The CMPT technology is a dense, multi-directional, metal weaving process that eliminates the need for machined layup-toolfaces from large, heavy metal ingots or castings that require a lot of time to make. This robotically controlled process produces up to 12-feet square, pure metal tools in the thickness from 3/8" to 2" made from any standard or hybrid alloy. The process combines accuracy, precision, and good surface qualities previously available only after machining. A CMPT tool can be used as received. The tool is close to 'net-net' compared to the master model.

• Can reduce open-mold metal tool making time to six weeks
• Can lower tooling costs by more than one-third
• Ideal for rapid prototypes and rapid tooling
• Extremely accurate and dimensionally stable
• Permits long or short runs for cures to 750°F
• Withstands compaction pressures to 1500 psi
• Can be made of any alloy - aluminum to zinc
• Shortens lead times for product delivery
• Ideal for complex-shaped reinforced composites
• Can make an open-mold metal tool-face as big as 12-feet square
• Duplicates the properties of a solid metal tool
• "Dense" structure exhibits fewer oxide voids
• Can eliminate surface finishing or extra machining
• Can be impregnated with permanent release
• Permits synergistically built-in piezo electronics
• Can be impregnated for vacuum integrity

General Magnaplate's patented* CMPT' process is a true breakthrough in open-mold lay-up technology that saves both time and money for fabricators of parts constructed from composite materials. It reduces the total time generally required to make open-mold tool-faces for large, contour-shaped, complex reinforced composites from the conventional six-to-twelve months to as little as six weeks. At the same time, it slashes tooling costs by one-third or more.

The CMPT technology is a dense, multi-directional, metal weaving process which eliminates the need to machine layup-toolfaces from large, heavy, metal ingots or castings that require so much time to make. This robotically-controlled process produces 0.5-inch thick, up to 12-feet square, pure metal tools made from any alloy. The tools can be used for fiberglass reinforced plastic (FRP), bismaleimide (BM), prepreg (GR/EP), or any other high performance layups. The process combines the accuracy, precision, and good surface qualities previously available only after machining- It also makes possible high temperature tooling for long or short production runs for cures up to 750°F (399°C). CMPT open-mold tool-faces can be fabricated at all five of our plants in the United States and Canada.

Alloy composition
A CMPT tool-face can be made from any alloy, from aluminum to zinc, including high nickel INVAR.

Thickness
A CMPT open-mold tool-face is normally 3/8" to 1/2" thick. Older technologies create very thin tool-faces that average only about 1/10". As a result, they require the use of a composite backing which can cause warping and cracking. Since the thin tool-face and the backup materials cannot maintain stability during repeated curing and lay-up cycles, their use in long production runs is generally not recommended. Being able to use the CMPT pure metal tool-face for long production runs is one of the benefits of this process.

Porosity
A CMPT open-mold tool-face can be impregnated to hold vacuum integrity or be made porous to allow the wicking of volatiles.

Cost-effectiveness
A CMPT open-mold tool-face duplicates all the properties of a solid metal tool, minus the high cost, high weight, long lead time, and lengthy finishing time. For example, a five-foot square, three-foot thick INVAR billet weighs 35,000 lbs- and generally takes four months before it is ready for CNC machining, and could cost as much as $20,000 - even before machining and finishing. But a five-foot square CMPT toolface with a 3-foot contour takes only about seven days to make, and is ready for production after being fitted onto a flex-contour holding table. The cost reduction is at least 60%.

Temperature Resistance
Historically, tooling that was not machined from billets or castings exhibited stress problems resulting from voids and iron oxide contamination. But a CMPT open-mold tool-face equivalent to a Grade 2 casting is more 'dense' and contains fewer oxide voids than those produced by other methods. It makes possible long production runs for laminate cure-cycles up to 750°F (399°C), and compaction pressures up to 1500 psi. This permits, for the first time, a pure metal tool-face for the production of high-temperature composites, e.g., bismaleimide resins.

Optional Embedments
Tool-faces can be created with "synergistically" built-in piezo electronics programmed to monitor voids, intra-layer damage, temperature, and rate controls, as well as surface positioning of the layup. All these controls help to assure perfect composite laminates and are unavailable with any other technology.

Additional Mold Release
General Magnaplate can "synergistically" impregnate the surface of the open-mold tool-face with a field-repairable PLASMADIZE coating to give it permanent release properties. This eliminates the use of sprayed-on or painted-on soap-based release agents or silicone release agents.

Weight
Because the toolface is thinner, it provides a big reduction in tool weight and tool handling. Only two people, for example, are needed to handle a 12-foot square unit, while a 20,000 lb. forklift truck would be needed to move most conventional tools of the same dimensions. A 5-foot square CMPT toolface with a 3-foot contour weighs just 400 lbs.

Use Of Holding Tables or Bases For Molds
After the open-mold toolface has been constructed, it can be made ready for use by positioning it on a flex-contoured backup structure made of a variety of different materials. A low-cost urethane backup structure can be quickly and easily machined. Wooden or metal framed holding tables can be constructed. Bolts can be integrated into the tool-face onto which an egg-crate or metal framework can be attached.

Typical applications

• Aircraft
• Trucks
• Large appliances
• Trains
• Automobiles
• Buses