Abstract: A method for duplex printing a three-dimensional structure by depositing droplets of printing ink at least partially side by side and one above the other, including: depositing droplets of printing ink in a first printing step in order to build up an intermediate first pre-structure, depositing droplets of printing ink in a second printing step in order to build up an intermediate second pre-structure on at least one side of the first pre-structure, rotating the first pre-structure and arranging the first pre-structure on a support structure in a rearrangement step between the first and the second printing step, wherein an extension of the first pre-structure is arranged on a carrier substructure of the support structure and a main body of the first pre-structure is arranged on an deformation-control substructure of the support structure. The teachings further relate to a duplex printed three-dimensional structure as well as a duplex printer.

Abstract: A method for printing a three-dimensional structure by depositing droplets of printing ink at least partially side by side and one above the other, including steps of: depositing droplets of printing ink in a first printing step in order to build up an intermediate first pre-structure, depositing droplets of printing ink in a second printing step in order to build up an intermediate second pre-structure on at least one side of the first pre-structure, rotating the first pre-structure and arranging the first pre-structure on a support structure in a rearrangement step between the first and the second printing step, where the support structure includes a carrier substructure and a deformation-control substructure, and where the deformation-control substructure comprises a pressure chamber. The present teachings further relate to a corresponding duplex printed three-dimensional structure and a duplex printer.

Abstract: This specification discloses an article of manufacture. The article of manufacture has at least one structural blank and at least one guide. The structural blank has a plurality of oriented fiber plies in a thermoplastic matrix. The guide has a plurality of random dispersed fibers in a thermoplastic matrix. The guide is affixed to the structural blank by injection molding and over molding the guide onto the structural blank. The article of manufacture can take a number of forms for use in industries such as aircraft, automobiles, motorcycles, bicycles, trains or watercraft.

Abstract: Meniscal extrusion can occur due detachment of the knee capsule from structures of the knee. Disclosed herein are methods to repair the meniscal detachment. Additionally, cadaveric and synthetic models can be used to teach said methods of repair.

Abstract: A method of coating a surface of an interior component for a vehicle may include coupling a mold cavity on the interior component seated on a core and closing the mold cavity, and coating a surface of the interior component by injecting polyurethane into an interior of the coupled mold cavity and the core.

Abstract: A reusable surgical implement is provided that is formed of a core positioned within an enclosure. The core is formed of a suitable rigid, and optionally flexible material to enable the implant to conform to the desired use for the implement in a surgical procedure. The material forming the enclosure is also stretchable and flexible to accommodate the configuration and/or any flexing of the core, and is biologically inert to enable the implant to be sterilized after use for use in subsequent surgical procedures while protecting the material forming the core. The enclosure can be molded around the core in separate portions or components using multiple molding steps to form an enclosure with the desired attributes.

Abstract: A method of making a housing includes: providing a substrate and cutting the substrate to form an opening. The substrate being spaced by the opening to form at least one main base. A plurality of metal sheets and a plurality of reinforcing members are provided. Placing the metal sheets, the reinforcing members and the main base into a mold. The metal sheets is positioned in the opening, adjusts width of each gap between adjacent metal sheets, and between the main base and one metal sheet adjacent to the main base. Locating the reinforcing members in the metal sheets and the main base. Liquid resin is filled into the gaps and covers the reinforcing members to bond the metal sheets, the main base and the reinforcing members together, forming the housing.

Abstract: A composite (100) comprises: an integrally molded article of two or more function parts (111) made of a cured material of a liquid resin composition and two or more connection parts (112); and a retention part (120) made of a resin composition different from the liquid resin composition and having two or more through-holes (121) or concave parts. The function parts (111) are respectively arranged inside the through-holes (121) or the concave parts of the retention part (120). The connection parts (112) are joined to a surface of the retention part (120).

Abstract: The invention includes a method and device for conveying pre-printed polymer oblates (IML), supplied in a roller, to a casting machine such as an injection press that molds items such as cups or lids, where the oblates must be integrated in items by the oblates being partially punched such that they remain fixed to the roller in points or bridges, after which the roller with the semi-punched oblates is placed on a device (1) from which the roller with oblates is rolled out in stages, such that the oblates pass through a tool (5) with holes (9) which are shaped to fit the circumference of the oblates, after which the oblates are removed with a device such as a robot with vacuum suction that tears over the river bridges that fix the oblate to the roller and transfers the oblates to the injection casting tool.

