Abstract: A part having an integrated, discrete component is produced by direct digital manufacturing and rapid, solid free-form fabrication techniques. A CAD file representing the part is modified to include an opening in the body of the part in which the component is to be inserted. The fabrication is performed by additive layering of a thermoplastic material, preferably using fused deposition modeling or stereolithography. The layering process is interrupted to allow the component to be inserted in the partially formed part, following which additional layers are added which secure the component in the part in place and complete the physical structure of the part.

Abstract: A light source with an integral surface of revolution to project an emergency warning light signal for a vehicle in a substantially horizontal 360° arc. A centrally positioned mirror assembly has a plurality of light sources spaced about the mirror assembly.

Abstract: A reclining seat includes a base for mounting on a floor, including left and right arms, left and right recliner mechanisms mounted between the left and right arms, a spring cushion secured between the left and right recliner mechanisms, the spring cushion including support for a plurality springs, a plurality of springs mounted on the support and twine tied in an eight-way, hand-tied pattern to the springs, to provide an eight-way hand-tied cushion for the reclining seat, and upholstery and padding covering the spring cushion.