Abstract: A system for preparing a bladder for use in manufacturing a composite stringer includes a sock application station, a film application station, and a composite ply application station. The sock application station has a sock cartridge configured to progressively apply a breather sock of breather material in tubular form onto a bladder as the bladder exits the sock cartridge to thereby result in a sock-bladder assembly. The film application station is located downstream of the sock application station and is configured to inflate a film from a flat shape into an open film tube prior to application over the sock-bladder assembly to thereby result in a film-sock-bladder assembly.

Abstract: A line roller for guiding a fishing line to a spool of a spinning reel includes a bearing member rotatable about a rotational axis. The line roller also includes a guide member disposed outside the bearing member in a radial direction from the rotational axis. The guide member includes a holding portion and a body. The holding portion is made of a metal or a ceramic. The holding portion is to hold a fishing line. The holding portion extends in a circumferential direction centered about the rotational axis. The body includes a resin, and a guide surface for leading the fishing line to the holding portion.

Abstract: A method of continuously forming an axially extensible and retractable hose comprising the steps of continuously forming an axially extending helix with axially spaced reinforcing coils from extruded thermoplastic material having a uniform cross-section along its length; and continuously bridging between an adjacent pair of the reinforcing coils with a continuous web of extruded thermoplastic material of substantially uniform width and relatively thin cross-section to form a continuous, helically extending sidewall, with the web having one of two opposite edge regions bonded continuously to a relatively flat outer bonding surface of a radially outwardly located portion of one of the adjacent pair of reinforcing coils, with the web having the other of the edge regions bonded continuously to a relatively flat inner bonding surface of a radially inwardly located portion of the other of the pair of reinforcing coils, and with the edge regions continuously radially separated from each other by the helix.

Abstract: An extensible-retractable helically reinforced hose is formed by helically wrapping a freshly extruded bead of thermoplastic material about a rotating mandrel to form a helical array of spaced reinforcing coils, and by helically wrapping a freshly extruded thin yet wide web of thermoplastic material so edge regions of the wide web are placed onto and bond continuously with the peripheries of each adjacent pair of the reinforcing coils, with a leading edge region of each new wrap of the web overlying and bonding to a trailing edge region of a prior web wrap. Central portions of each web wrap extend radially inwardly and are sandwiched between adjacent reinforcing coils when the hose is retracted to a minimal axial length.

Abstract: Helically reinforced, flexible tubing or hose is formed from continuously extruded thermoplastic material helically circumferentially wound at a wrapping station around an array of bearing-supported rods that are concurrently but individually turned and are canted relative to an imaginary center axis. The tubing or hose being formed has a continuous reinforcing rib helically wound therearound and continuously integrally connected thereto. The positions of the rods are progressively altered during formation of at least a contiguous portion of the length of tubing or hose, causing the resulting tubing or hose portion to exhibit a progressive continuous change in diametrical size. The resulting tubing or hose may be transversely severed at intervals along its length, and may be flattened to form cuffs near where severed.

Abstract: The invention relates to an aircraft protection device for protecting potentially exposed aircraft structures from direct impacts and a method of protecting an exposed edge of an aircraft component. The method includes the steps of winding filament around a foam core to create an impact protection device. A portion of the filament winding and foam core is removed from the impact protection device to create a receiving section whereby the receiving section is configured to correspond to and receive the exposed edge of the aircraft component. The impact protection device is secured to the exposed edge of the aircraft component such that the exposed edge is received in the receiving portion of the impact protection device.

Abstract: A composite enclosure for housing electronic devices, and methods related thereto, are provided. In particular, in some embodiments, a method of manufacturing a composite enclosure for housing electronic devices includes winding composite material about a mandrel and curing the composite material to create a composite hoop. A panel is formed in a separate process that includes stacking a plurality of composite layers in a mold and curing the composite layers to create a composite panel. The composite hoop and the composite panel are bonded together to form the composite enclosure.

Abstract: Approaches to providing z-filter media constructions are provided. Preferred corrugated media, filter constructions having such corrugated media, and filter systems using such filter constructions are provided. Also, preferred methods of forming filter constructions are provided.

