Abstract: A microchannel collimating array may be fabricated by casting an elastic sheet onto a substrate containing a plurality of pedestals. The elastic sheet may be cured, and then pulled away from the substrate, leaving the elastic sheet with a plurality of tubes at the locations of the pedestals. The plurality of tubes may collimate light incident on the elastic sheet.

Abstract: When variable pitches are classified into a plurality of groups (S, M, and L) depending on lengths thereof in the tire circumferential direction, all the differences of the average pitch lengths of one of the groups and the average pitch lengths of the other groups are 3 to 30 mm and in at least one group of the groups, any one of the pitch of the group differs from the average pitch length (PM) and among the differences of the average pitch lengths, when the minimum difference is defined to be Xmin, the pitch lengths of all the pitches of each group (M group) are modified to have the values of ±10% of the minimum difference is defined to be Xmin based on the average pitch length of the group.

Abstract: Methods and apparatus for producing cast articles with characteristics of original objects such as a stone panel. The cast articles can replicate the contours, textures, and colors of all or a portion of the original object and can be made in any shape or size and specifically can be formed to simulate rock walls, carved stone architecture details, and other construction components normally created by stone masons or sculptors on site and at a high cost. The processes used in making the cast articles include the production of a series of molds. The molds seek to replicate the size, shape, contour, and surface texture of an original object with or without modifications to the original object.

Abstract: A method of manufacturing a hearing aid preferably includes the steps of: placing a moldable material in the ear canal of a patient to cast a form; using the form to form a hollow shell with an outer surface that approximates the shape of the patient's ear canal, the shell being of a soft polymeric material providing a mounting member; mounting electronic hearing aid components to the mounting member; joining the mounting member to the hollow shell to define a mold cavity; and filling the shell with a soft polymeric material that substantially encapsulates at least one of the electronic components and bonds to the mounting member, wherein the combination of shell, electronic components and soft polymeric material define a soft structure that is compliant to ear canal movement during use.

Abstract: To provide a method of producing an encapsulating molding material tablet by which adhesion of an encapsulating molding material to the punch surface of a tablet forming machine can be reduced, an encapsulating molding material tablet produced by this method, and an electronic part apparatus equipped with an element encapsulated using this encapsulating molding material tablet. A method of producing an encapsulating molding material tablet in which a release agent dissolved in a solvent is fed to the punch surface of a tablet forming machine to form a release agent layer having a thickness of over 0.001 ?m and less than 0.07 ?m on the above-mentioned punch surface, then, an encapsulating molding material is fed to the above-mentioned tablet forming machine for molding the material, an encapsulating molding material tablet produced by this method or having a contact angle ratio of 1.15 or more and less than 1.

Abstract: A sacrificial plastic mold having an electroplatable backing is provided. One embodiment consists of the infusion of a softened or molten thermoplastic through a porous metal substrate (sheet, screen, mesh or foam) and into the features of a micro-scale molding tool contacting the porous metal substrate. Upon demolding, the porous metal substrate will be embedded within the thermoplastic and will project a plastic structure with features determined by the mold tool. This plastic structure, in turn, provides a sacrificial plastic mold mechanically bonded to the porous metal substrate which provides a conducting support suitable for electroplating either contiguous or non-contiguous metal replicates. After electroplating and lapping, the sacrificial plastic can be dissolved to leave the desired metal structure bonded to the porous metal substrate. Optionally, the electroplated structures may be debonded from the porous substrate by selective dissolution of the porous substrate or a coating thereon.

Abstract: A method and kit for preparing a last for footwear. The method includes applying an elastomeric liner having a smooth continuous inner surface on a foot to be molded inner surface and optionally spacers for pads or orthotics as needed, applying a pliable, hardenable sock structure over the liner in close conformity with the foot, liner and spacers, activating the hardening agent of the sock structure, removing the sock structure now having a mold cavity in the shape of the foot with the liner forming the inner surface of the mold cavity and with the mold cavity including the spacer geometries after the sock structure has hardened, pouring a settable last forming compound into the cavity of the sock structure and removing the sock structure with the liner after the settable last forming compound has cured, thereby yielding a positive impression of the foot that is directly usable as a last. A kit according to the present invention includes a combination of elements and materials used to carry out the process.

