Abstract: Provided are an injection mold and an injection molding method by which a boundary line between a first material and a second material curved so as to be sharply bent like a round chamfered shape can be formed reliably in a desired position, and a molded article molded using the injection mold and the injection molding method. The sum of a length w of an inclined-part forming part 51a and a length y of a thinned-part forming part 51b in a width direction of a linear part or a width direction of a curved part is at least equal to a prescribed value, and the thinned-part forming part 51b forming the curved part has a second length y longer than a first length in the width direction of the curved part.

Abstract: Methods and apparatuses for electromagnetic support tooling for use in composite part curing are described. In one example, a support tooling, such as a mandrel, includes an elastomeric housing that has ferromagnetic components. The mandrel also has electro-magnetic coils positioned within the elastomeric housing and operable to generate magnetic fields to repel or attract the ferromagnetic components of the elastomeric housing to the electro-magnetic coils. When the ferromagnetic components of the elastomeric housing are repelled by the electro-magnetic coils, the elastomeric housing has a rigid surface state. When the ferromagnetic components of the elastomeric housing are attracted to the electro-magnetic coils, the elastomeric housing is collapsed.

Abstract: The present disclosure is directed to prosthetic limb sockets that couple prosthetic limbs to residual limbs. The sockets include a conical cup sized to engage and couple to the residual limb, and a base to secure the socket to the prosthetic limb. The sockets are direct heat-formable onto the residual limb, such that they can be heated and formed as they are secured to the residual limb.

Abstract: A furnace includes a pedestal, a crucible, first and second heaters, and a controller. The crucible is arranged on a pedestal that is movable downwardly and is rotatable. The first and second heaters are spaced vertically along an outer wall of the crucible and are arranged around the crucible to heat pieces of solid material deposited in the crucible. A third heater is arranged above the crucible if the crucible includes a solid cylindrical mold or in a hollow cylindrical space of the crucible if the crucible includes a hollow cylindrical mold. The controller is configured to control the first and second heaters to heat the pieces of the solid material to form a melted liquid. The controller is configured to control the rotational and downward movements of the pedestal relative to the first and second heaters during solidification of the melted liquid to form an ingot.

Abstract: A plastic sintered body has a first compressed portion formed by heating plastic powder packed in a cavity of a metal mold and sintering a first portion of the plastic powder packed in the cavity in a first compression state. In addition, a second compressed portion is formed by sintering a second portion of the plastic powder packed in the cavity in a second compression state. A plurality of interconnected minute voids are formed in the first compressed portion and a plurality of interconnected minute voids smaller than the voids in the first compressed portion are formed in the second compressed portion. The manufacturing of the plastic sintered body as noted above is performed continuously in the metal mold. In addition, two types of porous portions including voids of different sizes are formed by sintering only one type of the plastic powder in the metal mold.

Abstract: Methods and apparatus for fabricating adhesive bonded joints while minimizing the voids and/or porosity found in the cured bondline. In accordance with various embodiments, the apparatus comprises an evacuation chamber combined with a pressure inducing device to produce bonded joints that are both void free and thoroughly compacted. The surfaces to be bonded are continuously evacuated throughout the bonding process (pre-mating, mating, debulking and cure). Continuous evacuation is provided via standard vacuum, while the induced pressure can be pneumatically or mechanically provided.

Abstract: In certain embodiments described herein, a heated line forming system includes a heating coil system configured to produce a heated line on a surface of a metal part. The heated line forming system also includes an air knife cooling system configured to maintain a dry area for the heated line, and to direct a coolant (e.g., cooling water, liquified gases such as liquid argon, solidified gases such as carbon dioxide snow, and so forth) around the heated line via a spray mechanism such that the coolant does not flow or splash into the heated line on the metal part. In certain embodiments, the heated line forming system includes multiple induction coils arranged along a line and spaced a short distance apart, but which, when operated simultaneously together, form a heated line on a surface of a metal part.

Abstract: A device for filling or creating a void within a construction medium. The device has a body having at least one inflatable body portion. Each inflatable body portion has one or more inflatable cavities. There is at least one valve member fluidly connected to the one or more inflatable cavity to control flow of fluid into and inflate said cavity. In-use, the one or more cavities are shaped to substantially fill or create the void in a construction medium when in an inflated state.

