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High-Precision Autoclave Cure Tools for Aerospace image

In aerospace manufacturing, the production of stiffened composite panels for aircraft fuselage sections requires tooling capable of withstanding high temperatures while maintaining extreme dimensional accuracy. Autoclave cure tools—such as stringer molds—are critical in this process, as even minimal deformation during curing can compromise the structural integrity of the final components.
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Advanced Manufacturing with Vipra AM and Invar 36

To meet these requirements, Caracol leveraged its Vipra AM platform, based on Wire Arc Additive Manufacturing (WAAM), to produce a high-precision stringer mold using Invar 36—a nickel-iron alloy known for its near-zero thermal expansion and excellent stability under thermal stress. The adoption of WAAM enabled the efficient production of a complex geometry while maintaining high material performance and process reliability.

Key manufacturing facts:

  • Technology: Vipra XP
  • Material: Invar 36
  • Post-processing: CNC
  • Size and Weight: 580 × 600 × 230 mm, 70 kg
  • Deposition Rate: 5 kg/h
  • 3D Printing Time: 14 hours

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Performance Benefits and Industrial Value

By combining Invar 36 with WAAM technology, Caracol delivers a tooling solution that ensures reliability, precision, and efficiency under demanding aerospace conditions:

  • Low thermal expansion (CTE): Invar 36 maintains dimensional stability up to 280°C, preventing deformation during autoclave curing and ensuring consistent composite quality.
  • Strength and fatigue resistance: The material withstands repeated thermal cycles without degradation, ensuring long-term performance.
  • Faster lead time with WAAM: The additive process significantly reduces production time compared to traditional methods such as casting or machining.
  • Durability and precision: The mold maintains tight tolerances over multiple cycles, preventing warping and ensuring consistent results.

This project demonstrates how advanced materials and metal additive manufacturing can be combined to deliver cost-effective, high-performance tooling solutions for aerospace and beyond.

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