Abstract: Provided are methods, systems, and computer program products for inspecting composite items. Specifically, a method involves analyzing an image of or, more generally, data characterizing condition of a top layer, which is disposed over a bottom layer. The method also involves performing a structural integrity check based on any anomalies detected in the top layer during this analysis as well as based on any anomalies previously detected in the bottom layer. As such, this structural integrity check accounts for characteristics of multiple layers, in some embodiments, all layers applied up to point of this inspection. In addition to the detected anomalies, the structural integrity check may account for previously performed repairs. The structural integrity check may be performed on individual portions of a composite item while, for example, other portions continue receiving a new composite layer, which may be referred to as an inline inspection.

Abstract: A securing structure for a light emitting element at a surface of a shell-like accessory and a manufacturing method for the securing structure are provided. According to an appearance of a handmade accessory, a mold, a positioning tenon and an adapter body are provided. The adapter body is supported and secured by combining the positioning tenon at the mold. With repeated applying operations, a plastic cementing agent is applied at an outer round surface of the adapter body to provide a combining effect. The mold and the positioning tenon are removed after the plastic cementing agent is set and shaped. Thus, using an axis and structure support of the adapter body, the light emitting grain installed is capable of securing an angular position of its optical axis as well as enhancing the combining strength.

Abstract: Molded metallized polymeric components are formed by methods of multi-shot injection molding of a first resin and a second resin, where the first resin forms a first polymer that is metal-platable and the second resin forms a second polymer that is colored and resistant to metallization. Select regions corresponding to the metal-platable polymer surface are metallized. Further, one or more interface regions between the first metal-platable polymer and the second colored polymer can be concealed from a visible direction. Molded decorative polymeric components formed from such methods are also provided.

Abstract: A tool apparatus comprises an operative member and a handle connected to the operative member. The handle comprises a core element having an elongated body, an outer surface and first and second ends opposite to each other. At least the second end is connected to the operative member. The tool handle also comprises at least one cavity extending inwardly from the outer surface of the core element and a plurality of insert blocks selectively receivable in the cavity. The tool handle further comprises an overlay disposed on the core element, wherein a height of the projection on exterior surface of the insert block is no less than a thickness of the overlay, thereby exposing the upper surface to an external environment so as to be visible to a viewer.

Abstract: The present invention provides apparatus and methods for growing fullerene nanotube forests, and forming nanotube films, threads and composite structures therefrom. In some embodiments, an interior-flow substrate includes a porous surface and one or more interior passages that provide reactant gas to an interior portion of a densely packed nanotube forest as it is growing. In some embodiments, a continuous-growth furnace is provided that includes an access port for removing nanotube forests without cooling the furnace substantially. In other embodiments, a nanotube film can be pulled from the nanotube forest without removing the forest from the furnace. A nanotube film loom is described. An apparatus for building layers of nanotube films on a continuous web is described.

Abstract: A composite wafer carrier according to an embodiment of the present invention comprises an operative portion formed of a first thermoplastic material and a support portion formed of a second different thermoplastic material. One of the operative portion and support portion is overmolded onto the other to form a gapless hermitic interface that securely bonds the portions together. The operative portion may be a transparent window, a portion of a latching mechanism or a wafer contact portion. Preferred embodiments of the invention include wafer carriers with said features, process carriers with said features and a process for manufacturing wafer carriers with said features.

Abstract: An injection molding system is configured to produce a multi-color molded article by simultaneously or sequentially injection-molding resins of a plurality of types by means of a plurality of injection molding machines. An insert mold is mounted in a mold of a first injection molding machine and a primary molded article is molded by this injection molding machine. Thereafter, a robot arm takes out the insert mold, along with the primary molded article, from the mold of the injection molding machine and attaches it to a mold of a second injection molding machine. A two-color molded article is injection-molded by the second injection molding machine and removed as a product.

