Abstract: A system and method for making and using a reconfigurable composite part mandrel operable in the manufacture of composite parts. The system may comprise an assembly fixture, a generic mandrel, a reconfigurable simulated skin, a reconfigurable frame portion, and state-changing material operable to harden into a desired configuration for forming a particular composite part. The method of forming and using the reconfigurable composite part mandrel may comprise: inserting the simulated skin within the assembly fixture, inserting or assembling the frame portion within the assembly fixture; inserting the generic mandrel into the assembly fixture; filling a cavity between the generic mandrel and the assembly fixture with the state-changing mixture to encapsulate the frame portion; hardening the state-changing mixture; and removing the assembly fixture and the simulated skin.

Abstract: The nanoimprint mold of the invention comprises a liquid crystal substance and has an indentation surface on which a relief structure is formed by orientation of the liquid crystal substance. The nanoimprint mold can be easily produced without providing joints, even when the area of the transfer indentation surface is large.

Abstract: A process for producing a polymer optical waveguide including: 1) preparing a rubber mold having a composite layer structure in which a rubber layer which has a concave portion corresponding to an optical waveguide core and contains a rubber mold-forming curable resin is buried in a rubber layer-forming concave portion of a rigid substrate having the rubber layer-forming concave portion; 2) bringing a cladding substrate into close contact with the rubber mold; 3) filling the concave portion of the rubber mold, with which the cladding substrate has been brought into close contact, with a core-forming curable resin; 4) curing the filled core-forming curable resin; 5) removing the rubber mold from the cladding substrate; and 6) forming a cladding layer on the cladding substrate on which the core has been formed.

Abstract: An object of the present invention is to provide a metal mold for micro components at low cost in a short time by using an optically molded object formed by an optical molding method. A method of manufacturing a mold for molding in accordance with the present invention includes forming a three-dimensional molded object by applying a photo-curable liquid resin composition, irradiating the photo-curable liquid resin composition with light, and removing non-cured portions of the photo-curable liquid resin composition, and forming the mold for molding based on the three-dimensional molded object, the method further including forming a metal coating covering the three-dimensional molded object, removing the three-dimensional molded object covered with the metal coating; and taking the metal coating as the mold for molding.

Abstract: The present invention relates to a homogeneous, photoactive film consisting of or comprising a polyelectrolyte carrying residues which may undergo a photoreaction, the polyelectrolyte mainly comprising at least one structure according to any of formulae (I) to (IV), namely [Pol(R*—P—R?)]oon+n/xAx? (I), n/xAx+[Pol(R*—P—R?)]oon? (II), [Pol(R1*-Q-R1?)]oon+n/x?x? (III), n/x?x+[Pol(R1*-Q-R1?)]oon? (IV), wherein Pol means a repeating unit of a linear or branched polymer chain, o indicates the number of the repeating unit of the polymer chain, and (R*—P—R?) and (R1*-Q-R1?) are n-fold positively or negatively charged side chains of the repeating unit Pol, wherein P is a group which is capable of photo-induced E/Z isomerization, Q is a group capable of participating in a photocycloaddition, or capable of participating in a photoinduced rearrangement, or the so called Photo-Fries reaction, A is a cation or anion which is oppositely charged, n is preferably 1 or 2, x is 1 or 2, and o is at least 2, with the proviso that

Abstract: Solid free form fabrication techniques such as fused deposition modeling and three-dimensional printing are used to create a shell or die used in the manufacture of a dental restoration. Three-dimensional printing includes ink-jet printing a binder into selected areas of sequentially deposited layers of powder. Each layer is created by spreading a thin layer of powder over the surface of a powder bed. Instructions for each layer may be derived directly from a CAD representation of the restoration. The area to be printed is obtained by computing the area of intersection between the desired plane and the CAD representation of the object. All the layers required for an aesthetically sound shell can be deposited concurrently slice after slice and sintered/cured simultaneously.

Abstract: An instrument panel with a one piece body constructed of a thermoformed material and exhibiting first and second visually differentiable surface patterns. An associated process includes the creation of an instrument panel, such as through the use of a clamshell slush mold, and including the formation of a groove between the surface patterns which exhibits a visually appealing and rounded cross sectional profile.

Abstract: A silicone mold comprising and oxidized, patterned surface and a layer of perfluoroether silane release agent is described. The mold enables 2nd generation silicone molds to be replicated, i.e. silicone molds from silicone molds.

