Abstract: The process of the present invention involves molding a 3-D molded product from a sheet. The molded product includes a product section, which turns out to be a product, and an extra product section, which is to be excised. The sheet is made of a thermoplastic polymeric material. The process includes clamping the sheet at its peripheral edge; heating and softening the sheet; deforming the heated and softened sheet by stretching the sheet along a 3-D molding surface of a mold; and adhering the sheet to the 3-D molding surface to mold the 3-D molded product. A thickness of the product section is made up by moving the sheet material at the extra product section to the product section during the deforming step by partially releasing a tensile stress of the extra product section.

Abstract: A poreless first layer is electroformed on the conductive surface of a mandrel in an electroforming solution containing a substantial amount of a surface active agent. After the mandrel and the first layer are lifted from the solution, small straight pores each having an approximately equal diameter along a length thereof are formed through the first layer defining the front side of a porous electroformed shell. A second layer is deposited on the back side of the first layer in an electroforming solution containing less than the substantial amount of a surface active agent to form the back side of the shell, while undeposited hollow portions are formed in alignment with the straight pores in the first layer in initial formation of the second layer, the hollow portions enlarging to form diametrically enlarged pores through the second layer, the enlarged pores having a diameter which becomes larger toward a surface of the second layer opposite from the first layer.

Abstract: A three-dimensional electroformed shell for a mold consists of a three-dimensional thin-walled body, and an electroformed coating deposited on it. The coating may, or may not close the base holes of the thin-walled body completely. If it does not close the base holes completely, the shell has a multiplicity of apertures. A process for manufacturing the shell is also disclosed.

Abstract: A porous die includes a porous die body with a plurality of pores formed therein; a cooling chamber provided in direct contact with the back side of the porous die body in order to cool the porous die body; a device for supplying a coolant to the cooling chamber; and suction holes through which the cooling chamber is evacuated and the air and the coolant entering the cooling chamber are simultaneously sucked.