Abstract: A process for producing molded products having portions formed with two separate materials is provided. The process involves forming a first component over a structural core in a first step, and forming a second component that is secured to the first component and the core in a second step. The second component can be formed directly over the first component or can be secured thereto after formation. The first and second components can additionally be formed with indicia thereon, or with recesses within which inserts containing the desired indicia can be positioned. Additionally, the first component can be formed with a ridge disposed on a projection formed on the first component that effectively seals off a portion of the first component when the second component is formed around the core and the first component to ensure the portion of the first component surrounded by the ridge remains visible after formation of the second component.

Abstract: A process for curing a porous muffler preform defined by a plurality of glass fibers and a heat-curing thermoset or thermoplastic materials applied to the plurality of glass fibers is disclosed herein. The process includes the step of enclosing the muffler preform in a chamber. The process also includes the step of surrounding the muffler preform with steam. The process also includes the step of causing steam to enter the muffler preform from multiple directions.

Abstract: An emblem assembly configured for attachment to a vehicle includes a first element and a second element. The first element is configured for attachment to the vehicle and has a first surface and a second surface recessed from the first surface. The second element is configured for attachment to the first element and has a third surface, a fourth surface spaced apart from the third surface, and a fifth surface extending between the third and fourth surfaces, wherein the fifth surface is spaced apart from the second surface to define a channel therebetween. The assembly includes a first coating disposed on the third surface and a tape disposed in contact with at least a portion of each of the second surface, the first coating, and the fifth surface to thereby fill at least a portion of the channel. A method of forming the assembly is also disclosed.

Abstract: An emblem assembly configured for attachment to a vehicle includes a first element configured for attachment to the vehicle and a second element configured for attachment to the first element. The first element has a first surface and a second surface recessed from the first surface. The second element has a third surface, a fourth surface spaced apart from the third surface, and a fifth surface extending between the third and fourth surfaces. The emblem assembly further includes a coating disposed on the third surface, and a molded resin disposed adjacent and in fixed contact with each of the fifth surface and the coating to contiguously encapsulate the coating and at least a portion of the fifth surface, wherein the molded resin is bondable to the first element. A method of forming the emblem assembly is also disclosed herein.

Abstract: The method for manufacturing a housing of a numeric display have the steps of: providing a first injection-molding step for forming a reflecting cover, wherein the reflecting cover has a plurality of pattern segment units, each pattern segment unit is defined by reflecting surfaces of the reflecting cover and has a through hole, and providing a second injection-molding step for forming a transparent injection-molded body into each pattern segment unit, surfaces of the formed transparent injection-molded body being bonded to the corresponding reflecting surfaces, and the reflecting cover and the transparent injection-molded body being constructed as the housing of the numeric display.

Abstract: A rail support block assembly includes a resilient member and a molded block having a top, a bottom and peripheral wall. The block is adapted for fastening one or more rails on the top. The prefabricated resilient member has an outer tray and inner tray arranged within the outer tray, and includes a resilient intermediate structure between the trays. The block is molded. The block is fixed in the inner tray to extend under the bottom of the block and along a lower region of the peripheral wall. The resilient member may form a part of the block mold, so that a mold member combined with the resilient member delimit the mold for the block. The moldable material is introduced and adheres directly to the inner tray of the prefabricated resilient member.

Abstract: The present invention provides apparatus and methods for growing fullerene nanotube forests, and forming nanotube films, threads and composite structures therefrom. In some embodiments, an interior-flow substrate includes a porous surface and one or more interior passages that provide reactant gas to an interior portion of a densely packed nanotube forest as it is growing. In some embodiments, a continuous-growth furnace is provided that includes an access port for removing nanotube forests without cooling the furnace substantially. In other embodiments, a nanotube film can be pulled from the nanotube forest without removing the forest from the furnace. A nanotube film loom is described. An apparatus for building layers of nanotube films on a continuous web is described.

Abstract: To provide an eraser molding toy with which it is possible to mold an eraser having a colored pattern or design, a plurality of thermofusible eraser members 1 of differing colors are placed in succession inside a molding container 2 so as to form a required pattern or design etc., and the molding container 2 is heated in order to fuse the surfaces of the eraser members 1 together to mold an eraser P having a colored pattern or design in the mold shape of the container.

