Abstract: Described herein are methods and systems for manufacturing composite stringers using independently movable pallets with independent vacuum controls. Specifically, a stringer forming system comprises a base plate and a plurality of sets of pallets (e.g., two or more sets of pallets), slidably coupled to the base plate and forming an adjustable cavity. Each pallet comprises a primary vacuum zone, fluidly connected to a separate vacuum port. The system allows for independent application of a reduced pressure to the primary vacuum zone of each pallet. For example, a reduced pressure is applied only to pallets that are already covered with a composite layup and to pallets that are being covered. Any pallets that are exposed are kept at an ambient pressure and decoupled from a vacuum source, thereby reducing the vacuum leakage through the overall system. As the composite layup is being formed over new pallets, these new pallets are subjected to the reduced pressure.

Abstract: A fibrous structure is disclosed. The fibrous structure exhibits a plurality of discrete knuckles arranged in a pattern of repeat units. The repeat units can include a plurality of rows arranged orthogonally in an X-Y plane, each row having a portion of the discrete knuckles, and each discrete knuckle separated from adjacent discrete knuckles in a row by a distance. Each of the discrete knuckles within the repeat unit can have substantially the same shape and size; and wherein the distance between at least two adjacent discrete knuckles in each row are non-uniform such that the repeat unit exhibits varying pillow width distances along the rows in both the X and Y axes.

Abstract: Methods for machining a composite material substrate are discloses comprising integrating a predetermined pattern area having a disbond material for the purpose of creating a disbond region into the composite material substrate at a predetermined thickness, detecting the disbond region and forming a plurality of recesses in the composite material substrate by removing a machined plug from the composite material substrate to form recesses positioned at locations corresponding to the predetermined pattern area, and composite components comprising the recesses machined according to such methods.

Abstract: Systems and methods are provided for fabricating composite parts. One embodiment is a method for fabricating a composite part. The method includes forming a skin panel preform comprising fiber reinforced material, disposing rigid end caps at the skin panel preform at end locations of stringer preforms that will be placed at the skin panel, locating the stringer preforms at the skin panel preform via the rigid end caps, and anchoring the stringer preforms to the skin panel preform.

Abstract: A method for manufacturing a medical introducer includes placing an introducer sheath onto a mandrel, and overmolding an introducer hub onto a proximal end of the introducer sheath. The introducer sheath has one or more score lines formed on an inner surface and the mandrel has a number of surface protrusions so that when the introducer sheath is positioned on the mandrel, each of the surface protrusions contacts one of the score lines formed on the introducer sheath. The surface protrusions on the mandrel prevent plastic material from the introducer hub from contacting the score lines thereby maintaining the score lines during the overmolding.

Abstract: An automated manufacturing method and system and in-mold coated plastic article produced thereby are provided. The system includes a compression mold and a plurality of program-controlled manipulators. An automatic sprayer supported on a first manipulator sprays at least a portion of a mold surface with an in-mold coating composition. An end effector supported on a second manipulator picks up a heated blank of moldable plastic sheet material from an oven and places the heated blank between upper and lower mold halves of the mold. An inner portion of the heated blank is forced into an article-defining cavity of the mold and into contact with at least a portion of the in-mold coating composition. The in-mold coating composition and the inner portion of the heated blank cure and bond to one another so as to form the coated plastic article.

Abstract: A method of over-molding a thermoplastic material over fabric includes: precision forming a mold cavity to match the final dimensions of a finished product; cutting a piece of fabric to a correct size; fixedly securing the fabric piece in the mold cavity; and injecting a thermoplastic material into the mold cavity at an appropriate temperature and pressure, on top of the fabric piece. The method may further include heating the thermoplastic material to a temperature for melting a surface layer of the fabric when injected thereon, and cooling of the thermoplastic material and fabric for bonding of the thermoplastic material to the surface of the fabric. The method may further include adding one or more additives from the group of additives consisting of: a UV stabilizer, an anti-blocking agent, a slip agents, a plasticizer, and a flame retardant; and securing a cord member onto an exposed portion of the fabric.

Abstract: A three dimensional (3D) printing apparatus to print an implantable bone scaffold (IBS) in an aseptic environment is described. The 3D printing apparatus includes a sterile cartridge. The sterile cartridge contains a sterile printing material, a print nozzle, and a plunger. The 3D printing apparatus also includes a heater configured to indirectly heat the printing material. In addition, the 3D printing apparatus includes a cartridge receiver configured to retain the sterile cartridge. A sterile receiving plate is positioned below the print nozzle. A cover encompasses and maintains the sterile cartridge and the sterile receiving plate in an aseptic environment. A filter fan unit (FFU) overlays a section of the cover. Positive laminar filtered air flow created by the FFU maintains the aseptic environment inside a printing chamber. An ultraviolet light source irradiates the receiving plate. A movable diaphragm separates a printer mechanism, below the receiving plate, from the printing chamber.

Abstract: A heat blanket system including a blanket including a first sub-area and a second sub-area. The heat blanket system also includes heating elements printed on the blanket. First spacings between first ones of the heating elements in the first sub-area varies relative to second spacings between second ones of the heating elements in the second sub-area. The first spacings and the second spacings vary according to a design. The design is configured for use on a uniquely defined rework area on a uniquely defined composite material object including a third area including a heat sink region and a fourth area including a non-heat sink region. The first sub-area is sized and dimensioned to be placed over the third area. The second sub-area is sized and dimensioned to be placed over the fourth area.

