TECHNICAL DATA SHEET

MANUFACTURING OF COMPOSITE TOOLING

DFORM® FABRIC TOOLING BMI

MANUFACTURING OF COMPOSITE TOOLING USING DFORM® FABRIC

TOOLING – BMI
INTRODUCTION TO DFORM® CONCEPT
®
DForm Fabric Tooling – BMI is an innovative prepreg system supplied in a convenient tile format. It combines short fibre
conformability with the handling and laminate characteristics of a conventional long fibre composite.
®
DForm Fabric Tooling – BMI reduces the need for time consuming detailed laminating. It is highly compliant with good tack
that adheres well to the mould surface; it conforms well to complex mould features using ‘fingertip’ pressure without the need
for time consuming tailoring of female and other complex mould geometry.
It requires a single autoclave debulk cycle in which the prepreg system deforms under pressure, replicating precise details.
Upon cure it retains thickness and fibre orientation and produces a high quality finish comparable with the legacy Solvay BMI
Duratool tooling systems with savings in labour in the order of 75%.
®
DForm Fabric Tooling – BMI unique deformation characteristics are achieved through selective fibre cutting of a fabric
prepreg that, when presented as a multi-layer 0/90 tile, is highly conformable and easily laminated.
®
DForm Fabric Tooling – BMI is a proven, high-performance bismaleimide (BMI) resin/carbon fibre tooling system that is
capable of continuous service at 190°C (375°F) and short cycle service at 204°C (400°F).
®
DForm Fabric Tooling – BMI allows high-quality tooling laminates to be produced directly from a high-temperature master
models or a variety of intermediate materials. After autoclave processing for the initial cure, the tool laminate can be de-
moulded and post-cured “free-standing”. In addition Solvay carbon fibre and sizing technology is employed for optimum
matrix/fibre interfacial performance during repeated high temperature cycles.

Features and Benefits

• Convenient tile format 62.25cm x 62.25cm • 28 days tack life at 20°C (68°F).
(24.5” x 24.5”).
• 45 days work life at 20°C (68°F).
• Simplified lay-up procedures.
• 24 months storage at -18°C (0°F).
• Proven resin technology.
• Contains no MDA or VCHDs.
• 75% + reduction in lay-up time typical, more
complexity increases this time saving. • Excellent ambient temperature tack.

• Excellent tack and drape. • Initial cure temperature 175°C (350°F).

• Self-contained system - no need for a separate • Free-standing post-cure.

surfacing solution. • Maximum DMA E’ onset Tg of 257°C (495°F) after
*
• Improved detail replication with no compromise of post-cure to 240°C (464°F).
surface quality. • Sustained Thermal Oxidative stability during 190°C
(375°F) service.

*Tg data is not applicable for U.S. export control classification or licensing. For export-related information please contact us.

 
 
 
 
 

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MANUFACTURING OF COMPOSITE TOOLING
DFORM® FABRIC TOOLING BMI

STANDARD TILE FORMAT

Table 1
 
Tile Ply number Fabric Type Fibre direction (degrees)
1 6k 365 gsm Twill 0/90
2 6k 365 gsm Twill 0/90
3 6k 365 gsm Twill 0/90
Tile construction 4 6k 365 gsm Twill 0/90
(Cured thickness ~3mm, 1/8”) 5 6k 365 gsm Twill 0/90
6 6k 365 gsm Twill 0/90
7 6k 365 gsm Twill 0/90
8 6k 365 gsm Twill 0/90