Abstract: The invention is directed to a polymer shim and a roll-to-roll process for its manufacture.

Abstract: To provide a flexible mold (10) useful for manufacturing a PDP rib having a lattice pattern and other microstructures, and capable of highly precisely manufacturing the microstructures without involving defects such as occurrence of bubbles and pattern deformation. A flexible mold (10) comprises a base layer (2) made of a first curable material having a viscosity of 3,000 to 100,000 cps at 10 to 80° C. and a coating layer (3) coating a surface of the base layer (2) and made of a second curable material having a viscosity of 200 cps or below at 10 to 80° C.

Abstract: Disclosed herein are a plastic microchip used in counting the number of microparticles and including direction indicators and a method for manufacturing the same. The plastic microchip includes a negative microgrid pattern formed on a lower substrate and direction indicators indicating the position of the microgrid pattern and formed in the vicinity of the microgrid pattern. The method for manufacturing the plastic microchip includes injection-molding a lower substrate including a negative microgrid pattern and direction indicators formed in the vicinity of the negative microgrid pattern, and injecting a solvent through solvent inlets so as to fix an upper substrate to the lower substrate. Accordingly, the present invention provides a plastic microchip including the direction indicators indicating the position of the microgrid pattern and formed on the lower substrate so that an observer can readily find the microgrid pattern through a microscope, thus facilitating the observation of a sample.

Abstract: Disclosed is a paste pattern formation method comprising the steps of: forming a transfer pattern material on a film base material to prepare a transfer film; sticking the transfer film on a substrate on which a transfer pattern is formed so that the transfer pattern material contacts the substrate; separating the film base material from the transfer pattern material; filling a paste into the transfer pattern depression; solidifying the paste; and removing the transfer pattern material.

Abstract: A method for constructing a three-dimensional laminar body of large dimensions is provided. Starting from a true-to-scale model of the three-dimensional laminar body to be obtained, which comprises the entirety of said body or parts thereof, one or several negative molds which unitarily or together comprise the entire working surface of the three-dimensional laminar body are shaped on the model, and then used to mold, with a fine finish, the entire three-dimensional laminar body or the different constituent parts thereof.

Abstract: A method of manufacturing a stamper is disclosed. By using a method that includes: manufacturing a small stamper, in which a first relievo is formed; repeatedly imprinting the small stamper on a large master mold to form a first intaglio corresponding to the first relievo; and molding such that a second relievo is formed, which is in correspondence with the first intaglio, a broad stamper having identical repeated patterns may be manufactured.

Abstract: A stamping device stamps characteristic data, especially in the form of code numbers (22), into plastic products. Such containers are preferably produced according to blowing, filling and gelling methods. At least one stamp (32), having a stamping unit (34) with interchangeable characteristic data units (42), is guided in the longitudinal direction in the frame (24) of the device. When the stamp is in an elevated position, the products to be stamped and/or have been stamped can be fed or removed. When in a lowered position, the products are stamped.

Abstract: A method of making an imprint lithography template includes applying a curable material to a patterned surface of a master imprint template, allowing the curable material to cure and thereby forming a second imprint template having a patterned surface which is the inverse of the patterned surface of the master imprint template; removing the second imprint template from the master imprint template; applying inorganic sol-gel to a substrate; imprinting the inorganic sol-gel with the second imprint template; allowing the inorganic sol-gel to cure; and removing the second imprint template from the cured inorganic sol-gel, such that the inorganic sol-gel forms a third imprint template having a patterned surface which corresponds with the patterned surface of the master imprint template.

Abstract: A method for manufacturing a wax mold of a golf club head includes steps of positioning a male die assembly in a first cavity of a first female die, injecting dissolvable wax into the first cavity to form a dissolvable wax mold, removing the first female die to take out the solidified dissolvable wax mold, positioning the dissolvable wax mold and the male die assembly in a second cavity of a second female die, injecting wax for precision casting into the second cavity to form a head wax mold, removing the second female die to take out the solidified head wax mold, and injecting solvent into the head wax mold to dissolve the dissolvable wax mold.

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: Numerous embodiments of a method and apparatus for forming an imprinting tool are disclosed. In one embodiment, a method of forming an imprinting tool comprises forming a first mold by use of one or more printing processes, forming a second mold from the first mold, and forming an imprinting tool from the second mold, where the imprinting tool is formed at least in part by metalizing at least a portion of the second mold.