Abstract: There is provided a manufacturing method of a tank including a liner. The manufacturing method comprises (A) a process of winding fibers in a sheet-like form impregnated with a resin on a mandrel having a higher rigidity than rigidity of the liner and heating and curing the wound fibers in the sheet-like form to form a sheet layer; (B) a process of pulling out the mandrel from the sheet layer; and (C) fitting the liner into the sheet layer, after the process (B).

Abstract: Methods and apparatuses for blow molding a fuel tank with multiple concentric needles to form an opening in the fuel tank, and/or for calibrating the opening in the fuel tank as it cools.

Abstract: Systems and methods for assembling a skin of a composite structure are disclosed herein. The methods include operatively attaching a charge of composite material to a flexible substrate to define an initial conformation for a composite-substrate assembly and locating the composite-substrate assembly and a layup mandrel proximal to one another. The methods further include pressing the composite-substrate assembly against an outer surface of the layup mandrel to deform the composite-substrate assembly to a final conformation. The methods also include affixing the charge of composite material to the outer surface of the layup mandrel and releasing the charge of composite material from the flexible substrate while retaining the charge of composite material on the outer surface of the layup mandrel. The systems include the flexible substrate, the layup mandrel, and an assembly deformation structure that is configured to press the composite-substrate assembly against the outer surface of the layup mandrel.

Abstract: To provide a lamination method and a lamination system capable of excellently laminating a film-type laminate without damage even though the semiconductor is a brittle lamination target such as a foil-type semiconductor or a semiconductor made of highly brittle material. In a lamination method for laminating a film-type laminate to a brittle lamination target by overlapping the brittle lamination target and the film-type laminate and heating and pressing the brittle lamination target and the film-type laminate, with respect to the brittle lamination target mounted on a mount member and carried into a lamination device, an elastic film member is expanded into a vacuum chamber of the lamination device from the above to press and laminate the brittle lamination target and the film-type laminate.

Abstract: A method and support apparatus for providing structural support to a mold or mandrel, such as a shape memory polymer (SMP) apparatus configured for shaping a composite part. The support apparatus may comprise a rigid structural member and a plurality of SMP cells attached thereto and configured to inflate or deploy in a malleable state toward and against a surface of the SMP apparatus, mold, or mandrel. Then the SMP cells may be returned to a rigid state while still pressed against this surface, thereby providing structural support when composite material is applied to an opposite surface of the SMP apparatus, mold, or mandrel. After the composite material is cured into the finished composite part, the SMP cells may be deflated or otherwise collapse toward the structural member to provide enough clearance to be removed from the cured composite part.

Abstract: Prosthesis to treat hernia, can include a single mesh sheet having biocompatible fibers. It has a flat portion, an unstiffened protuberance formed from the flat portion, and an opening in the flat portion formed by the protuberance having a first diameter. The protuberance includes a proximal portion closest to the flat portion having a proximal portion height, and a distal portion disposed farthest from the flat portion having a distal portion height, a second diameter, and an end of the distal portion is unstiffened. The proximal portion height is a distance from the flat portion to a beginning of the distal portion, and the distal portion height can be a distance from the flat portion to the end of the distal portion. The second diameter is greater than the first diameter, and a first ratio of the distal portion height to the proximal portion height is approximately 1.4 to 3.0.

Abstract: Methods for manufacturing a composite fan inlet housing are disclosed. The methods include inserting a first piece of composite material and a second piece of composite material into a molding tool, inserting an inflatable bladder between the first piece and the second piece, and pressurizing the inflatable bladder to a curing pressure for a length of time sufficient to allow the first piece and second piece to cure.

Abstract: A sports racquet having a plurality of string port holes and conventional string holes is formed of a single tube of prepreg material. When molded, mold elements press opposed portions of the prepreg tube into contact with one another, and shape the adjoining prepreg material into a string port hole blanks. The portion of the pressed-together material which initially blocks the string port hole is removed after molding so that the string port holes extend through the frame. Alternatively, the mold elements cause the prepreg tube to follow a serpentine shape, thereby defining string port holes which are open alternately along the top and bottom surface of the frame. A pair of cover rings may be secured to the top and bottom racquet surfaces to cover the open sides of the string port holes.