INSTRUCTIONS FOR USE – ‘AT A GLANCE’ SUMMARY OF OPERATIONS

Table 2
Operation 1: Preparation
Operation 2: Edge Trim
Operation 3: Condition
Operation 4: Laminate
Operation 5: Manipulate
Operation 6: Consumables
Operation 7: Autoclave Debulk
Operation 8: Condition
Operation 9: Laminate
Operation 10: Manipulate
Operation 11: Consumables
Operation 12: Final Cure
**FIFO – First in First out
Master Model - Clean, Release & Vacuum Integrity Check.
Cut tile edge bevels using oscillating tool to an acute angle.
**
Condition the first layer tiles (Tile 1), 50°C± 5°C 120°F± 10°F for 3-5 minutes – FIFO.
Remove separator film and apply tile.
Manipulate the tile into female corners and onto mould contours.
Solid Film, A3000 breather, Stretch-Vac 250 (see Table 6).
Autoclave debulk 6.2-6.9 bar (90-100psi), 80°C± 5°C 180°F± 10°F for 5 minutes.
Condition the second layer tiles (Tile 2), 50°C± 5°C 120°F± 10°F for 3-5 minutes – FIFO
Apply Tile 2 – stagger joints in adjacent tiles by maximum possible.
Manipulate the tile into female corners and onto mould contours.
Edge breath, Solid release Film, Nylon 66 breather and Bagging Film (see Table 6).
90-100psi, vacuum applied, dwell at recommended temperature (Table 3).

Notes:

A fan assisted laboratory oven or heater blanket can be used to warm the tile. It is suggested to condition the tile for approximately 5 minutes.
Adjacent tiles should be connected using a mitrered butt joint. This bevelled edge can be cut with an oscillating tool. Gaps should be avoided, a small overlap is
better than leaving a gap.

Joints in adjacent tile layers should be staggered.

Material can be cut with sturdy scissors during laminating or the use of the oscillating tools has been found to be very effective.

For tools that will be used in an envelope bag configuration, an insert can be laminated into the tool by placing rings of prepreg in a pyramid fashion between
plies until the insert height is achieved.

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MANUFACTURING OF COMPOSITE TOOLING
DFORM® FABRIC TOOLING BMI

INSERTS
Where inserts, i.e. drill bushings / tooling balls etc., are to be positioned in the tool and the tool will be bagged on one face
only, it is recommended these are ideally “encapsulated” and then laminated in and debulked with the first DForm ply.

Cured prepreg encapsulated insert

75mm x 75mm (3”x 3”) 2 ply prepreg pad – see Cross Section of typical insert inclusion (shown on
notes dowel)

Figure 1 Figure 2
Notes: The pad (Figure 1) should be 2 plies thick. This can be taken from a conditioned tile of DForm by peeling away two plies which are then cut to about
75mm x 75mm (3”x 3”). After making a small central hole, position the pregreg on the surface over the dowel pin. Place the cured prepreg encapsulated insert
on the dowel pin. Finally, laminate the DForm® Fabric Tooling – BMI in the normal manner. There are many scenarios that involve inserts (shape, size, location
challenges etc.) - Contact Solvay Technical Services for specific advice.

TOOL THICKNESS AND DEBULK SCHEDULE

®
DForm Fabric Tooling – BMI can be used to build toolface of up to 25mm (1 inch) thickness, however an autoclave debulk
should be carried out after all “odd number layers” have been applied, some examples relative to tool thickness are
explained in Table 3
Table 3
 
Operation Comment Thickness Applied
Tile 1 3mm, 1/8”
Autoclave Debulk
Tile 2 See Figure 3 3mm, 1/8”
= Minimum tool thickness OR go to Tile 3 6mm /
1/4” tool
Tile 3 3mm, 1/8”
Autoclave Debulk See Figure 3
Tile 4 3mm, 1/8”
Cure OR go to Tile 5
12mm /
1/2” tool
Tile 5 3mm, 1/8”
Autoclave Debulk See Figure 3
Tile 6 3mm, 1/8”
18mm /
Cure OR go to Tile 7
3/4” tool
Tile 7 3mm, 1/8”
Autoclave Debulk See Figure 3
Tile 8 3mm, 1/8”
25mm / 1”
Cure OR go to Tile 9 etc
tool
Note: Additional autoclave debulks can be used for high complexity details if desired. 

