Bonded tab and tooling device

1. A method for forming a tooling device and a composite part, the method comprising:

positioning a first number of layers of composite material with respect to a first tool; and

positioning the tooling device on the first number of layers of composite material, wherein the tooling device comprises:

a tooling plate comprising a second number of layers of composite material;

a tab; and

a group of alignment features associated with the tab, wherein the group of alignment features comprises:

a first alignment feature configured to position the tooling plate with respect to the first tool, the first alignment feature comprising a first opening configured to receive a first pin associated with the first tool; and

a second alignment feature configured to position the tab with respect to a second tool and an offsetting spacer, the second alignment feature comprising a second opening configured to receive a second pin associated with the second tool; wherein the tab:

has a first portion that is interposed between layers of the second number of layers of composite material;

has a second portion that extends from a first end of the tooling plate;

is positioned using the second alignment feature, the second tool, and the offsetting spacer; and

after being positioned, is co-bonded with the second number of layers of composite material to form the tooling device.

2. The method of claim 1 , wherein a portion of the second number of layers of composite material is lain up to cover a planar structure of the tab.

3. The method of claim 1 , wherein positioning the tooling device further comprises:

receiving the first pin extending from a surface of the first tool in the first alignment feature to position the tooling device on the first number of layers of composite material.

4. The method of claim 1 , wherein positioning the tab further comprises:

receiving a third pin extending from a surface of the second tool in a third alignment feature.

5. The method of claim 1 further comprising:

curing the first number of layers of composite material to form the composite part, wherein the tooling device is used to form a surface of the composite part during curing of the first number of layers of composite material.

6. The method of claim 1 further comprising:

forming an outer mold line of the composite part with an inner surface of the tooling plate.

7. The method of claim 1 further comprising:

reducing movement of the tooling plate in a number of directions with the group of alignment features with respect to the first tool when forming the composite part.

8. The method of claim 1 wherein the tooling plate and the group of alignment features form an indexed caul plate.

9. The method of claim 1 , wherein the group of alignment features comprises openings having a shape selected from at least one of a circular shape, a rectangular shape, a hexagonal shape, a triangular shape, or an oval shape.

10. The method of claim 1 , further comprising:

positioning a vacuum bag over the composite part; and

apply a vacuum during formation of the composite part.

11. The method of claim 1 , wherein

the first number of layers of composite material comprises at least one of a fabric composite material, a cloth composite material, a tape composite material, or a tow composite material.

12. The method of claim 1 , wherein the tab comprises a material selected from at least one of a thermoplastic material, a thermoset material, a phenolic resin, a metal, a metal alloy, or fluorinated ethylene propylene.

13. The method of claim 4 , wherein the offsetting spacer is configured to support the tab during co-bonding of the tab with the tooling plate, the offsetting spacer comprising:

a set of clearance holes configured to accommodate the second pin and the third pin; and

a spacer thickness that is substantially a same thickness as a thickness of a plurality of layers of the second number of layers of composite material, such that the tab rests on a coplanar surface.

14. A method comprising:

positioning a first number of layers of composite material with respect to a first tool; and

positioning a tooling device on the first number of layers of composite material, wherein the tooling device comprises:

a tooling plate comprising a second number of layers of composite material;

a tab; and

a group of alignment features associated with the tab, wherein the group of alignment features comprises:

a first alignment feature configured to position the tooling plate with respect to the first tool, the first alignment feature comprising a first opening configured to receive a first pin associated with the first tool; and

a second alignment feature configured to position the tab with respect to a second tool and a spacer, the second alignment feature comprising a second opening configured to receive a second pin associated with the second tool, the spacer configured to support the tab during a co-bonding process of the tab with the tooling plate; wherein the tab:

has a first portion that is between layers of the second number of layers of composite material;

has a second portion that extends from a first end of the tooling plate;

is positioned using the second alignment feature, the second tool, and the spacer; and

after being positioned, is co-bonded with the second number of layers of composite material to form the tooling device.

15. The method of claim 14 , wherein the spacer comprises:

a clearance hole configured to accommodate the second pin; and

a first thickness that is substantially a same thickness as a second thickness of layers of the second number of layers of composite material, such that the tab rests on a coplanar surface.

16. The method of claim 15 , wherein a portion of the second number of layers of composite material is lain up to cover a planar structure of the tab.

17. A method comprising:

positioning a first number of layers of composite material with respect to a first tool; and

positioning a tooling device on the first number of layers of composite material, wherein the tooling device comprises:

a tooling plate comprising a second number of layers of composite material;

a tab; and

a group of alignment features associated with the tab, wherein the group of alignment features comprises:

a first alignment feature configured to position the tooling plate with respect to the first tool, the first alignment feature comprising a first opening configured to receive a first pin associated with the first tool; and

a second alignment feature configured to position the tab with respect to a second tool and a spacer, the second alignment feature comprising a second opening configured to receive a second pin associated with the second tool, the spacer comprising a clearance hole configured to accommodate the second pin; wherein the tab:

has a first portion that is between layers of the second number of layers of composite material;

has a second portion that extends from a first end of the tooling plate;

is positioned using the second alignment feature, the second tool, and the spacer; and

after being positioned, is co-bonded with the second number of layers of composite material to form the tooling device.

18. The method of claim 17 , wherein the spacer comprises a thickness that is substantially a same thickness as a third number of layers of the second number of layers of composite material, such that the tab rests on a coplanar surface.

19. The method of claim 18 , wherein positioning the tooling device further comprises:

receiving the first pin extending from a surface of the first tool in the first alignment feature to position the tooling device on the first number of layers of composite material.

20. The method of claim 19 , further comprising:

curing the first number of layers of composite material to form a composite part, wherein the tooling device is used to form a surface of the composite part during curing of the first number of layers of composite material.