Abstract: The invention relates to a mold insert, the interior surface thereof having an average quadratic roughness of less than 10 nm. Said insert is covered with a protective layer exhibiting a Vickers hardness of more than 1000 HV, a thickness of between 0.2 and 5 &mgr;m, and an adhesive strength greater than 15 N. The invention also relates to a method for the production thereof. The invention is used for the production of ophthalmic lenses.

Abstract: A hearing aid instrument of the in-the-ear type (and preferably CIC) provides a receptacle with electronic hearing aid components mounted thereto. The receptacle has a cavity for holding electronic components (eg. battery, microphone, amplifier). A soft polymeric body is preliminarily formed by encapsulating a plurality of the electronic hearing aid component shaped inserts. The body is soft and is shaped to conform to the ear canal of the user. After forming, the insert is removed to provide an insert cavity that can carry electronic components. The soft polymeric body and encapsulated electronic hearing aid components define a soft structure compliant to the ear canal during use and that is substantially solid and free of void spaces between at least some of the components and the ear canal.

Abstract: A hearing aid instrument of the in-the-ear type (and preferably CIC) provides a plate member with electronic hearing aid components mounted thereto. The plate member is preferably of a harder material such as hard plastic. A soft polymeric body is bonded to the plate member and encapsulates preferably a plurality of the electronic hearing aid components. The body is soft and is shaped to conform to the ear canal of the user. The soft polymeric body and encapsulated electronic hearing aid components define a soft structure compliant to the ear canal during use and that is substantially solid and free of void spaces between at least some of the components and the ear canal. This combination of soft compliant structure and encapsulated electronic hearing aid components addresses problems of peripheral leakage, poor fit, pivotal displacement that occurs with jaw motion and internal cross talk of components housed in prior art hollow type hearing aids.

Abstract: A method of forming a composite panel with a facade comprising a planar arrangement of thin discrete facers on a body of structural backing material. The method comprises the steps of providing a horizontal casting bed, providing a plurality of facers each with chamfers at corners between side-rear and end-rear walls, arranging the facers in abutting relationship atop the casting bed and in a selected pattern in a face down planar configuration so that the chamfers on the facers open upwardly and define narrow elongated sealant channels at joints between contiguous facers. Depositing a sealant in the channels and pouring concrete as a structural backing material atop the facers, the rear surfaces of the facers and the concrete adhering to form a composite panel.

Abstract: A method for preparing a mold form includes forming a mold blank having a surface corresponding to the surface of the article desired and enclosing the mold blank in an open ended enclosure. A thin layer of polymer resin, preferably polyurea is sprayed on the surface of the mold blank and allowed to cure. Heat transfer tubing is inserted over the resin layer. A mixture of metallic pellets and epoxy are inserted over the heat transfer tubing and then another layer of resin is sprayed over the mixture. After the resin has cured, the mold blank is removed to expose the mold form having an outer surface of polyurea.

Abstract: A method of making a mold directly from the object to be molded is disclosed. The object is placed within a walled enclosure having a closed bottom and open top. A plurality of elongated metal rod elements is vertically introduced and packed into the enclosure in vertical contact with said object and side by side contact with one another. An infiltration agent, such as a liquid resin or metal, is introduced over the elongated metal rod elements and allow to permeate into the spaces between the rod elements. The mass consisting of the liquid infiltration agent and the elongated metal elements is allowed to solidify into a mold which is removed from the object.

Abstract: A method is described comprising the steps of modifying a natural article to a predetermined configuration, making a mold of at least part of the modified natural article, filling the mold with a castable material to produce a reproduction of at least part of the surface of the modified natural article, modifying the reproduction to a predetermined configuration, making another mold from the modified reproduction and filling this mold with a castable material to produce another reproduction of at least part of the surface of the modified natural article; the second mold can be used to produce reproductions in commercial quantities.