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RECOMMENDED BAGGING ARRANGEMENT – AUTOCLAVE DEBULK STAGE

 
Release Film [Solid, positioned ~12mm (0.5 inch) beyond the
Stretch-Vac 250 Bagging laminate edge]

Breather ~4oz

Sealant Tape

Released Tool Surface

Laminate Lay-up

Figure 3

CUTTING TILE EDGE BEVELS

An oscillating tool with a half moon “drywall blade is recommended for cutting bevels. An acute angle is desired to provide
best contact between adjacent tiles during the layup. Bevel cutting is best performed before the tile is conditioned as
warming the tile results in tacky resin which can make the bevel cutting operation problematic. Contact Solvay Technical
Services for more details on the oscillating tool / cutting blade and specific recommendations for its use.

RECOMMENDED BAGGING ARRANGEMENT – FINAL AUTOCLAVE CURE

Bag the completed tooling laminate according to the following steps. Refer to Figure 4 and Figure 5 for details.
1. Place two or more thermocouples into the prepreg between ply 1 and ply 2, ideally situated near the thickest part of the
master model and in a trim area.
Ensure the edge of the laminate is neatly trimmed to allow for breathing.
2. Create “breather dam” sections by wrapping EB520 75mm (3in) wide fibreglass boat cloth (See Table 8) around strips of
bag sealing compound, leaving 50 – 60% of one side of the sealant exposed (Refer to Figure 3, steps a, b and c).
3. Place the “breather dam” in contact with the edge of the laminate securing it in place with the exposed portion of the
sealing compound.
The loose boat cloth tape (EB520) should extend over the top of the sealing compound away from the tool laminate
(Refer to Figure 4, step d).
4. Stack sufficient layers of “breather dam” on top of each other so that they extend 3.0mm (1/8 inch) higher than the
laminate thickness (Refer to figure 5).
As resin flows into the boat cloth during cure the vacuum paths will close eliminating excess resin bleed.
5. Peel ply is not generally recommended for use with DForm as it restricts the compliancy of the tiles, if it is desired, it
should be used only locally (intended secondary bonding areas) and always cut clear of complex geometry and female
corners.
6. Cover the layup with a continuous layer of non-perforated A5000 release film (See Table 8).
Extend the release film over the breather dam sealing tucks and folds with high temperature adhesive tape.
7. Tape the release film in place ensuring a minimum of 25mm (1 inch) of boat cloth (EB520) from each of the “breather
dam” layers is exposed so that it can contact the breather pack.
8. Apply the breather pack using suitable breather (See Table 8) ensuring no bridging.
Ensure the breather extends over the boat cloth layers from the “breather dams”.

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9. Locate a minimum of two vacuum ports on breather pads, for a laminate up to 2 square meters (20 square feet) and
another port for each additional 1 square meter (10 square feet).
Do not locate vacuum ports directly on top of the laminate. Position them against the master model/intermediate or in
tucks in the vacuum bag ensuring they are connected to the breather pack and always use an even number of vacuum
ports.
10. Using a second non-perforated A5000 release film layer (See Table 6), cover the tool and breather to protect the
vacuum bag film. Do not block the vacuum path from ports to the breather pack.
11. Vacuum bag the lay-up using a good quality BMI-resistant bagging film (See Table 8) ensuring no bridging.
12. Check the vacuum integrity by pulling a full vacuum 950-980mbar (28-29” Hg) then disconnecting the vacuum source.
If the bag loses more than 70mbar (2” Hg) in 15 minutes check and seal leaks.
13. Maintain 950mbar (28” Hg) vacuum and debulk the laminate.

a) Start with fiberglass boat cloth and bag b) Place sealant strip on top of the boat cloth
sealing compound as shown

c) Fold the boat cloth over the sealant strip d) Place the “breather dam” in contact with
leaving approximately half of the strip the edge of the lay-up; secure it to the
width exposed master model/intermediate using the
exposed sealant

Figure 4 | Creation of “Breather Dam” Assembly

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Release film   Vacuum bag   Stack additional strips of “breather dam”  

(Step 1  0)  (Step  11)  assembly as needed (Step 4)   
Breather pack  
(Step 8)  
Fibreglass boat cloth wrapped around strips of bag  
sealing compound to form “breather dam”
Release film   (Step  
(Step 6  ) 
Exposed boat cloth from “breather dams”  
must contact breather pack (Step  
   
Vacuum port 
Bag sealing  
compound 
Dform Tiles 
   

Master Model /
Intermediate 
Use uncovered portion of bag sealing compound  
to adhere “breather dam” to the master  
  
model/intermediate surface (Step 3)

®
Figure 5 | DForm Fabric Tooling – BMI Bagging Scheme
NOTE: Step numbers refer to Final Bagging Procedure section, See Table 6 for details of consumables to be used.

