Project Objective:
The primary goal was to enhance efficiency, reduce material usage and manufacturing costs, and validate additive manufacturing as a scalable solution for aerospace tooling.

Methodology and Development:

• BSU students created an optimization workflow leveraging nTop Platform, which included parametric CAD modeling, meshing, FEA, and cost/material analysis.

• A prototype mold was designed using this workflow, manufactured via Fused Deposition Modeling (FDM), and tested through vacuum bagging to simulate real composite layup conditions.

• Material testing and simulation verified structural integrity, and design iterations helped reduce stress concentrations and excess material.

Key Results:

• The optimized mold demonstrated a 76% volume reduction compared to traditional MDF tooling, leading to significant material and cost savings.

• The part retained sufficient dimensional accuracy and structural performance during composite layup.

• Reduced non recurring engineering costs associated to manufacturing of large complex tooling and reduced risk of manufacturing defects and repair.

Conclusion:
The developed workflow effectively met project goals by minimizing material waste, preserving structural reliability, and reducing manufacturing costs. It represents a viable, scalable alternative to conventional tooling methods. Hosting this project allowed Mach One Solutions to support emerging engineering talent while exploring innovative, cost-effective manufacturing approaches relevant to our strategic goals in composite production.

Future Recommendations:
The team suggests exploring further design iterations and material combinations to enhance performance and broaden application scope. Continued focus on simulation-driven design will maximize benefits in cost, weight, and production time.