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ClaveCore combines many of the individual advantages of existing materials (solubility, layup rigidity, and pressurization) into a single material. It is a rigid tooling system that develops expanding pressure once it is thermally activated. Precision mandrels can be formed, laid up with conventional pre-preg materials, placed into a female cavity tool, and heated inside a conventional oven. Its pressurization behavior can be engineered via composition to control the pressure onset temperature and magnitude of pressure.

Mandrels are formed by filling a mold cavity with powder and heating the mold to 80-100°C. At this temperature, the powder reaches an activation point and the powder mixture is converted into a solid mandrel. The mold is allowed to cool to room temperature and the mandrel demolded.

When the mandrel material is used, it is wrapped with prepreg and placed inside a female mold. Upon thermal activation, the mandrel expands. It pushes and consolidates the individual plies against the containment tool surface.

Downloadable Content

ClaveCore Data Sheet

ClaveCore Film HT Datasheet

Safety Datasheet

Specifications and Features

ClaveCore Features

ClaveCore™ is a tooling system that helps shape and cure high quality, complex hollow shapes. It is targeted at the carbon fiber composites industry (aerospace, automotive, sporting goods etc).

  • Can handle more complex geometries
  • Conventional lay-ups
  • High quality OML&IML surface
  • 40% savings compared to autoclave processes

ClaveCore Film HT key properties:

  • Expands and self-pressurizes when heated
  • Temperature-Pressure-Volume Expansion Models Exist
  • Pressures up to 700psi are possible depending on grade / process requirements
  • Produces precision OML dimensions
  • Produces high surface quality
  • Bendable/Conformable when applied to tooled surface
  • Bendable/Collapsible to aid removal allowing zero/negative draft
  • Allows for complex, seamless (unbonded) structures
  • Designed for >250°C (480°F) applications (thermoset or thermoplastic)

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