Abstract: A system and method for molding the shell of a medical device or other molded article is provided. The system includes a multi-axis rotational molding machine in which a mold is mounted. The mold has a cavity in the shape of the article to be molded. The mold seals to hold a vacuum. In operation, silicone or other molding material is inserted into the mold, vacuum is applied to the mold, the mold is rotated about at least two axes and a molding material coats the inside walls of the mold to form the shell or other desired article. A rotationally molded medical article is also provided.

Abstract: There is disclosed a method for simulating the appearance of an article having surface texture comprising the step of applying a textured skin having a surface texture to a prototype to produce a textured prototype, thereby to simulate the appearance of the article having surface texture.

Abstract: A method of making a mould directly from the object to be moulded is disclosed. The object is placed within a walled enclosure having a closed bottom and open top. A plurality of elongated metal rod elements is vertically introduced and packed into the enclosure in vertical contact with said object and side by side contact with one another. An infiltration agent, such as a liquid resin or metal, is introduced over the elongated metal rod elements and allow to permeate into the spaces between the rod elements. The mass consisting of the liquid infiltration agent and the elongated metal elements is allowed to solidify into a mould which is removed from the object.

Abstract: This patent application describes the use of molecular imprinting as a means for preparation of anti-idiotypic imprint matrices. With this technique, imprints of artificial or natural molecules including their recognition sites, such as of molecularly imprinted polymers or biological receptors, antibodies or enzymes, can be prepared. In the former case, using the original imprints as casts or molds in a subsequent polymerisation step, utilising preferentially functionally complementary monomers, the formation of imprint materials containing recognition sites complementary in shape and functionality with the original imprint can be obtained but being of different composition. Alternatively, imprints or images of the artificial or biological species can be obtained directly. The so formed preparations can be used in a vast variety of applications, e.g. as new drugs, inhibitors or new affinity materials.

Abstract: Methods and apparatus useful in the development of molds are disclosed. In particular, the methods and apparatus of the present invention are useful, for example, in the context of dimensionally expanding and printing a picture image on a printable sheet for use in making a picture print thermoforming female mold of castible shrinkable material. In addition, a process for producing a male mold which replicates brush strokes of an original painting is disclosed.

Abstract: Replicas are molded by curing a photo-curable liquid silicone rubber composition to form a transparent mother mold having a cavity corresponding to the outer contour of a master model, casting a photo-curable liquid resin into the mold cavity, and irradiating light to the liquid resin through the mold wall. Replicas can be fabricated by simple steps and within a short time.

Abstract: A hearing aid instrument of the in-the-ear type (and preferably CIC) provides a plate member with electronic hearing aid components mounted thereto. The plate member is preferably of a harder material such as hard plastic. A soft polymeric body is bonded to the plate member and encapsulates preferably a plurality of the electronic hearing aid components. The body is soft and is shaped to conform to the ear canal of the user. The soft polymeric body and encapsulated electronic hearing aid components define a soft structure compliant to the ear canal during use and that is substantially solid and free of void spaces between at least some of the components and the ear canal. This combination of soft compliant structure and encapsulated electronic hearing aid components addresses problems of peripheral leakage, poor fit, pivotal displacement that occurs with jaw motion and internal cross talk of components housed in prior art hollow type hearing aids.

Abstract: The invention relates to a process for the preparation of molecularly imprinted polymers useful for separation of enzymes, which comprises the steps of reacting a complex of enzyme and affinity monomer, a comonomer and a crosslinker, with a polymerization initiator and a polymerization accelerator at ambient temperature and pressure for a period ranging between 2 to 24 hrs, thereby obtaining a crosslinked polymer, crushing the cross linked polymer obtained to fine particles, adding a solvent and extracting imprinted enzyme from the polymer, obtaining the molecularly imprinted polymer, contacting the imprinted polymer with aqueous solution containing imprinted enzyme or a mixture of imprinted enzyme and other enzymes and isolating the enzyme-adsorbed polymer.