CURE CYCLE SUMMARY

AUTOCLAVE CURE
Table 4
 
†
Vacuum bag pressure Minimum of 950 mbar (28”Hg)*
Autoclave pressure 6.2 bar (90 psi)
Ramp rate 1 to 2°C (2 to 4°F)/minute
Recommended cure cycle 6 hours at 177°C, +3/-3°C (350°F, +5/-5°F)
Cool down (under pressure) Maximum of 3°C (5°F)/minute to 60°C (140°F)
*This is the ideal vacuum level, however, it is recognised that it is not always possible to attain due to elevation. If in doubt, please contact Solvay Technical
Service staff for advice.

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RECOMMENDED CURE PROCEDURE

1. Apply a minimum of 950mbar (28inch of Hg) vacuum.
Allow sufficient time for the vacuum to penetrate the DForm laminate – for large tools his can require 24 hours prior to
the autoclave cure cycle, please consult Solvay Technical Services for advice.
2. Apply a minimum of 6.2 bar (90psi) autoclave pressure [6.2+ bar (90psi +) preferred] with full vacuum.
3. Heat the laminate at a rate of 1 – 2°C/minute (2-4°F/minute) until the lagging thermocouple reaches a cure temperature
of 177 ± 3°C (350 ± 5 °F).
To promote even heat up do not allow autoclave temperature to exceed 10°C (20°F) above the cure temperature.
4. Hold the laminate at 177 ± 3°C (350 ± 5 °F) for a dwell time of 6 hours minimum.
5. Cool the laminate under pressure to 60°C (140°F) at 3.0°C/minute (5°F/minute) maximum rate.

RELEASE PROCEDURE
1. Remove the bagging materials from the laminate.
2. Attach support structure if desired.
Most composite tools require some kind of support structure. This may take the form of an extended flange or a complex
structure designed to prevent deflection under normal service conditions. These usually fall into one of two categories.
• Egg crate structures: This kind of structure is prefabricated from either solid or honeycomb cored composite panels
and can be applied before demoulding or after post-cure. Attachment is by wet lay-up “cleats”, silicone RTV
adhesive or mechanical fasteners. The structure should be spaced 2-3mm ~1/8” away from the back face of the tool
laminate.
• Tubular structures: This kind of structure is also prefabricated using composite tube sections and can be applied
before de-moulding or after post-cure. Attachment is by wet lay-up “cleats” or mechanical fasteners. Additional pads
are usually added to the back of the tool laminate to spread loads at the local attachment points.
3. Carefully release the laminate around its entire periphery and ease it off the master model/intermediate.
Always use “soft” plastic wedges; never use metal chisels or scrapers.

POST –CURE PROCEDURE (SIMPLY SUPPORTED VS TIED-IN CONSIDERATIONS)

®
To achieve maximum stability DForm Fabric Tooling – BMI must undergo a post-cure cycle in addition to the initial 177°C
(350°F) cure to develop its maximum Tg and temperature resistance. For most postcures the tool skin should be lightly
supported during the post-cure cycle. The tool backing structure may be used as a cradle, but should not be rigidly attached
to the tool skin. There are many schools of thought on the relative merits of attaching (Tied In) backing compared with not
attaching backing structure, we recommend you contact us to discuss the merits of each approach with respect to your
application.

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Table 5
 
Ramp rate for “Lightly Supported” 0.3°C (0.5°F)/minute
*
Post-cure cycle 6 hours at 226°C (440°F)
Cool down Maximum of 1-2°C (2-4°F)/minute to 60°C (140°F)
* Temperature must be measured by the lagging thermocouple attached to the tool.

