customized composite debulking caul

Abstract

A caul for debulking a composite part broadly includes opposing first and second surfaces, a plurality of through-holes, and a coating. The first surface may have a curvature complementary to a shape of the composite part. The through-holes pass through the caul from the first surface to the second surface. The coating may be a chemically inert material to ensure the caul does not affect the composite part. The caul is configured to be positioned against the composite part for debulking. The caul may be made out of silicone rubber or any other suitable material and may be reusable.

1 . A caul for debulking a composite part, the caul comprising:
 a first surface having a curvature complementary to a shape of the composite part;   a second surface opposite the first surface; and   a plurality of through-holes extending from the first surface to the second surface to allow air to flow from the first surface to the second surface during debulking.   
     
     
         2 . The caul of  claim 1 , the through-holes being perforations. 
     
     
         3 . The caul of  claim 1 , the through-holes being evenly spaced from each other. 
     
     
         4 . The caul of  claim 1 , the caul being coated with a chemically inert material. 
     
     
         5 . The caul of  claim 1 , the caul being made of silicone rubber. 
     
     
         6 . The caul of  claim 1 , the caul being reusable. 
     
     
         7 . A method of debulking a composite part, the method comprising the steps of:
 shaping a first surface of a caul to be complementary to a shape of the composite part;   forming through-holes in the caul such that he through-holes extend from the first surface to a second surface opposite the first surface;   positioning the caul on the composite part such that the first surface of the caul contacts a surface of the composite part;   positioning a porous sheet on the caul such that the porous sheet contacts the second surface of the caul;   enclosing the caul, the porous sheet, and the composite part in a vacuum bag; and   drawing air from the composite part through through-holes of the caul and the porous sheet via a vacuum pump.   
     
     
         8 . The method of  claim 7 , further comprising the step of coating the caul with a chemically inert material. 
     
     
         9 . The method of  claim 7 , the step of shaping the first surface of the caul including removing material. 
     
     
         10 . The method of  claim 7 , the step of shaping the first surface of the caul including adding material via additive manufacturing. 
     
     
         11 . The method of  claim 7 , the step of forming through-holes including evenly spacing the through-holes from each other. 
     
     
         12 . The method of  claim 7 , the step of forming the through-holes including perforating the caul. 
     
     
         13 . A system for debulking a composite part, the system comprising:
 a caul comprising:
 a first surface having a curvature complementary to a shape of the composite part; 
 a second surface opposite the first surface; and 
 a plurality of through-holes extending from the first surface to the second surface to allow air to flow through the caul from the first surface to the second surface during debulking; 
   a porous sheet adjacent the second surface, the porous sheet configured to the air to flow out of the plurality of through-holes;   a vacuum bag enclosing the caul, the porous sheet, and the composite part; and   a vacuum pump configured to draw the air from the composite part, through the through-holes of the caul, and through the porous sheet.   
     
     
         14 . The system of  claim 13 , the through-holes being perforations. 
     
     
         15 . The system of  claim 13 , the through-holes being evenly spaced from each other. 
     
     
         16 . The system of  claim 13 , the caul being coated with a chemically inert material. 
     
     
         17 . The system of  claim 13 , the caul being made of silicone rubber. 
     
     
         18 . The system of  claim 13 , the caul being reusable. 
     
     
         19 . The system of  claim 13 , the porous sheet being release film. 
     
     
         20 . The system of  claim 13 , further comprising a tool configured to be positioned adjacent the composite part, the caul being configured to be positioned adjacent the composite part opposite the tool.