Rapid reconfigurable fuselage mandrel

1. A method of forming and using a reconfigurable composite part mandrel, the method comprising:

applying a simulated skin within an assembly fixture, wherein the simulated skin is configurable to represent a composite part to be formed;

assembling a frame portion within the assembly fixture;

inserting a generic mandrel into the assembly fixture;

filling a cavity between the generic mandrel and the assembly fixture with a state-changing mixture to encapsulate the frame portion;

hardening the state-changing mixture;

removing the assembly fixture and the simulated skin;

winding, laying up, or placing composite material around the frame portion, hardened state-changing mixture, and generic mandrel;

inserting the composite material, frame portion, hardened state-changing mixture, and generic mandrel back into the assembly fixture; and

curing the composite material in the assembly fixture.

2. The method of claim 1 , further comprising inserting a bag over the frame portion and at least a portion of the assembly fixture prior to inserting the generic mandrel, and pulling the bag down against the frame portion by vacuum force.

3. The method of claim 1 , wherein the state-changing mixture is hardened by pumping liquid contained in the state-changing mixture out of the cavity between the generic mandrel and the assembly fixture and heating the state-changing mixture.

4. The method of claim 1 , further comprising applying liquid to the state-changing mixture to soften the mixture and allow the composite material and frame portion to slide off of the reconfigurable composite part mandrel.

5. The method of claim 1 , wherein the assembly fixture is a clamshell or bond assembly jig.