Carbon fiber tooling addresses aerocomposites pain points

The result of extensive R&D, BlackBoard by Harcourt Industrial Inc. (Madison Heights, Mich., U.S.) is a lightweight, high-performance carbon fiber tooling material designed to address the pain points experienced with traditional Invar layup molds in aerospace composites manufacturing. It offers a range of advantages that enhance efficiency, reduce costs and improve overall manufacturing performance.

BlackBoard enables close-tolerance, direct-to-part tooling, significantly reducing lead times from weeks or months to mere days, according to the company. Its characteristics allow for the creation of precise molds, ensuring tight tolerances and dimensional stability during the curing process.

One of its standout features is BlackBoard’s lightweight nature. Weighing only 0.05 lb/in³, BlackBoard is approximately 80% lighter than Invar, 75% lighter than steel and 50% lighter than aluminum. This weight reduction streamlines handling, transportation and installation, improving overall efficiency and maneuverability.

In addition, BlackBoard’s easy machinability and clean machining process make it a convenient option for manufacturers. It can be easily drilled, tapped and machined, achieving greater design flexibility and faster production cycles. Manufacturers can reportedly explore complex or intricate mold geometries without the limitations posed by the hardness and limited machinability of Invar.

BlackBoard’s cost-effectiveness (offering similar or improved properties at a lower cost compared to Invar) and reusability (capable of multiple machining cycles) further add to its advantages. High thermal stability ensures consistent dimensional performance throughout the curing process. Its ultra-low coefficient of thermal expansion (CTE) minimizes the risk of distortion or warping in composite parts, resulting in high-quality components and improved performance.