Abstract: A method is provided for fabricating a cure tool for curing materials at elevated temperatures. A facility tool is formed having a tool surface defining a mold line corresponding to a pattern of the object to be molded, to which a release coating is then applied. A mixture of a first resin surface coating is then prepared and de-aired to remove air trapped therein before being applied to the tool surface of the facility tool. The layer of the first mixture is then allowed to tack off for a predetermined period of time before being re-smoothed to promote substantially even application thereof to the tool surface. A mixture of a second resin surface coating is then prepared, preferably having a mix ratio by mass of about half the mix ratio by mass of the first mixture, and then de-aired to remove air trapped therein. A layer of the second mixture is then applied to the layer of the first mixture after the layer of the first mixture has tacked off.

Abstract: Replicas are molded by curing a photo-curable liquid silicone rubber composition to form a transparent mother mold having a cavity corresponding to the outer contour of a master model, casting a photo-curable liquid resin into the mold cavity, and irradiating light to the liquid resin through the mold wall. Replicas can be fabricated by simple steps and within a short time.

Abstract: Methods and apparatus useful in the development of molds are disclosed. In particular, the methods and apparatus of the present invention are useful, for example, in the context of dimensionally expanding and printing a picture image on a printable sheet for use in making a picture print thermoforming female mold of castible shrinkable material. In addition, a process for producing a male mold which replicates brush strokes of an original painting is disclosed.

Abstract: Methods for reproducing a 3D object surface are provided. A preferred method according to this invention includes (1) identifying a real object surface, (2) acquiring at least a 3D data set with a 3D surface imaging device, (3) acquiring at least a 2D data set using a 2D surface imaging device with a surface resolution of at least about 0.1 mm2, (4) synthesizing a 3D composite data set by orienting a first virtual image of the first data set and a second virtual image of the second data set to form a composite virtual image that corresponds to the composite data set, and (5) making a reproduction of the object surface with the composite data set. Orientation of the virtual images is relative to each other and without substantial loss of surface resolution.

Abstract: The method for forming a retroreflective sheeting includes providing a first layer and forming a prism array on the first layer. A second layer is applied to the prism array. The first thermoplastic layer is welded to the second thermoplastic layer, while applying a die having a plurality of cells with multi-course, hatched patterned perimeters to the layers to dislocate a portion of the prism array, thereby allowing the first layer to be bonded to the second layer at the portion.

Abstract: A method of forming a flexible mold (12) and resulting article is provided where a model (10) having the contour of the article to be molded is provided. The model (10) is partially encapsulated within a flexible and substantially liquid impervious layer (14). The combined model (10) and liquid impervious layer (14) is immersed into a curable liquid composition and handle members (36, 38) are inserted into the curable liquid composition. The curable liquid composition (34) is cured having the handles (36, 38) embedded within the composition (34) and subsequent to curing, forms a solid flexible mold encompassing structure (44). Handle members (36, 38) are actuated to release the model (10) from the layer (14) to form the flexible mold (12) for the article to be produced.

Abstract: A female mold (2, 12, 22, 32, 42, 52, 62) having a desirable pattern is formed on a substrate (1, 11, 21, 31, 41, 51, 61). Next, ceramic material (3, 13, 23, 33, 43, 53, 63) is filled in spaces in the female mold. Thereafter, the female mold is removed by heating the entire substrate, whereby a desirable thick film pattern can be finely and easily formed. The inorganic paste material comprising inorganic liquid vehicle containing water glass as main ingredient and powdery solid dispersed in the inorganic liquid vehicle is used as the ceramic material. The volume change of the inorganic paste material is small during the drying and calcinating processes, thus the inorganic paste material is prevented from being broken.