Abstract: To provide an eraser molding toy with which it is possible to mold an eraser having a colored pattern or design, a plurality of thermofusible eraser members 1 of differing colors are placed in succession inside a molding container 2 so as to form a required pattern or design etc., and the molding container 2 is heated in order to fuse the surfaces of the eraser members 1 together to mold an eraser P having a colored pattern or design in the mold shape of the container.

Abstract: Procedure for the manufacture of a tube made of a flexible material and comprising a skirt and a head, in which a unit formed by the skirt and an appendage is disposed or manufactured in an injection procedure, the appendage totally or partially closing one end of the skirt and including the injection point(s), in which the appendage is cut totally or partially, and the cut part is removed, and in which the head over-molded on any area of the part of the unit formed by the skirt and appendage that remains once the cut part has been removed. The appendage offers several advantages, such as improving the finish of the over-molded head or, in the event of the unit being manufactured, easing the removal of the unit from the mound.

Abstract: A method of manufacturing a handle for a personal grooming device includes forming a substrate portion of a first material. The substrate portion has first and second walls forming a channel extending along a long axis of the substrate portion. An insert member is formed separate from the substrate portion and disposed within the channel. A grip portion of a second material is formed on the substrate portion. The second material substantially encases the insert member.

Abstract: Processes for manufacturing hollow structures such as spars for helicopter rotor blades, fixed wings for aircraft, and other aerostructures can include the provision of a path for gases to exit the material from which the spar is formed as the material is heated and cured, to help eliminate voids within the material caused by the presence of such gases.

Abstract: A method of decorating a molded article is provided that includes the steps of: (a) providing a mold insert comprising a plurality of flock fibers and a permanent adhesive layer; (b) positioning the mold insert in a mold; and (c) introducing resin into the mold, such that a resin contacts the mold insert to form a molded article. The melting point of the permanent adhesive layer is preferably greater than a temperature of the resin during molding.

Abstract: To provide an eraser moulding toy with which it is possible to mould an eraser having a coloured pattern or design, a plurality of thermofusible eraser members 1 of differing colours are placed in succession inside a moulding container 2 so as to form a required pattern or design etc., and the moulding container 2 is heated in order to fuse the surfaces of the eraser members 1 together to mould an eraser P having a coloured pattern or design in the mould shape of the container.

Abstract: A method and apparatus is provided for molding a pet toy having one or more fabric inserts molded into a portion of the surface of the toy. The mold may comprise a cover plate, a cavity plate and a separator plate, the cavity plate including one or more projections and the separator plate including one or more complementary-shaped openings such that pieces of fabric placed on the projections may have skirt areas engaged by the engagement of the separator plate to the cavity plate. The fabric may stretch when the mold is filled with rubber or plastic to form discrete fabric-covered areas on the toy.

Abstract: A method of forming a composite article having a decal occurs in a mold. The mold includes a surface that defines a mold cavity. A decal is introduced to the surface of the mold. A polyurethane elastomer composition is applied into the mold cavity to form an elastomeric layer over the decal. The composite article including the elastomeric layer and the decal may then be demolded from the mold. Alternatively, a paint composition is applied into the mold cavity to form a paint layer over the decal. The polyurethane elastomer composition is applied into the mold cavity to form an elastomeric backing layer over the paint layer. The composite article including the paint layer, the decal, and the elastomeric backing layer may then be demolded from the mold. The composite article may be a seat for an all-terrain vehicle.

Abstract: A golf club grip includes a first grip member and a second grip member. The first grip member has a dark color and a first material density. The second grip member which has a light color and a second material density which is greater than the first material density, wherein the first grip member is integrated with the second grip member in an edge-to-edge manner to form an elongated tubular structure. When the first grip member and the second grip member is heated to integrate with each other, particles of the second grip member crosses over the first grip member to form a predetermined amount of light color at the first grip member, while the light color formed at the first grip member is adapted to be overlaid by the dark color so as to render the light color and the dark color sharply distinguishable on the gold club grip.