Abstract: Disclosed herein is a method of forming a mold comprising disposing a film having a textured surface on a support; where the support has a shape of an article to be manufactured; pressing the film onto the support to cover a surface of the support; disposing a backing on the film; separating the support from the backing; and molding a material in the backing. Disclosed herein too is a method comprising contacting a first mandrel with a first mold; where the first mold has a textured surface; texturing a surface of the first mandrel with the first mold; disposing the first mandrel in a die; disposing a first material in the die to contact the first mandrel; imparting a texture from the surface of the first mandrel onto the material to form a second mold; and disposing a texture from the second mold onto a second material; where the second material is different from the first material.

Abstract: Disclosed herein is a cure tool for managing a thermal cycle of a composite component. The cure tool, in certain examples, includes a base plate comprising a work surface, for supporting the composite component, and a back surface opposite the work surface. The cure tool also includes one or more fins protruding from the back surface of the base plate and in thermal communication with the base plate. The cure tool additionally includes one or more heating elements coupled to each of the one or more fins and configured to selectively provide heat to the base plate.

Abstract: A substrate bonding apparatus for bonding a first substrate to a second substrate includes a first bonding chuck configured to fix the first substrate to a first surface of the first bonding chuck; a second bonding chuck configured to fix the second substrate to a second surface of the second bonding chuck, the second surface facing the first surface; a process gas injector surrounding at least one selected from the first bonding chuck and the second bonding chuck in a plan view, the process gas injector configured to inject a process gas between the first substrate and the second substrate when respectively disposed on the first bonding chuck and the second bonding chuck; and an air curtain generator disposed at an outside of the process gas injector in the plan view, the air curtain generator configured to inject an air curtain forming gas to form an air curtain surrounding the first substrate and the second substrate.

Abstract: A method and device for adjusting the concentricity of a die component of an extrusion assembly relative to a tip component in a manner that minimizes time and effort. The concentricity adjusting extrusion device includes an extrusion die body assembly including a die subassembly and a body, a die tip module and an adjustment sleeve subassembly; wherein said adjustment sleeve subassembly adjusts the concentricity of the die subassembly relative to the die tip module.

Abstract: A method of manufacturing an impeller for a thermal management device includes partially curing a curable liquid in a curable liquid bath to form a first stage rotor, removing the first stage rotor from the curable liquid bath, the first stage rotor having excess curable liquid on a surface thereof, rotating the first stage rotor to displace the excess curable liquid radially outward from a rotational axis to compensate for imbalances in the first stage rotor, and fully curing the first stage rotor and at least a portion of the excess curable liquid to produce a second stage rotor that is more rotationally balanced than the first stage rotor.

Abstract: A tire mold for processing a green tire includes a movable block, an upper sidewall plate, and a lower sidewall plate. A curved surface corresponding to the green tire is provided at a junction of the movable block and the upper sidewall plate/the lower sidewall plate. The movable block, the upper sidewall plate and the lower sidewall plate cooperate with each other to surround a tire cavity for accommodating the green tire. Thereby, the edge of the upper sidewall plate or the lower sidewall plate won't penetrate the green tire to form a joint fin when the mold is closed, which is beneficial to save the rubber material, improves production efficiency and reduces manufacturing costs.

Abstract: Methods and apparatus are provided for the separation of a feedstock stream comprising a principle component and at least one secondary component such that at least one component has greater friability that the others using a rotary impact separator. The methods allow the recovery of two or more streams, one rich in the more friable component, and one lean in the more friable component.

Abstract: A taco shell mold for cooking tortillas may include a tortilla cage sized and shaped to accommodate a tortilla. The tortilla cage may include an outer frame with a substantially U-shaped cross section and an inner frame nested within the outer frame, the inner frame having a substantially U-shaped cross section, wherein the inner frame is spaced from the outer frame, defining a tortilla slot between the inner frame and the outer frame. A handle attachment may be attached to the cage. Some versions of the taco shell mold may include a plurality of taco cages nested within one another.

Abstract: A stiffening element comprises a tension and compression member, a shear member, an attachment member, and a plurality of beads. The tension and compression member is positioned spaced apart from the skin and configured to bear tension or compression forces that stiffen the skin and prevent the skin from buckling or bending. The shear member is connected to the tension and compression member and configured to bear shear forces between the skin and the tension and compression member. The attachment member is connected to the shear member and is configured to connect to the skin. The beads each create out-of-plane feature that is positioned in at least one of the shear member and the attachment member. The beads permit the stiffening element be reshaped to adjust a longitudinal curvature of the stiffening element.

Abstract: Provided are methods and devices for supporting of variety of different pre-cured composite stringers after forming and prior to curing. A post-forming processing device comprises a base with a channel for receiving hat portions of different stringers. The device also comprises a support structure, at least partially extending within the channel. The support structure is configured to conform to different hat portions and to retain the shape of these hat portions. For example, the support structure is made from a flexible material, which conforms to any shape variations. In some examples, the support structure is made from a jamming material that is reshaped together with each of the pre-cured composite stringers. A post-forming processing device is used for supporting different pre-cured composite stringers while various operations are performed on these stringers, such as stringer trimming, inspection, installation of bladders and noodles, and the like.

Abstract: A method for reconditioning a rollable wheel includes coupling a polymeric wheel to a reconditioning system, the polymeric wheel having an outer surface including an abraded area, the abraded area having a first average surface roughness, and applying heat to the abraded area of the outer surface with one or more heater of the reconditioning system, such that a substantial portion of the abraded area is transformed to have a second average surface roughness, the second average surface roughness less than the first average surface roughness.