Abstract: A process is described for making gourd molds useful in the production of decorative ceramic and other articles which bear the textures of the gourd interior. Articles produced may also serve as models for use in the manufacture of production molds. Steps in making the gourd molds include selection, cutting, and removal of pulp; steps in using the gourd molds include treating with a release agent, casting, and removal of the gourd mold from the molded article.

Abstract: A method of forming prosthetic sockets is provided that first creates a negative mold of the patient's residual limb while it is disposed in a positive flexion position. The mold is then removed and shaped to permit the desired range of flexion when the mold is repositioned on the residual limb. A second cast is made of the residual limb that incorporates the mold. A positive model of the residual limb is then formed, from which test or definitive sockets may be formed. The present method further lends itself to the formation of sockets using a cast-in-place methodology while the limb is disposed in a positive flexion position.

Abstract: Method for producing an embossing roller from silicone rubber for the continuous embossing of the surface of a thermoplastic film, with the embossing surface having a negative form of a surface structure to be embossed. An auxiliary roller is provided which is plastic, at least in the region of its circumferential surface. A laser beam is directed onto the circumferential surface and controlled for defining a real imaginary pattern in such a way that a surface structure of the pattern is created as a positive form on the surface. A layer of silicone rubber provided on the surface produces an embossing matrix which is pulled off the surface, turned inside out, and adhered to a surface of an embossing roller, with the negatively structured embossing surface facing outward. Thus, multiple embossing matrices can be created after a one-time structuring of the surface of an auxiliary roller, using a casting process.

Abstract: A wall mountable device has a body of predetermined shape for forming a wall feature and a flat, peripheral flange of predetermined width projecting outwardly from the perimeter of the body. The body may be a light sconce or valance, niche, shelving unit, bas-relief, or other wall feature. The flange has a periphery of predetermined shape for mounting in a wall opening of corresponding shape and dimensions with the outer face of the flange flush with the surrounding wall surface, and the seam or joint between the flange and wall opening is finished such that the body appears to be molded integrally with the wall.

Abstract: Numerous embodiments of a method and apparatus for forming an imprinting tool are disclosed. In one embodiment, a method of forming an imprinting tool comprises forming a first mold by use of one or more printing processes, forming a second mold from the first mold, and forming an imprinting tool from the second mold, where the imprinting tool is formed at least in part by metalizing at least a portion of the second mold.

Abstract: Solid free form fabrication techniques such as fused deposition modeling and three-dimensional printing are used to create a shell used in the manufacture of a dental restoration. Three-dimensional printing includes ink-jet printing a binder into selected areas of sequentially deposited layers of powder. Each layer is created by spreading a thin layer of powder over the surface of a powder bed. Instructions for each layer may be derived directly from a CAD representation of the restoration. The area to be printed is obtained by computing the area of intersection between the desired plane and the CAD representation of the object. All the layers required for an aesthetically sound shell can be deposited concurrently slice after slice and sintered/cured simultaneously.

Abstract: In a method for forming a micro-pattern on a substrate (200), polymer material having a solvent is coated on the substrate, thereby forming a polymer film on the substrate. Then, a mold (204) having a predetermined shape is compressed into the polymer film (202) on the substrate by employing a predetermined compression technique to entail a plastic deformation of the polymer film, thereby patterning the polymer film. This compression procedure is performed at a room temperature, e.g., of about 10 to about 30° C. In the present invention, before the mold (204) is pressed into the polymer film (202), a free volume in the polymer film is previously increased so that a pressure applied on the polymer material needed to plastically deform the polymer film is reduced. Thereafter, etching is performed on the substrate through the use of the patterned polymer film as an etching mask, thereby forming a micro-pattern on the substrate.

Abstract: A mold for relatively uniform heating and molding of a work material to form a workpiece using a microwave oven, includes upper and lower mold members and a sidewall mold member. The mold members are formed from materials selected to have an approximately equal effective thermosensitivity. The effective thermosensitivity of work material is its dissipation factor divided by the product of its dielectric constant, density and specific heat. The effective thermosensitivity of the material of mold layer of each mold member is its dissipation factor divided by the product of its dielectric constant, density, and specific heat and multiplied by the fraction of the mass of its mold layer divided by the total mass of this mold member. A metal sleeve is formed on an inner surface of the sidewall mold member with microwave absorbing material formed on the outside thereof and inner surfaces of the end mold members may also be coated with metal or other highly thermally conductive and wear resistant material.