Abstract: The invention concerns a decorated injection molded article and a process for the production of a decorated injection molded article by means of inmold technology, wherein inter alia an IMD-capable transfer film with a release layer of highly cross-linked plastic material is used. The decorated injection molded article formed has a high level of optical quality based on double-sided coating of a decorative element which is optionally joined to an auxiliary film web which is formed by a transfer layer of a transfer film and provides a decoration for the injection molded article, by means of injection molding.

Abstract: A method of molding a container closure providing selective fluid communication between an interior of a fluid container and an exterior environment, the method comprising: (i) configuring and closing a mold having a first cavity negatively defining a base of a container closure that includes a spout and a container mount, where the spout and container mount cooperate to define a conduit therethrough in fluid communication with an outlet orifice of the spout; (ii) injecting a first material into the first cavity to mold the base; (iii) cooling the first material in the mold to impart at least minimal rigidity to the base; (iv) reconfiguring at least a portion of the mold to define a second cavity adjacent to the first material, the second cavity negatively defining a cap covering the outlet orifice of the spout; (v) injecting a second material into the second cavity to mold the cap over the outlet orifice; (vi) cooling the second material in the mold to impart at least minimal rigidity to the cap; and (vii) r

Abstract: A multicolor molding method including: sandwiching, between a first cavity member having a through hole and a second cavity member, a substrate film on which an in-mold layer is formed so that the in-mold layer is positioned between the through hole and the second cavity member, the second cavity member closing one of openings of the through hole; disposing a core in a primary cavity formed of at least the through hole and injecting a first molding material into the primary cavity, to mold a primary molding layer on a surface of which the in-mold layer is transferred; and disposing the core in a secondary cavity and injecting a second molding material into the secondary cavity, to mold a secondary molding layer that covers the in-mold layer, the core being provided with the primary molding layer.

Abstract: A high quality finished prototype fuselage structure of an aircraft is manufactured using a cured female tool and an automated composite layup machine, and then touched up by hand to meet a tolerance or other specification. The female tool is preferably made from a male mold, by depositing layers of composite material over the mold, curing the tool together at a first cure temperature, separating the tool from the mold, and then curing the tool at a second, higher temperature. The first cure temperature should be at or below an upper limit temperature no greater than 180° F. The second cure temperature is preferably in the range of 250° F. to 350° F. The step of hand touching up can comprise one or more of mechanically abrading and deforming a first portion of the fuselage structure to mate with a second portion of the fuselage structure.

Abstract: In at least certain embodiments, the present invention relates to a trim panel and an apparatus and method of making the same. In at least one embodiment, the trim panel comprises a first portion and a second portion with a transition portion extending therebetween with the first portion and the second portion having curved portions having radii of less than 5 mm.

Abstract: A method of manufacturing a syringe for use in enteral feeding includes providing a premolded syringe body having a plunger end and an outlet end, loading the premolded syringe body into a mold having a core pin extending into the outlet end of the premolded syringe body, closing the mold to thereby retain the premolded syringe therein and to close a mold cavity around the outlet end of the syringe body, injection molding by injecting plastic molding material into the mold cavity and cooling to thereby form a tip at the outlet end of the premolded syringe body, and opening the mold and extracting the syringe body and the tip.

Abstract: Process for producing an injected article to which a flocked decoration is applied that includes the production of a flocked substrate (11) based on a temporary substrate (1) covered by a temporary adhesive (2) that keeps the flock fibers (3) in place, positioning of the flocked substrate in an injection mold of the article to be produced, injection of a polymer (12) being melted in the closed mold through an injection opening (4), removal of the injected article from the mold and the peeling off of the temporary substrate (1) and the temporary adhesive (2) from the injected article, characterized in that the flocked substrate (11) is positioned in the mold so that the flock fibers (3) are oriented toward the interior of the mold.

Abstract: An in-mold-decoration method for plastic articles is provided. An uninterrupted film is provided and transported into a mold. A predetermined area of the film attaches to an inner surface of a cavity of a female mold of the mold. The predetermined area of the film is cut from the uninterrupted film during closing the mold.