Abstract: The purpose of the invention is to produce a shaped article having a uniform dull surface with less noticeable weld line and other surface detects. The injection molded synthetic resin article of the invention has a weld portion and is characterized in that the weld line on the surface of the injection molded article has a dent of no more than 2 .mu.m, the surface of the injection molded article is a dull surface with no more than 30% gloss, the general portion, the weld portion and the resin flow end portion of the surface of the injection molded article provide a uniform dull surface, said dull surface having such abrasion resistance that no visible flaws develops at a hardness of 2B and below in a pencil scratch test. Such molded article can be produced without post-molding paint application and yet it has practical utility, thus presenting a maximum economic advantage.

Abstract: Shaped article replicas which are proportionately accurate replicas of a shaped article and which are equal, greater or smaller in size than said shaped article are made by preparing a swellable polymer replica of said shaped article; immersing said swellable polymer replica in a swelling agent system under conditions which will enlarge said polymer replica to a predetermined extent; forming a casting mold of such enlarged polymer replica; making a powder compact in said casting mold and heating said powder compact to produced a proportionately accurate solid replica of a predetermined size.

Abstract: The method for forming a retroreflective sheeting includes providing a first layer and forming a prism array on the first layer. A second layer is applied to the prism array. The first thermoplastic layer is welded to the second thermoplastic layer, while applying a die having a plurality of cells with multi-course, hatched patterned perimeters to the layers to dislocate a portion of the prism array, thereby allowing the first layer to be bonded to the second layer at the portion.

Abstract: A flexible and resilient positive pattern is made for a desired high temperature metal or ceramic part such as a gas turbine impeller having a complex geometry with walls defining undercut spaces, and the pattern with flexible walls is dipped into a ceramic molding media capable of drying and hardening. The pattern is removed from the media to form a ceramic layer on the flexible pattern, and the layer is coated with sand and air dried to form a ceramic layer. The dipping, sanding and drying operations are repeated several times to form a multiple layer ceramic shell. The flexible wall pattern is removed from the shell, by partially collapsing with suction if necessary, to form a first ceramic shell mold with a negative cavity defining the part and to provide for reusing the pattern. A second ceramic shell mold is formed on the first shell mold to define the back of the part and a pour passage, and the combined shell molds are fired in a kiln.

Abstract: An implant having an integrally-textured, hemocompatible blood-contacting surface and a method for producing the same is provided. The implantable device can include a device body having a textured surface and a predefined complex shape, such as a bladder or a generally U-shaped conduit. The device body can be composed of a first device material, and the textured surface can be formed of a second device material on the obverse side of the device. The textured surface can have multiple, blood-compatible structures integrally formed thereon. The structures can be fibrils that are suitable for a generally uniform biological layer to be established thereupon.

Abstract: An embossed substrate comprising a substrate of a plastic material and having a surface and an embossed surface carried by the surface of the substrate. The embossed surface is characterized by having a pattern with an average roughness of between 100 nanometers and 300 nanometers with the roughness being distributed substantially uniformly over the surface, the pattern has ridges and valleys with the horizontal distance between adjacent ridges and/or valleys being greater than the depth between the ridges and the valleys. The peaks and the valleys are randomly disposed without periodicity to cause diffusion of light impinging thereon to minimize or eliminate interference effects when the embossed surface overcoated with thin planar organic layers is exposed to light.

Abstract: The invention relates to a material of a three-dimensional framework of supporting, trabecular structures encompassing cavities which are connected with one another and which can be predeterminedly adjusted. The material is obtainable by forming the framework around the shaped bodies serving as space retainers for the cavities and subsequently removing the shaped bodies. The material according to the invention can be used for example as a implant or as a filter.

Abstract: The present invention is a process for making a nanochannel glass (NCG) rica, having the steps of: coating a face of an etched NCG with a replica material (with or without an intervening buffer layer), where the etched NCG face has a plurality of channels arranged in a desired pattern, to form a replica coating on the NCG conforming to the pattern; and removing the replica coating from the etched NCG. The present invention is also the replica made by this process.

