Abstract: A system and a method of fabricating a complex three dimensional part are described. The system comprises a rapid prototyping machine configured to provide a disposable mold having a negative imprint of a complex three dimensional structure, a mixer, an injection molding machine, and a furnace system. A slurry comprising a powder and a binder is introduced into the disposable mold, the binder is cured, the disposable mold is removed, and the binder is removed, leaving an intact cured structure. The cured structure is sintered to fabricate the complex three dimensional part.

Abstract: A system and a method of fabricating a complex three dimensional part are described. The system comprises a rapid prototyping machine configured to provide a disposable mold having a negative imprint of a complex three dimensional structure, a mixer, an injection molding machine, and a furnace system. A slurry comprising a powder and a binder is introduced into the disposable mold, the binder is cured, the disposable mold is removed, and the binder is removed, leaving an intact cured structure. The cured structure is sintered to fabricate the complex three dimensional part.

Abstract: A simulation system for generating a predicted performance for fabricated parts comprises a rheological degradation database for storing rheological degradation data for associated materials, a mechanical degradation database for storing mechanical degradation data for associated materials and a computer coupled to the rheological degradation database and the mechanical degradation database for computing part performance predictions for a respective material with a predetermined geometry under predetermined processing conditions, partially based on the rheological degradation data and the mechanical degradation data.

Abstract: A method for enabling design of a profile extrusion capping die includes, obtaining a size and configuration of a land formable by the capping die, obtaining material properties of a capping resin, obtaining operating conditions for processing the capping resin, and determining, from the size and configuration of the land, the material properties, the operating conditions, at least one of a velocity distribution and a pressure distribution of the capping resin adjacent to an outlet of the land. Desirably, the method also includes obtaining a size and configuration of a runner formable by the profile extrusion capping die, and determining at least one of the velocity distribution and the pressure distribution of the capping resin in the land and the runner. Advantageously, the method is implemented on a system or computer using a finite element mesh of the land and the runner and graphically displaying the velocity distribution and the pressure distribution.

Abstract: A spray coating simulation for a robotic spray gun assembly imports a discretized model of an object geometry. Next, the simulator imports a numerically characterized spray pattern file and a robot motion file having a plurality of motion positions, dwell times and orientations defining a motion path of the spray gun. The individual motion positions within the motion file are read and a determination is made as to which portions of the object geometry are visible at each motion position. Next, a coating thickness at each visible portion of the object geometry is computed, based on the specified spray pattern data, the dwell time and the orientation of the robot motion path, for each motion position. Finally, the total coating thickness over the object geometry is calculated.

Abstract: The present invention discloses a method for designing a profile extrusion die for shaping a polymer resin material into a profile having a plurality of sections. In the present invention, a plurality of operating conditions for shaping the resin material into the profile are determined. The dimensions of each of the plurality of sections of the profile are then specified. The profile dimensions include width and thickness. Extrusion information for the polymer resin including die swell/drawdown and flow balance is obtained. Die dimensions for shaping the profile in accordance with the operating conditions, the profile dimensions, and the extrusion information are then determined.

Abstract: A method for filling a compartment cavity, such as a refrigerative unit cavity, with a foam produced by an expansion and solidification of a foaming mixture of predetermined chemicals. A known amount of the foaming mixture is created in a test chamber cavity and preselected parameters (such as free surface height and pressure) are measured to obtain the average density and apparent viscosity of the foam as a function of time. A computer program uses the average density and apparent viscosity data to simulate the foaming process for various starting quantifies and starting locations of the foaming mixture. A preferred quantity and location are chosen from a particular computer run which satisfies predetermined fill criteria. The preferred quantity of the foaming mixture is then created at the preferred location in the compartment cavity.