Abstract: A method of manufacturing a wind turbine blade shell part comprising fiber material impregnated with cured resin is described. The method comprises the steps of: a) providing a first mold part having a first forming surface with a contour that defines at least a part of an outer surface of turbine blade shell part, b) arranging fiber material in the first mold part, the fiber material comprising fibers of a magnetizable material, c) providing a resin in the first mold part simultaneous with and/or subsequent to step b), and d) curing the resin in order to form the wind turbine blade shell part or wind turbine blade. The fiber material is retained against the first forming surface by use of magnet means during step b) and/or step c).

Abstract: Molds and processes that permit high-speed, mass production of retaining wall blocks having patterned or other processed front faces, as well as retaining wall blocks formed by such processes. The invention permits the front face of the block to be impressed with a pattern or otherwise directly processed, to allow the formation of pre-determined block front faces, while at the same time facilitating high-speed, high-volume production of blocks. A mirror image of the desired pattern can be created on a stripper shoe by selecting a desired three-dimensional surface from a naturally occurring or man made object and digitally scanning the selected three-dimensional pattern to create scanned data. The scanned data can then be used to machine a face of the stripper shoe that is the mirror image of the selected pattern.

Abstract: A method for producing an integral reinforced fiber composite component comprising at least one hollow fiber reinforcing component and a shell component is disclosed and can include first providing a mold core having a target cross-section deviating from a round cross-section adaptable to an inner cross-section of the hollow reinforcing component, introducing the mold core into a cavity of the hollow reinforcing component and fixing it thereafter in the cavity with a fixing agent applying the hollow reinforcing component with the mold core fixed therein to the shell component, and subjecting the mold core to a pressurized medium while applying heat and/or pressure to this arrangement to produce the integral reinforced fiber composite component.

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: The present application relates to a full wafer nanoimprint lithography device comprises a wafer stage, a full wafer coated with a liquid resist, a demolding nozzle, a composite mold, an imprint head, a pressure passageway, a vacuum passageway and a UV light source. The present application also relates to an imprinting method using the full wafer nanoimprint lithography device comprises the following steps: 1) a pretreatment process; 2) an imprinting process; 3) a curing process; and 4) a demolding process. The device and the method can be used for high volume manufacturing photonic crystal LEDs, nano patterned sapphire substrates and the like in large scale patterning on the non-planar surface or substrate.

Abstract: A method (and apparatus) for nano lithography, includes applying a pneumatic pressure to at least one of a surface of a semi-rigid mask or template and a portion of a surface of a resist-coated workpiece, and, by the applying of the pneumatic pressure, transferring a pattern from the mask to the workpiece.

Abstract: A press with a pressure chamber and a lid. The chamber is filled with a substantially incompressible medium and the medium at least partially encloses an elastomeric pressure vessel. The vessel is filled with a substantially incompressible fluid that is in fluid communication with a pressurized source of the fluid.

Abstract: A roller nanoimprint apparatus is disclosed which is capable of preventing a workpiece film with nanostructures having been transferred from the mold roller from being uneven in thickness and allowing easy replacement of the mold roller. At least one embodiment of the present invention is directed to a roller nanoimprint apparatus including a mold roller and continuously transferring nanosized protrusions to a surface of a workpiece film by rotating the mold roller, wherein the mold roller is a cylindrical body having an outer circumference surface with nanosized recesses formed thereon, the roller nanoimprint apparatus further includes a fluid container having an elastic film inflatable by injecting fluid into the container, the fluid container being arranged in a region defined by an inner circumference surface of the mold roller, the mold roller is mounted or demounted when the elastic film is shrunken, and the mold roller is supported from the inside when the elastic film is inflated.

Abstract: A method of manufacturing a rim for a bicycle wheel includes wrapping plys of fibers in a resin matrix around a mandrel; curing the plys to form the rim; and reducing a size of the mandrel to allow the mandrel to be removed from the rim.

Abstract: A hot isostatic pressing method is disclosed wherein workpieces are accommodated within a high pressure vessel and the interior of the high pressure vessel is filled with an inert gas of a high temperature and a high pressure to treat the workpieces. The method includes a cooling step which is performed after maintaining the interior of the high pressure vessel at a high temperature and a high pressure for a predetermined time and in which a liquid inert gas is fed into the high pressure vessel. According to this method it is possible to shorten the cycle time of an HIP apparatus.