Abstract: A method for producing a composite mandrel (20) for use in creating a precise set of surface features inside a hot isostatic pressed (HIP) billet for producing a desired tool uses a composite nickel shell (16) and ceramic interior (18). A free form fabrication (FFF) or wax positive pattern (10) of the desired tool is made first, then a layer of nickel is deposited on the surface of the FFF positive pattern to produce a nickel shell (16) which is a negative of the desired tool. The final step in creating the composite mandrel (20) is filling the nickel shell (16) with ceramic material (18) to increase the rigidity of the nickel shell thereby forming a mandrel for use in an HIP process to make the desired tool.

Abstract: Fiber-reinforced thermosetting polyester composites containing in excess of 30 wt %, based on the weight of the composite, reinforcing fiber, are made by a vacuum-assisted transfer molding technique from a 1-phase composite matrix precursor comprising a polyester, a reactive monomer, and a low-profile additive. The polyester has a molecular weight/double bond factor of between about 150 and 190, styrene is a preferred reactive monomer, and a preferred low-profile additive is a thermoplastic polymer with a weight average molecular weight in excess of 3,000 and which is miscible in the polyester and reactive monomer. The polyester composite is formed by coating the surface of a mold with a gel coat; applying a skin laminate over the partially cured gel coat; applying a fiber reinforcement to the skin laminate; closing the mold; and injecting the 1-phase matrix precursor while the mold is under vacuum.

Abstract: A nail polish or nail polish/enamel composition is applied to imperfections, errors, distortions or porosities in the model. The composition is thus used to correct the model's shape. The composition can be added at room temperature, and avoids the need to utilize high temperatures in the process of building the model. The nail polish or nail polish/enamel compositions may be utilized to add jewelry design elements to the model.

Abstract: A method for preparing mimics of a wide variety of drugs and other biologlly active molecules using molecular imprinting techniques, and the mimics produced thereby, is disclosed. Specifically, the mimic is designed by: (i) polymerization of functional monomers around a known drug or biologically active molecule (the template) that exhibits a desired activity; (ii) removal of the template molecule; and then (iii) polymerization of a second class of monomers in the void left by the template, to provide a new organic molecule which exhibits one or more desired properties which are similar to that of the template.

Abstract: An improved metal working tool or die having an outer surface formed from synthetic resin material that is filled with a hardener. The outer surface is formed of a material that consists of a synthetic resin mixed with tabular alumina and a surface treating agent such as gamma-Methacryloxypropyltrimethoxysilane. The tool or die is formed over a pattern by applying the outer hard surface layer to the pattern and then a second or intermediate layer of synthetic resin that is filled with calcium silicate. A third layer of material that includes a reinforcing fiber such as fiber glass is applied over the intermediate layer.

Abstract: A method for micromolding ceramic articles and structures having spatial features as small as 0.1 .mu.m and having a depth ranging from 2.0 .mu.m to 100 .mu.m. A master mold of the article or structure to be molded is first fabricated using a silicon wafer and dry etching technology. A negative master mold is then produced by placing the silicon master mold device in a surrounding mold form and filling the surrounding mold form with a silicone or silicone rubber, preferably an RTV.TM. (a room temperature-vulcanizing silicone rubber compound). Such material replicates each of the micro features of the master mold in great detail to a resolution on the order of 0.1 .mu.m. The negative master mold is then used in a die to mold the desired individual elements or structures from a ceramic powder which is capable of replicating each of the micro features of the negative master mold to the desired resolution.

Abstract: Products having a real wood appearance from synthetic resins, are produced by creating a mold from a wood plug having a grain pattern of the type desired; treating the wood to the extent necessary to open the grain pores as desired; creating a mold from an impression from the wood plug; molding products from the mold, applying a pigmented viscous paste to the products and wiping the paste on the products to produce the desired finish color; the paste containing dryers to promote prompt drying; and applying a clear finish coat over the surfaces of the products.