Abstract: Systems, tools, and methods for forming composite tubular stringers and stiffened composite structures having composite tubular stringers are disclosed. Systems include a tool, a supply of pliable blanks for forming composite tubular stringers with the tool, a supply of skin segments for forming a skin, and a layup mandrel for receiving the composite tubular stringers and the skin to form a stiffened composite structure. Tools include a wrapping mandrel for forming from a pliable blank a tubular structure with a first circumferential profile, and a transition mandrel for conforming the tubular structure to a second circumferential profile. Methods include wrapping a pliable blank around a wrapping mandrel to define a tubular structure having a first circumferential profile, and transitioning the tubular structure from having the first circumferential profile to having a second circumferential profile.

Abstract: Systems, tools, and methods for forming composite tubular stringers and stiffened composite structures having composite tubular stringers are disclosed. Systems include a tool, a supply of pliable blanks for forming composite tubular stringers with the tool, a supply of skin segments for forming a skin, and a layup mandrel for receiving the composite tubular stringers and the skin to form a stiffened composite structure. Tools include a wrapping mandrel for forming from a pliable blank a tubular structure with a first circumferential profile, and a transition mandrel for conforming the tubular structure to a second circumferential profile. Methods include wrapping a pliable blank around a wrapping mandrel to define a tubular structure having a first circumferential profile, and transitioning the tubular structure from having the first circumferential profile to having a second circumferential profile.

Abstract: A method for forming a tubular sheet product roll includes providing a sheet product roll having a first configuration and a void, centering a rotational axis of the sheet product roll on a longitudinal axis of a first tool, and inserting the first tool into the void of the sheet product roll to define an inner diameter of the void and to form the sheet product roll having a second configuration different from the first configuration.

Abstract: A method of manufacturing a fan case with a liner includes the steps of providing a preform having a circular cross-section with a cut and a first diameter, flexing the preform to reduce the first diameter to a second diameter, and adhering the preform to an inner surface of a fan case. A fan case for a gas turbine engine includes a fan case body having an inner surface. A preform is adhered to the inner surface and has a cut providing a gap.

Abstract: Method for manufacturing a continuous composite tube comprising translating a tube liner through a manufacturing station wherein the manufacturing station comprises a winding station and a consolidation station located at a distance downstream of the winding station; winding a composite tape on the tube liner at the winding station for forming a tape layer; consolidating the composite tape on the tube liner at a consolidation zone of the consolidation station by pressing and heating to the tape.

Abstract: This invention provides a method for molding a continuous fiber prepreg part whereby a continuous fiber prepreg part comprising thermoplastic prepreg tape can be molded in a shape that allows the exhibition of desired physical properties without the sacrifice of productivity. Prepreg tape 11 is wound around a plurality of rods 21 so as to form a rolled continuous fiber prepreg part 12, slack is removed from the prepreg tape 11 by shifting the plurality of rods 21 in opposite directions so as to generate tension in the continuous fiber prepreg part 12, the continuous fiber prepreg part 12 is pressed with a press jig 41 so as to mold the prepreg part into the final shape, and the continuous fiber prepreg part 12 is cured by heating and cooling after heating.

Abstract: Approaches to providing z-filter media constructions are provided. Preferred corrugated media, filter constructions having such corrugated media, and filter systems using such filter constructions are provided. Also, preferred methods of forming filter constructions are provided.

Abstract: An object is to achieve a golf club shaft and a method of producing the same, wherein the weight balance in the shaft longitudinal direction can be reproducibly and easily set and wherein the golf club shaft is produced at a low cost and has high durability. The golf club shaft includes a hollow-cylindrical shaft body made of fiber-reinforced resin and a weight-adding cylinder installed in a cylindrical space of the shaft body. At least a part of an outer diameter side of the weight-adding cylinder is embedded in an cylindrical embedded recess that is formed in an inner wall of the shaft body, wherein a grip-side cylindrical end surface of the weight-adding cylinder and a grip-side cylindrical end surface of the cylindrical embedded recess are in contact with each other.

Abstract: Methods for manufacturing a protective helmet for the military and other uses are disclosed. Embodiments of the method include winding ballistic-tolerant tape or fibers to create a preform, placing the preform into a first mold member having an interior that defines a helmet-shaped cavity, and pressing together the first mold member against a second mold member that includes a pressurized bladder member. The method may further include pressurizing the bladder until the first and second mold members are heated and adhesives have melted or cured. The first and second mold members are cooled and the preform is removed from the first and second mold members.