Abstract: The ceramic builder based investment is coloured to simulate naturally prepared tooth dentin. Upon final set, the solid refractory dies are fired to enable them to receive porcelain. The expansion and contraction of the refractory die upon temperature fluctuations, is correlated with the corresponding porcelains' expansion. This correlation of the materials enables the restoration to maintain proper form and shape through multiple firings. The primary basis of this invention is the ability to colour (chromatize) individual refractory dies to simulate natural prepared teeth from the dentist.

Abstract: A method of fabricating a PVC ornamental article having effects of imitated materials includes steps of: (a) mold casting: making a prototype of a desired ornamental article, exploding said prototype into a plurality of blank elements, coating said blank elements with silicone to form hollow silicone molds, injecting a wax material into said hollow silicone molds to obtain a wax object, taking out said wax object for trimming and electroplating said wax object, and melting said wax object to obtain a mold; (b) blank formation: adding colorants into said PVC plastic material and mixing said colorants to obtain desired colors, injecting said PVC plastic material into said mold, utilizing centrifugal force to affix said PVC plastic material onto an inner wall of said mold, and removing molded PVC from said mold to form a blank by force before said molded PVC dries, filling a filler into said blank to increase hardness; and (c) assembly: assembling blanks together and joining the blanks with other decorations to

Abstract: A method of forming a three-dimensional sculpture comprises the steps of providing a mold having a lining and a casting cavity, applying a powder to the mold lining, pouring a casting material into the casting cavity and curing the casting material to form a casting object, said powder being transferred to said casting object during curing of said casting material, and removing said casting object from said casting cavity to form a powder-laden three-dimensional sculpture.

Abstract: A method of fabricating a PVC ornamental article having effects of imitated materials includes steps of: (a) mold casting: making a prototype of a desired ornamental article, exploding said prototype into a plurality of blank elements, coating said blank elements with silicone to form hollow silicone molds, injecting a wax material into said hollow silicone molds to obtain a wax object, taking out said wax object for trimming and electroplating said wax object, and melting said wax object to obtain a mold; (b) blank formation: adding colorants into said PVC plastic material and mixing said colorants to obtain desired colors, injecting said PVC plastic material into said mold, utilizing centrifugal force to affix said PVC plastic material onto an inner wall of said mold, and removing molded PVC from said mold to form a blank by force before said molded PVC dries, filling a filler into said blank to increase hardness; and (c) assembly: assembling blanks together and joining the blanks with other decorations to

Abstract: The invention overcomes prior art problems associated with mass-production of technology-based commercial products like watch cases, mobile telephone housings, medical appliances, etc. such as high investment in tooling, delays in production, short economic tool life, inconsistence and mismatching between parts made in different geographical locations, etc., through the use of standardized, interchangeable ceramic mold inserts.

Abstract: A custom-fitting prosthetics liner is made without mixing silicone and without making a mold. A thermoformable liner is made by preparing a negative cast from a patient's residual limb, preparing a positive cast from the negative cast, and placing a thermoformable tubular liner over the positive cast. The positive cast and liner are heated in an oven for a predetermined time and temperature. Having acquired a new geometry, the cast and liner are removed from the oven and allowed to cool to room temperature. The liner is then removed from the cast. Alternatively the liner is heated, placed over the positive cast, cooled and removed. The interior surface of the liner conforms to the shape of the cast. The liner is elastic so that it returns to its new geometry when stretched and released. It therefore holds on to a residual limb even when the residual limb shrinks.

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 method of replacing a lost denture includes the steps of forming a mold 20 as an impression of the original denture, and of fabricating a replacement denture using this mold. The mold consists of a tissue side mold section and an exterior side mold section. The tissue side mold section is made of a dimensionally stable material, such as dental stone or an addition-cured silicone rubber, so that the tissue side of the denture can be accurately reproduced at a later time. The exterior side mold is made of a resilient material, so that the original denture and its duplicate can be removed from the mold. An injection passage and overflow passages can be drilled into the exterior side mold section so that a liquid resin can be injected to adequately fill the mold cavity to form the gum portion of the duplicate denture.

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 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: Methods of rapidly prototyping microstructures such as HARMs are disclosed. A high precision process uses polymeric microstructure replication techniques and sacrificial layer etching techniques to mass produce high aspect ratio metallic and polymer micromold inserts. In one embodiment, after fabrication of an initial micromold insert, high aspect ratio replications are created by casting replication material, such as PDMS, directly onto the initial micromold insert. The replicated HARM is coated with a sacrificial layer and then electroplated to replicate another set of micromold inserts. After the electroplating process is completed, the sacrificial layer is etched away to release the replicated micromold inserts.

