Active self-shaping non-Newtonian fluid based system and method for rapid mold tooling

1. A rapid mold tooling fabrication system using non-Newtonian shear thickening fluid (STF), the system comprising:

at least one molding unit comprising:

a frame encompassing a fabrication area;

a plurality of actuatable hydraulic pillars arranged in a two-dimensional array, wherein each hydraulic pillar extends in a first direction to a distal end and is configured to be extended or retracted along the first direction;

an expandable STF chamber comprising a first preform layer and an opposing second preform layer,

wherein the first preform layer is a boundary layer and extends across the distal ends of the hydraulic pillars such that the pillars push or pull against the boundary layer when extended or retracted, and

wherein the second preform layer is an interface layer having an outer surface against which a mold can be formed;

a fluid storage container for storing the STF and a pump configured to pump the STF from the fluid storage container into the STF chamber during operation;

a signal emitter circuit provided at one or more of the first and second preform layers, wherein the signal emitter circuits is configured to emit an electric signal into the STF, wherein the electric signal stimulates the STF and thereby transitions the STF from a liquid to a solid state; and

a controller, the controller comprising a non-transitory computer readable storage medium and a processor electronically coupled to the storage medium, the signal emitter circuit and the fluid storage container, wherein the processor is configured by executing instructions stored on the storage medium to:

cause the plurality of pillars to respectively extend or retract according to a prescribed shape,

cause STF to be pumped from the fluid storage container into the STF chamber,

cause the signal emitter circuit to emit the electric signal into the STF within the chamber and thereby transitioning the STF from a liquid to a solid state, and

after transitioning the STF from the liquid to the solid state, initiating a molding process during which a material placed against the outer surface of the interface layer is compressed against the interface layer to form the mold having the prescribed shape.

2. The system of claim 1 , wherein the processor is further configured to cause a prescribed volume of STF to be pumped into the STF chamber as a function of the prescribed shape.

3. The system of claim 1 , wherein the processor is further configured to selectively modulate an intensity of the electric signal as a function of time during forming of the mold.

4. The system of claim 1 , wherein a plurality of signal emitter circuits are arranged at respective locations over the boundary layer, and wherein the processor is further configured to cause the electrical signal to be selectively emitted from one or more of the plurality of signal emitter circuits as a function of location.

5. The system of claim 1 , wherein the outer surface of the interface layer comprises a non-stick material.

6. The system of claim 1 , further comprising: two opposing molding units arranged on opposing sides of the fabrication area, wherein compression of the material between the interface layer of a first molding unit and the interface layer of a second molding unit forms the mold having the prescribed shape.

7. The system of claim 1 , wherein the molding process comprises one or more of a compression molding process and an injection molding process.