In many applications the value of composites is limited, sometimes severely, by the demands ofthe tooling required. The next generation in rapid tooling, as described in this paper, offersoptions that can free designers and manufacturers from tooling limitations, even for complexgeometries, by offering combinations of properties that are available with no other tooling. As aresult this technology, represented by Green-Aero~((SM)) tooling from Nevada Composites, can offereven more-the enabling technology to make possible previously unattainable designs andcomponents.The key to this enabling technology, however, may be the ability to tailor the properties andconfiguration of the new tooling. Several approaches are possible, including altering the toolingmaterial formulations, changing surface properties with coatings, sealants, or films, selectingdifferent tool-fabrication processes or combining different processes, and/or bonding togethermultiple tooling units.This paper reports our work to date on tailoring next-generation rapid tooling and includes realworldexamples.
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