System and Method for Producing a Structure with an Electrostatic Spray

1 . A system, comprising:

an electrostatic spray system, comprising:

an electrostatic tool configured to spray a material with an electrostatic charge; and

a target with a surface finish greater than or equal to a number 4 mirror finish configured to receive a material sprayed by the electrostatic tool.

2 . The system of claim 1 , wherein the target includes a friction reducing coating.

3 . The system of claim 2 , wherein the friction reducing coating has a surface finish between a number four and a number eight minor finish.

4 . The system of claim 3 , wherein the friction reducing coating comprises polytetrafluoroethylene (PTFE), fluorinated ethylene propylene (tetrafluoroethylene), hexafluoropropylene (FEP), or perfluoroalkoxy (PFA).

5 . The system of claim 1 , wherein the target is a mandrel.

6 . The system of claim 5 , wherein the mandrel is made of an electrically conductive material.

7 . The system of claim 6 , wherein the electrically conductive material comprises stainless steel.

8 . The system of claim 1 , wherein the electrostatic tool comprises a rotary atomizer.

9 . A system comprising:

an electrostatic spray system controller configured to change operating parameters of a electrostatic spray system that discharges electrically charged material with slow rates of electrical charge decay.

10 . The system of claim 9 , wherein the electrostatic sprayer system includes an electrostatic tool configured to spray the electrically charged material at a target.

11 . The system of claim 10 , wherein the controller includes a processor.

12 . The system of claim 11 , wherein the controller includes a memory with instructions for the processor, and wherein the instructions change parameters of the electrostatic sprayer system.

13 . The system of claim 12 , wherein the parameters include a bell speed of the electrostatic tool, a speed of shaping air, a distance between the electrostic tool and the target, a rotation percentage of the target or the electrostatic tool, an angle of the electrostatic tool, a partial cure time of the electrically charged material, a spraying duration of the electrically charged material, a number of coatings, and a voltage applied to the electrically charged material.

14 . The system of claim 9 , wherein the controller is configured to remove an electric charge from the material while the electrostatic tool is spraying the material.

15 . A method for producing a target for an electrostatic spray system, comprising:

forming a target with electrically conductive material; and

polishing a target surface of the target.

16 . The method of claim 15 , wherein polishing the target surface comprises polishing to at least a number four minor finish.

17 . The method of claim 15 , comprising applying a low friction coating to the target surface.

18 . The method of claim 17 , comprising polishing the low friction coating to at least a number four mirror finish.

19 . A method for producing a target for an electrostatic spray system comprising:

forming a target with an electrically conductive material;

applying a low friction coating to a surface of the target;

polishing the low friction coating to at least a number four minor finish.

20 . A method for producing a part with an electrostatic spray system, comprising:

preparing a coating material;

preparing a target for receipt of the coating material;

adjust parameters of the electrostatic spray system;

electrostatically spraying a coating material onto the target to create a layer of a wall;

partially curing the layer of coating material;

determining if a thickness of the wall is equal to or greater than a threshold;

applying another layer of the coating material if the thickness is less than the threshold;

curing the coating material; and

removing the wall from the target.