Abstract: A method of manufacturing decorative appliqués having a decorative outer layer, a clear backing layer which provides exceptional “depth of image” and a substrate layer is provided. Decorative or protective appliqués' having a wide range of decorative patterns may be formed by injection molding a clear plastic behind the surface of a thin substantially transparent film, fabric or sheet and backing such decorative composites with a substrate layer. The presence of the clear layer behind the relatively transparent decorative layer provides enhanced depth of image to the features of the decorative layer.

Abstract: A method of forming an identifying imprint on a resin-molded product, includes the step of dividing a material into a first portion and a second portion, to form an identifying surface on at least one of the first portion and the second portion. The method also includes the steps of molding a resin material into the resin-molded product, and transferring an imprint of the identifying surface onto the resin-molded product.

Abstract: A method and apparatus are provided for constructing a filter element, having enhanced structural capabilities, through use of a molded end cap having first and second foam portions of differing physical properties meeting at a common juncture of the first and second foam portions and simultaneously cured with one another.

Abstract: A method and apparatus for inserting wicks into candles formed in jars or containers characterized by a device comprised of a hollow tube, sealed on one end, in which a wick and wick base can snugly fit, and a crosspiece having width greater than width of the mouth of a jar so that after candle wax is poured, the wick straightening device is inserted into the jar and is removed after the wax has cooled so that the wick will remain straight even after the candle wax has cooled.

Abstract: To provide an eraser moulding toy with which it is possible to mould an eraser having a coloured pattern or design, a plurality of thermofusible eraser members 1 of differing colours are placed in succession inside a moulding container 2 so as to form a required pattern or design etc., and the moulding container 2 is heated in order to fuse the surfaces of the eraser members 1 together to mould an eraser P having a coloured pattern or design in the mould shape of the container.

Abstract: A method of dual injection molding is provided herewith. Generally, the method comprises the steps of providing a first mold to produce an inner portion of a product; forming the inner portion from a first plastic material such as polypropylene; providing an insert in the form of a logo or other indicia; combining the insert with the inner portion of the product; providing a second mold to receive the inner portion and insert combination; and injecting a second plastic material such as Santoprene® into the second mold around the core-insert combination, thereby forming a cover around the core and leaving at least one surface of the insert exposed so that it is visible.

Abstract: A method for making an article of footwear is disclosed. The method can include a number of steps where various molds are used to attach or mold a tread element onto a substrate or matrix lining. The tread element can be formed by compressing a rubber block between various molding members to cause the resulting rubber material to flow through at least one injection cavity, which penetrates through holes in the matrix lining, into at least one lug cavity disposed on the side of the matrix lining opposite to the injection cavity. The rubber material eventually enters the lug cavity and becomes attached to the matrix lining.

Abstract: A method for fabricating a curved beam from fiber composite material. A flat fiber composite laminate including a plurality of layers and at least two different fiber directions is formed. The fiber composite laminate is disposed in contact with a male tool includes a first flange, a second flange and an intermediate web. The male tool is curved in its longitudinal direction with a radius of curvature in such a way that the first flange has a shorter longitudinal extent than the second flange. The fiber composite laminate is brought into contact with and secured to the first flange of the male tool. The male tool and the fiber composite laminate are then rotated relative to one another so that the fiber composite laminate is brought into contact with the intermediate web of the male tool in a first rotational movement, and brought into contact with the second flange of the male tool in a second rotational movement.

Abstract: This invention is an indicia transfer and method for its use to impart indicia to polyolefin objects during rotational molding. The transfer is a laminate of at least two, and preferably, three coats on a carrier sheet, which is preferably a flexible, transparent polymer sheet. The coats, as successive layers on the carrier sheet are: an optional backing coat of a backing-coat pressure sensitive adhesive, an indicia coat of a colorants in a graphic or alphanumerical array, and a top coat of a pressure sensitive adhesive. The pressure sensitive adhesive used for the backing coat has a transition melting temperature less than the surface temperature of the mold to which the transfer is to be applied while the top-coat pressure sensitive adhesive has a temperature sensitive adhesive which becomes tacky at the demolding temperature to enable transfer of the coats to the interior surface of a rotational mold.