Abstract: Approaches to providing z-filter media constructions are provided. Preferred corrugated media, filter constructions having such corrugated media, and filter systems using such filter constructions are provided. Also, preferred methods of forming filter constructions are provided.

Abstract: A ballistic-resistant panel in which the entire panel or a strike-face portion thereof is formed of a plurality of sheets of high modulus high molecular weight polyethylene tape. The sheets of high modulus polyethylene tape can be in the form of cross-plied laminated layers of tape strips or a woven fabric of tape strips. The strips of UHMWPE tape include a width of at least one inch and a modulus of greater than 1400 grams per denier. The ballistic-resistant panel may include a backing layer of conventional high modulus fibers embedded in resin. A wide variety of adhesives were found acceptable for bonding the cross-plied layers of high modulus polyethylene tape together for forming the ballistic-resistant panels of the present invention.

Abstract: A composite hockey stick and related method of manufacture is provided. The hockey stick includes a blade joined with a tapered and elongated hosel that is further joined with an elongated handle or shaft. The method includes providing a cured blade, bladder-molding the elongated hosel while partially seated within the cured blade, and bladder-molding the shaft while partially seated within the cured hosel. The hosel can be tapered to have a toe-to-heel width that decreases and a side-to-side width increases as the hosel extends upwardly from the blade. The hosel can extend greater than the length of the blade to emphasize the gradual transition from the blade cross-section to the shaft cross-section. The resulting hockey stick can improve energy transfer during play while also providing a streamlined appearance and an improved resistance to breaking.

Abstract: Composite tubes may be fabricated by filament winding a layer of resin impregnated carbon fiber with a near-axial fiber orientation over a mandrel and over end-fittings. Bands of resin-impregnated fibers are then wound circumferentially around this near-axial layer in a position that coincides with a circumferential groove in the underlying end-fittings. The ends of the near-axial layer are folded back over the bands, resulting in a double layer of intact near-axial fibers locked into the groove on the end-fittings by the bands of intact circumferential fibers. Testing has shown this arrangement to be effective for introducing very high axial loads onto the composite tube.

Abstract: In a method for manufacturing a wrap-around tube from at lest one strip-shaped material, the wrapping is brought about by at least one rotating wrapping element which is indirectly or directly in engagement with the wrap-around tube, and the strip-shaped material is wrapped onto a stationary wrapping core. An apparatus for manufacturing a wrap-around tube from at least one strip-shaped material is distinguished by the fact that it has a rotating wrapping element, which is indirectly or directly in engagement with the wrap-around tube, and a stationary wrapping core, onto which the at least one strip-shaped material is wrapped.

Abstract: A housing includes a main body defining a mounting hole; a screen guard mounting in the mounting hole, the screen guard is glass; and a transparent layer formed on an outer surface of the main body and surrounds a peripheral surface of the screen guard. The transparent layer is made of transparent thermosetting plastic.

Abstract: Approaches to providing z-filter media constructions are provided. Preferred corrugated media, filter constructions having such corrugated media, and filter systems using such filter constructions are provided. Also, preferred methods of forming filter constructions are provided.

Abstract: A non-fibrous, high tenacity, highly oriented UHMWPE tape or sheet of high molecular weight having a substantially large aspect ratio, a high tenacity, and a substantially higher tensile modulus. The UHMWPE tape includes an average molecular weight of 2,000,000 or greater, a width of ½-inch or greater, a thickness of between 0.0008 and 0.004 inch, and a modulus of between 1600 and 2500 grams per denier.

Abstract: Process for producing a laminate being built of at least two monolayers of polymeric tapes, the polymeric tapes having a tensile strength of at least 200 MPa, said process comprises the steps of -forming a first monolayer of polymeric tapes by pre-tensioning the polymeric tapes and subsequently positioning the polymeric tapes under tension in a unidirectional, parallel manner, -forming at least a second monolayer over the first monolayer in the same manner the first monolayer is formed, thereby -stacking the at least two monolayers of polymeric tapes in such a way that the direction of the polymeric tapes is the same in every monolayer and that the polymeric tapes of each monolayer are offset to the tapes of the adjoining monolayer above or below that monolayer -consolidating the thus stacked monolayers of polymeric tapes to obtain a laminate.

