Abstract: A mold is provided. First and second materials are introduced into respective first and second portions of the mold to create a first and second parts of the item. The first and second parts of the item are allowed to solidify. The mold is opened and a heating element is inserted into the mold. A section of each of the first and second parts of the item is heated to above their glass transition temperatures with the heating element. The heating element is removed from the mold. The mold is closed such that the sections of the first and second parts of the item come into contact with each other. The sections of the first and second parts are cooled to below their glass transition temperatures to become joined. The mold is opened such that the item can be removed from the mold.

Abstract: A mold is provided. First and second materials are introduced into respective first and second portions of the mold to create a first and second parts of the item. The first and second parts of the item are allowed to solidify. The mold is opened and a heating element is inserted into the mold. A section of each of the first and second parts of the item is heated to above their glass transition temperatures with the heating element. The heating element is removed from the mold. The mold is closed such that the sections of the first and second parts of the item come into contact with each other. The sections of the first and second parts are cooled to below their glass transition temperatures to become joined. The mold is opened such that the item can be removed from the mold.

Abstract: A bumper system includes a bumper beam having top and bottom attachment features, such as apertures or concavities for attachment. A thermoformed polymeric energy absorber includes a base flange for engaging the face of the beam, protruding crush lobes for absorbing energy upon an impact, and top and bottom rear flanges. The top and bottom rear flanges include inwardly-facing protrusions defining a second dimension less than a first dimension of the beam's face, but the base flange is sufficiently resilient and flexible at desired locations and with desired force of flexures to provide tunable flexure points so the protrusions can be temporarily resiliently flexed apart to the first dimension for assembly and then upon release, the protrusions flex back to the second dimension engaging the attachment features to temporarily but positively retain the energy absorber on the beam.

Abstract: Standardized bumper testing includes a barrier adapted for testing vehicle bumper impact strength and engagement. The present improvement includes first and/or second thermoformed components attached to the barrier to replicate a profile and crush characteristics of a “generic” vehicle bumper. The first face component is an energy absorbing component with crush boxes for impact absorption, and replicates an energy absorber. The second component covers the first component and replicates a fascia.