Advancements in Hybrid Materials and Structures through Submerged Bobbin Tool (SBT) Processing

Submerged Bobbin Tool (SBT) tunneling technology is an emerging green fabrication innovation that promotes sustainable manufacturing. This goal is achieved through efficiently forming integral pathways in malleable components incorporated in transportation vehicles and manufacturing equipment. Because SBT toolsets form enclosed sub-surface channels within structural components, they serve a different but complementary function with respect to machining operations, making it possible to produce parts in a minimal number of setups. Channels are designed for use in a variety of ways and on different structures for 1) light-weighting fabrication, 2) integrating internal sensors in smart structures, 3) producing out-of-autoclave (OOA) tooling, 4) simplifying casting production, 5) stiffening structures via composite inserts, 6) reducing manufacturing steps and energy consumption, and 7) enabling agile fabrication across multiple machine platforms. As such, SBT tunneling is well suited for use in the production of Hybrids, Plug-in Hybrid Electric Vehicles (PHEV), and Battery Electric Vehicles (BEVs). SBT tunneling is intended to be especially beneficial in applications requiring curvilinear internal pathways and internal spaces for the placement of solid materials like composites. Specific uses for channels produced by SBTs are considered in this presentation, including internal pathways for wire management, distribution of gases and fluids, and placement of internal stiffening members. Example components incorporating these channels include heat exchangers, cold plates, vacuum tools, out-of-autoclave composite and bonding tooling, and stiffened beam structures.