Abstract: A method of manufacturing two or more composite parts, the method comprising: assembling the composite parts on a mandrel by laying a series of layers of bands of composite material onto the mandrel with a placement machine,—rotating the mandrel as the bands are laid onto the mandrel; attaching two or more debulk frames (10, 11) to the mandrel between opposed edges of the composite parts after the composite parts have been assembled; wrapping the mandrel, debulk frames (10, 11) and composite parts in a debulk bag; heating the composite parts,—forming a vacuum between the mandrel and the debulk bag so that the debulk bag is sucked into voids between the debulk frames and the heated composite parts and progressively presses against the heated composite parts whereby excess material is squeezed by the debulk bag towards their opposed edges; and removing the debulk bag and the composite parts from the mandrel.

Abstract: A method of manufacturing a laminate of polymeric tapes is provided. Polymeric tapes of the core-cladding type are used, in which the core material has a higher melting temperature than the cladding material. The method includes pretensioning the polymeric tapes, and positioning the polymeric tapes and consolidating the polymeric tapes to obtain the laminate. The positioning is carried out in two, three, four or more planes. The polymeric tapes are arranged in each plane in a parallel, side-by-side relationship in a first direction, the polymeric tapes of each plane are offset in a second direction relative to the polymeric tapes in an adjacent plane, the second direction being substantially perpendicular to the first direction. The polymeric tapes of the laminate are unidirectionally arranged in a single direction in all of the two, three, four or more planes.

Abstract: A non-fibrous ultra high molecular weight polyethylene tape having a width of 1-inch or greater and a modulus of 1,400 grams per denier or greater. The non-fibrous UHMWPE tape is obtained by compression molding ultrahigh molecular weight polyethylene powder at a temperature below its melting point and then drawing and stretching the entire resultant compression molded UHMWPE sheet, with no slitting or splitting of the sheet, at a draw ratio of at least 100:1. The UHMWPE tape can be produced in weights of 6,000 to 90,000 denier or greater. The UHMWPE tape of the present invention minimizes the effect of stress concentrators that are prevalent with fibers and thereby enables the tape to be drawn at much higher draw ratios than is possible with fibrous UHMWPE. When used in ballistics panels, the high modulus high molecular weight polyethylene tape of the present invention improves ballistic performance by providing enhanced dissipation of the impact energy of a projectile.

Abstract: In a method for producing a ceramic filter element for an exhaust gas filter for an internal combustion engine or a catalyst support, a combustible non-ceramic support web is used and holes or recesses are introduced into the non-ceramic support web at defined locations.

Abstract: A composite mandrel includes a filament-wound composite tube, and composite material molded over the filament-wound composite tube. For example, the composite material includes chopped fibers and a matrix of thermoset resin. The chopped fibers are arranged in layers upon the filament-wound composite tube, and the chopped fibers in each of the layers are randomly oriented along first and second orthogonal directions in each of the layers. The composite material includes at least one sheet of the composite material wound over the filament-wound tube, and at least one strip of the composite material wound over the sheet of the composite material and forming a head on the composite mandrel. An internal cavity of the filament-wound composite tube may provide a lumen for the composite mandrel. The internal cavity may be threaded to receive a removable bridge plug.

Abstract: A custom grip may be molded on a handle. Examples of handles that may benefit from a custom grip include baseball bats, hockey sticks, pool sticks, lacrosse sticks, tennis racquets, golf clubs and the like. The molding of the grip may be a combined synergy of thermal energy resulting from friction and electrical current flowing through a material that hardens in response to both thermal and electrical stimulus. This hardening process may occur while undergoing the dynamics that the end product experiences when in use by the intended user. The resulting handle may be both uniquely matched to the user's hands as well as his or her style of use.

Abstract: A non-fibrous ultra high molecular weight polyethylene tape having a width of 1-inch or greater and a modulus of 1,400 grams per denier or greater. The non-fibrous UHMWPE tape is obtained by compression molding ultrahigh molecular weight polyethylene powder at a temperature below its melting point and then drawing and stretching the entire resultant compression molded UHMWPE sheet, with no slitting or splitting of the sheet, at a draw ratio of at least 100:1. The UHMWPE tape can be produced in weights of 6,000 to 90,000 denier or greater. The UHMWPE tape of the present invention minimizes the effect of stress concentrators that are prevalent with fibers and thereby enables the tape to be drawn at much higher draw ratios than is possible with fibrous UHMWPE. When used in ballistics panels, the high modulus high molecular weight polyethylene tape of the present invention improves ballistic performance by providing enhanced dissipation of the impact energy of a projectile.