Notes:

Large tool faces should be adequately supported to avoid distortion.

Other post-cure cycles to achieve a range of Tg’s are available. Please contact Solvay Technical Services for advice.
Temperature must be measured by the lagging thermocouple attached to the part.

Adequate considerations with respect to “Tied-in” structures and suitability of resin deployed for this purpose are critical, if in any doubt, use slow ramp for
Lightly Supported Structures, 0.3°C (0.5°F)/minute. Always verify Dry Tg suitability of attachment resins used for Tabs/Cleats.

DISPOSAL OF SCRAP MATERIAL

Disposal of scrap material should be in accordance with local, state, and federal regulations.

EXOTHERM
BMI prepregs whilst being a reactive formulation, exhibit a very low risk of exothermic reaction during the curing process.
Please contact our Solvay Technical Service staff for further information on the exotherm behaviour of this prepreg.

SURFACE MACHINING
®
DForm Fabric Tooling – BMI is designed for the manufacture of cast tools and machined tools. Post machined Solvay BMI
tools have an extensive history with good service performance. Solvay Technical Services can assist with recommendations
for machining the BMI tool surface with guidelines on feeds and speeds, suitable cutters and parasitic material requirements.

PHYSICAL PROPERTIES
Table 6
 
3
Cured resin density 1.25 g/cm
Tg (DMA) Postcured to 210°C (410°F) 220°C (426°F)
Tg (DMA) Postcured to 226°C (440°F) 240°C (465°F)
Tg (DMA) Postcured to 240°C (464°F) 257°C (495°F)
-6 -6
CTE 2.6×10 /°C (1.4×10 /°F)
In-plane shrinkage ~0.055%
 
 
 
 
 
 
 
 

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STORAGE
Table 7
 
Out life at 21°C (70°F) 45 Days
Storage life -18°C (0°F) 24 months
®
DForm Fabric Tooling – BMI should be stored in a freezer at all times, it is supplied in packs of 6 tiles 62.25cm x 62.25cm
(24.5” × 24.5”) in a sealed polythene bag. On removal from the freezer, the pack should be allowed to thaw before the
polythene bag is opened. A full pack of frozen tiles will take between 1 and 3 hours to reach room temperature. If material is
not fully thawed prior to use, condensation may form on the surface, thereby presenting a condition that can be detrimental
to the final laminate properties.

RECOMMENDED VACUUM BAGGING MATERIALS

Table 8 | Recommended Consumables (Refer to Solvay Process Materials contact details below)

Type Name Operation Comment

Tacky Tape SM-5142 All Debulks and Final Bagging
Bagging Film Stretch–VAC 250 All Debulks Light Blue
Bagging Film HS6262 Final Bagging Light Blue
Release Film A5000 Debulks and Final Bagging Purple or White
Nylon Breather Material RC-3000-10NB Final Bagging
Polyester Breather Material A 3000 Autoclave Debulks 115gsm (4oz/yd)
3” Dry Glass Tape EB520 Final Bagging (edge breathing) 3” X 50 yards

HEALTH & SAFETY

Please refer to the product MSDS for safe handling, personal protective equipment recommendations and disposal
considerations.

DISCLAIMER: The data and information provided in this document have been obtained from carefully controlled samples and are considered to be
representative of the product described. Solvay does not express or imply any guarantee or warranty of any kind including, but not limited to, the accuracy, the
completeness or the relevance of the data and information set out herein. Because the properties of this product can be significantly affected by the fabrication
and testing techniques employed, and since Solvay does not control the conditions under which its products are tested and used, Solvay cannot guarantee the
properties provided will be obtained with other processes and equipment. No guarantee or warranty is provided if the product is adapted for a specific use or
purpose. Solvay declines any liability with respect to the use made by any third party of the data and information contained herein. Solvay has the right to
change any data or information when deemed appropriate. All trademarks are the property of their respective owners. ©2016, Solvay. All rights reserved.
 

Solvay
Composite Materials
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Tempe, AZ 85284 USA

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