Abstract: A two-part reusable mask to protect objects to be plated. The mask can be used for painting, chemical treatment or other treatments. By adjusting the shape of the mask, any object can be plated. In the case of coins or medallions, a two sided mask is formed. For use with coins, the coin is laid on a piece of glass. A dam is formed around the coin. A quantity of ultraviolet-sensitive liquid polymer is poured on and around the coin. The dam is covered with another piece of glass and the mold is clamped and cured. The mold is removed and an exact copy of the coin is left in the rubber. The rubber mask is then placed on a hard surface and the areas to be plated are cut out. After the mask is cut out, it is placed back over the coin and aligned. A piece of clear, hard plastic is bonded to the rubber using a clear adhesive. After the glue is cured, the plastic is cut out to match the corresponding pattern cut in the rubber. The mask is then ready to use.

Abstract: A method of making microstructure bodies of plastic material. A microstructured plate-like base body which is made by any known molding procedure and which has a first side serving as a first reference plane and a second side which has plastic microstructures projecting therefrom is covered at its second side with a material layer that engages the microstructures, whereupon the material layer is machined to provide a second reference surface parallel to the first reference surface and the base body is then machined parallel to the second reference surface to expose the microstructures projecting therefrom and the material layer is finally removed selectively with respect to the plastic material to release the microstructured bodies.

Abstract: An elastic layer is formed stably of constant shape without cutting of surface thereof and without difficult processing to make an internal surface of hollow in a mold into an off-right-circular cylinder shape. A matrix 1 is produced by shaping a periphery of rod material into an inverted crown shape of off-right-circular cylinder. Annular reinforcements 2, 3 are fixed on the both ends of inverted crown portion of matrix 1. The matrix 1 with the reinforcements 2, 3 is dipped in an electrolytic solution 5a, so that a nickel alloy is deposited over a surface of matrix 1 by electroforming to obtain a mold 4. The mold 4 is cut outside the reinforcements 2, 3 and a hollow for dissolution removal is perforated along the axis of matrix 1. The mold 4 is dipped in a corrosive solution which can dissolve only the matrix 1, so that only the matrix 1 is dissolved to remove away from the mold 4. The remaining mold 4 will have a hollow of inverted crown therein.

Abstract: A method and apparatus for making a hollow tool which is used to impart shape to an article. The method comprises: (a) building an outer box around a model of the article; (b) constructing an inner box disposed within and spaced apart from the outer box; (c) applying a fluid laminating agent to an inside surface of the inner box and to the model; (d) removing the inner box after the fluid laminating agent cures to form a solidified shell; (e) supporting the shell so that a space is formed between it and the model; (f) pouring a filling agent into the space, the filling agent bonding to the shell and forming a face that replicates the model; and (g) installing a support structure inside the shell to form the hollow tool, thereby imbuing the tool with the physical characteristics of lightness in weight and durability in shape retention after prolonged exposure to thermal cycling and the thermal characteristics of a uniform heat conductivity over all sections of the tool, regardless of its outside dimensions.

Abstract: A three-dimensional electroformed shell for a mold consists of a three-dimensional thin-walled body, and an electroformed coating deposited on it. The coating may, or may not close the base holes of the thin-walled body completely. If it does not close the base holes completely, the shell has a multiplicity of apertures. A process for manufacturing the shell is also disclosed.

Abstract: A method of making a concave aspheric mold insert by electroplating nickel over a silver release agent coating on an aspheric surface formed in a copper substrate to form a master having a convex surface which is a negative image of the aspheric surface. After the master has been separated from the substrate its convex surface is coated with a silver release agent and electroplated with nickel to form an element having a concave surface which is a replication of the aspheric surface and the opposite surface of which is convex. After the convex surface of the element has been trued to spherical shape, a slightly oversize spherical D-seg is formed in the aspheric surface. The aspheric surface is then trued to reduce the D-seg to final size to produce the insert. A number of elements are formed from the master and are provided with D-segs of different radii.