Abstract: A ballistic resistant panel including a strike face portion and a backing portion. The strike face portion includes a plurality of interleaved layers of non-fibrous ultra high molecular weight polyethylene tape. The backing portion includes a plurality of interleaved layers of cross-plied fibers of ultra high molecular weight polyethylene. The entire stack of interleaved layers is compressed at high temperature and pressure to form a ballistic resistant panel having a strike face on one side. It has been found that ballistic resistance increases as the weight ratio of the strike face portion with respect to the backing portion decreases. A composite panel having a strike face Tensylon tape with at most 40% of the total weight of the panel exhibits improved ballistic resistance properties as compared to a monolithic structure of strictly interleaved layers of cross-plied high modulus fibers.

Abstract: A ballistic-resistant molded article having a sandwich-type structure including two outer portions of a first high modulus material surrounding an inner portion of a second high modulus material. The outer portions are comprised of a plurality of interleaved layers of adhesive coated cross-plied non-fibrous ultra high molecular weight polyethylene tape. The inner portion is comprised of a plurality of interleaved layers of high modulus cross-plied fibers embedded in resin. The stack of interleaved layers is compressed at high temperature and pressure to form a hybrid sandwich ballistic-resistant molded article that includes a mix of high modulus materials. It has been found that ballistic resistance is higher for the hybrid structure than for a monolithic structure of comparable areal density.

Abstract: A stack having at least one layer of tapes and at least one layer of multifilament yarn.

Abstract: A wide sheet of highly oriented ultra high molecular weight polyethylene comprising a plurality of strips of highly oriented ultra high molecular weight polyethylene partially overlapped or abutted longitudinally to define joints between adjoining strips wherein the thickness of the joint is less than about 80% of the thickness of the sum of the thicknesses of the adjoining strips that make up the joint. A continuous method for the production of such materials comprising subjecting longitudinally overlapping or abutted strips of these materials to temperatures below the melting point of the UHMWPE and pressures over 300 pli is also disclosed.

Abstract: A ballistic-resistant panel in which the entire panel or a strike-face portion thereof is formed of a plurality of sheets of high modulus high molecular weight polyethylene tape. The sheets of high modulus polyethylene tape can be in the form of cross-plied laminated layers of tape strips or a woven fabric of tape strips. The strips of UHMWPE tape include a width of at least one inch and a modulus of greater than 1400 grams per denier. The ballistic-resistant panel may include a backing layer of conventional high modulus fibers embedded in resin. A wide variety of adhesives were found acceptable for bonding the cross-plied layers of high modulus polyethylene tape together for forming the ballistic-resistant panels of the present invention.

Abstract: A non-woven ballistic material that demonstrates exceptional ballistic properties which ballistic material is fabricated by the lamination or angular lamination of a plurality of wide sheets of UHMWPE comprising a plurality of strips of highly oriented ultra high molecular weight polyethylene partially overlapped or abutted longitudinally to define joints between adjoining strips wherein the thickness of the joint is less than about 80% of the thickness of the sum of the thicknesses of the adjoining strips that make up the joint.

Abstract: Methods for making articles having a substantially cylindrical body including providing a substantially cylindrical tool, providing at least one ply of a material, the material being a weave fabric, a non-crimp fabric, or a combination thereof, wrapping the at least one ply of material about the tool to produce an article preform having a plurality of circumferential layers, applying a resin to the article preform, and curing the article preform to produce an article having a substantially cylindrical body.

Abstract: A wide sheet of highly oriented ultra high molecular weight polyethylene comprising a plurality of strips of highly oriented ultra high molecular weight polyethylene partially overlapped or abutted longitudinally to define joints between adjoining strips wherein the thickness of the joint is less than about 80% of the thickness of the sum of the thicknesses of the adjoining strips that make up the joint. A continuous method for the production of such materials comprising subjecting longitudinally overlapping or abutted strips of these materials to temperatures below the melting point of the UHMWPE and pressures over 300 pli is also disclosed.