Abstract: A process of making a microcontact printing stamp useful in microcontact printing of microcircuits. In this process an elastomeric microcontact printing stamp is formed by curing an elastomeric monomer or oligomer in a mold in which a photoresist master, defining a microcircuit in negative relief, is predisposed above a flat and rigid backplane laminate. The flat and rigid plane member of the backplane laminate is delaminated from the backplane after the printing stamp is removed from the mold.

Abstract: A method is described that includes making a first impression of the face of a surgical patient prior to the commencing of surgery and of making a second impression of the face after the first impression has been made. Typically, the first and second impressions are a negative first and second impression that are each used in turn to make a first and a second positive impression of the face which are then used for making a comparison therebetween and also for teaching purposes. The second impression may be taken during the actual surgical procedure or it may be taken after surgery has been completed and the patient has fully healed. If desired, a third impression may be made after the second impression has been taken. The third impression is typically a third negative impression that is used to create a third positive impression. The third positive impression is also used for comparison purposes.

Abstract: A mold apparatus and method for creating designs on the interior of molds includes a resilient form with an exterior and an interior, with a design formed on the exterior. A rigid support member is removably attached to the interior of the resilient form. A mold pattern, conformed to removably receive the rigid support member and the resilient form in combination, completes the basic elements of the invention. In one aspect of the invention, a passageway in the rigid support member is provided for introducing a gas between the rigid support member and the resilient form. In another aspect of the invention, a vacuum application device is provided for applying a vacuum to the interior of the resilient form.

Abstract: A method for producing a human body part prosthesis, in the case where one pattern of human body part is lost or removed from a generally symmetrical human body part consisting of the left pattern and the right pattern, for restoring the lost or removed human body part, the method comprising: a reverse molding step in which a form of the remaining human body part BL of the other pattern is impression modeled directly from the remaining human body part of the other pattern, and an impression model of one pattern which is lost or removed is reverse-molded from the impression model 10 of the other pattern thus impression modeled, and a prosthesis molding step for molding a human body part prosthesis 1 of the lost or removed side from the reversed impression model 18 molded in the reverse molding step.

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: A method is provided for manufacturing molded simulated stone and wood architectural articles for buildings and homes. The method incorporates a unique mold assembly including a resilient silicone rubber mold supported within a rigid mold cradle/foundation, and a vented lid having a High-Density Polyethylene (HDPE) interior surface. The silicone rubber mold is initially treated with a liquid polyester gel coating that is cured and then coated with an acrylic/vinyl ester back coating. Once the back coating is cured, a predetermined volume of a modified high-density, natural mineral fiber-reinforced, 2-component hybrid polyurethane liquid expanding composition is dispensed therein and the mold is covered with the vented lid. The system is pressurized and heated to produce a molecularly-fused, lightweight rigid article having the desired architectural shape.

Abstract: A method of producing a mould by forming around a pattern (20, 21) of an article to be produced comprises, (a) pressing a mould matrix (50) material around said pattern (20, 21) in a chamber bounded by solid retaining means (40, 80); (b) causing said mould matrix (50) material to harden to produce a flexible mould (50) having the following physical properties; flexural strength in the range 20-175 Mpa; flexural modulus in the range 700-5,000 Mpa; tensile strength in the range 10-120 Mpa; tensile modulus in the range 850-4,000 Mpa; compressive strength in the range 30-200 Mpa; compressive modulus in the range 400-5,000 Mpa; hardness in the range 5-20 Vickers; relative density in the range 0.5 to 3.0 g/cm3, and (c) removing the pattern (20, 21) to leave a mould (50), conforming to the pattern; wherein said mould matrix material (50) contains from 10 to 90% by volume of fibres, said fibres having a length in the range from 10 to 1000 &mgr;m and a thickness in the range from 0.1 to 30 &mgr;m.

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 for forming the outer surface of a breast prosthesis is disclosed. A digital, three-dimensional image is formed of a patient's breast using a computerized scanner. A computer-controlled milling machine utilizes the image to form a solid model of the breast. A sheet of flexible, moldable material having a uniform, precise thickness is then vacuum-formed over the breast model. A hard, two-piece mold is cast from the flexible sheet. A soft, curable material is then either poured or injected between the two pieces of the mold to form the breast prosthesis outer surface. The breast prosthesis outer surface is then turned inside out to form a shape that is a mirror image of the patient's breast.