Abstract: Embodiments include an infusion-occlusion system having a delivery catheter, a guide catheter adapted to receive the delivery catheter, and a guidewire with an occlusion device adapted to be received within the guide catheter. The guide catheter of the catheter kit may be provided with an occlusion device at the distal end of the guide catheter. The delivery catheter may have an accessory lumen, coaxial or co-linear lumen, a supporting mandrel, or an occlusion device at its distal end. Moreover, according to some embodiments, occlusion devices may be a single material or a composite balloon having an inner liner and an outer layer of different materials, a high compliance low pressure balloon, or a filter device that restricts particles from passing through but does not restrict fluid, such as blood. An inflation device with a large volume and low volume syringe can be used to inflate the balloon.

Abstract: A method of making an expanded polytetrafluoroethylene (ePTFE) membrane including the steps of: providing an unsintered or partially sintered ePTFE membrane; matting the unsintered or partially sintered ePTFE membrane; and immediately thereafter, sintering the matted ePTFE membrane. A method for making ePTFE tubes includes the steps of: providing an unsintered or partially sintered ePTFE membrane; wrapping the ePTFE membrane around a mandrel or form tool to form an ePTFE tube; matting the ePTFE tube; immediately thereafter, sintering the matted ePTFE tube; and removing the sintered ePTFE tube from the mandrel or form tool.

Abstract: A apparatus for low AC loss thermal shielding includes a plurality of thermally conducting fibers positioned along a desired direction of heat conduction. The fibers are electrically insulated from each other. The fibers are bonded together with a matrix, and a thermal link connects the bonded fibers to a cryogenic cold head.

Abstract: A piping element (1) comprises at least one flow pipe (4), an insulator (3) arranged outside it and a corrugated outer sheath (2) arranged outside the insulator (3) in such a way that the piping element (1) is bendable in its entirety. The outer diameter of the insulator (3) is reduced before conducting it to a corrugator (13) inside the outer sheath (2). In the corrugator (13), the insulator (3) reverts towards its larger outer diameter. The free outer diameter of the insulator layer is formed larger than the smallest inner diameter of the outer sheath (2).

Abstract: A method of curing an inflatable packing is provided that includes providing a packer assembly having an inflatable packer around a mandrel; a polyamide bandage around the inflatable packer; and a sealing layer around both the polyamide bandage and the inflatable packer to from an airtight seal about the inflatable packer, wherein the method further includes curing the assembled packer assembly.

Abstract: The present invention relates to a device for making electric energy storage assemblies the device including multiple feed means for feeding sheet structures, means for laminating sheet structures received from the various feed means, winder means for winding the resulting laminate, and control means for controlling continuously and in controlled synchronous the feed means, the laminator means, and the winder means.

Abstract: A porous material manufactured Polyvinylidene Difluoride, or PVDF may be used in several configurations as a separator material for Lithium Ion and other types of batteries. The PVDF separator may be used with electrodes manufactured from a PVDF substrate for various lamination techniques in various configurations. The PVDF separator may be used in several configurations to enable more active material into a given battery construction, ensure better adhesion between layers, and overall increase the performance and capacity of a battery.

Abstract: A non-compliant fiber-reinforced medical balloon comprises a first fiber layer and a second fiber layer embedded in a continuous matrix of thermally-weldable polymer material defining a barrel wall, cone walls and neck walls. The fibers of the first fiber layer run substantially parallel to one another and substantially parallel to the longitudinal axis. The fibers of the first fiber layer have a pattern of different lengths and are divisible into a first group and a second group based on length. Each fiber of the first group begins in the neck wall at one end of the balloon, extends continuously in the longitudinal direction and terminates in the neck wall at the opposite end of the balloon. Substantially all of the fibers of the first group have a generally uniform length. Each fiber of the second group begins in the cone wall at one end of the balloon, extends continuously in the longitudinal direction and terminates in the cone wall at the opposite end of the balloon.

Abstract: The invention provides a method of making a formable hockey stick blade, the method comprising: (a) providing a core having a blade element with a thickness, the core being made of expandable foam having a Poisson ratio of at least 0.33; (b) forming a preformed stick blade by wrapping the core with a layer of fibers pre-impregnated with a thermoplastic material; (c) placing the preformed stick blade in a mold; (d) applying heat and pressure to the mold for bringing the thermoplastic material to its amorphous form and for compressing the preformed stick blade such that the thickness of the blade element of the core is reduced; (e) cooling the mold such that the thermoplastic material is set; and (f) removing the formable stick blade from the mold.