Abstract: An optofluidic lithography system including a membrane, a microfluidic channel, and a pneumatic chamber is provided. The membrane may be positioned between a pneumatic chamber and a microfluidic channel. The microfluidic channel may have a height corresponding to a displacement of the membrane and have a fluid flowing therein, the fluid being cured by light irradiated from the bottom to form a microstructure. The pneumatic chamber may induce the displacement of the membrane depending on an internal atmospheric pressure thereof.

Abstract: An internal stiffening member of varying configurations in which the stiffening elements support the skin using a compression-only load path is disclosed. A rib can be inserted into an assembled structural box beam, and a filler material can be used to fill any gaps between the slip-in rib and the interior surface of the structural box beam. The filler material is preferably an expandable material, such as an expandable foam-type material. However, in situations where a slip-in rib forms a primary structural rib, the filler material is preferably a structural adhesive or liquid shim material. A solid adhesive or filler would not crush under the clamping forces from fasteners or bolts at localized fitting attachments.

Abstract: In a method for manufacturing components from composite fiber materials, at least one placeholder is inserted into a recess in a molding tool, wherein the unfinished component is subsequently produced, the placeholder is removed, at least one lifting pad is inserted into the recess and the unfinished component is removed from the molding tool by inflating the lifting pad. In a system for manufacturing components from composite fiber materials, the component removal process is monitored and controlled by a computer unit in order to prevent predetermined maximum component loads from being exceeded. The gentle component removal process makes it possible to avoid consequential costs for repairing or reworking the components.

Abstract: A material forming apparatus and method for shaping a material to a forming tool having complex contours. The material forming apparatus may comprise a bladder sealed to a support structure, cooperatively forming a hollow space therebetween into which air or another gas may be pumped to inflate the bladder. The forming tool may comprise a protrusion of any shape to which the material may conform. The material may be placed between the bladder and the protrusion and the support structure may be actuated toward the forming tool. As the support structure progresses toward the forming tool, an area of material pressed against the protrusion by the bladder increases in an outward direction. A pressure regulator may regulate an amount of pressure applied to the material by the bladder as the bladder presses the material against the forming tool.

Abstract: A green pneumatic tyre is built on a rigid toroidal support externally having a forming surface of a conformation corresponding to the inner shape of a tyre. The green tyre engaged on the expandable toroidal support is introduced into a vulcanisation mould and submitted to a vulcanisation cycle. During vulcanisation, axial moving apart of side portions of the toroidal support is caused so as to press the beads and sidewalls of the tyre against the vulcanisation mould.

Abstract: In accordance with one aspect of the present invention, methods for molding and curing of composite articles are provided. In one embodiment, the method includes providing a molding apparatus including an elastic layer disposed on a rigid support and a mold disposed on the elastic layer and the support. In one embodiment, the mold includes an inner surface, the inner surface further including a molding surface, and wherein a first surface of the elastic layer and the inner surface of the mold define a molding chamber. In one embodiment, a prepreg is further disposed within the molding chamber, wherein the prepreg is disposed on the first surface of the elastic layer. In one embodiment, the method includes providing a fluid via a fluid inlet against a second surface of the elastic layer, thereby expanding the elastic layer against the inner surface of the mold, and pushing the prepreg against the molding surface of the mold to form a molded composite article.

Abstract: The present invention relates to a process for producing reclaimed casting sand, which has step (I) of grinding recovered sand in the presence of an additive (A) containing a liquid having a surface tension of not higher than 35 mN/m at 25° C. and a boiling point of not lower than 150° C. at 1 atmospheric pressure.

Abstract: Molds and processes that permit high-speed, mass production of retaining wall blocks having patterned or other processed front faces, as well as retaining wall blocks formed by such processes. The invention permits the front face of the block to be impressed with a pattern or otherwise directly processed, to allow the formation of pre-determined block front faces, while at the same time facilitating high-speed, high-volume production of blocks. A mirror image of the desired pattern can be created on a stripper shoe by selecting a desired three-dimensional surface from a naturally occurring or man made object and digitally scanning the selected three-dimensional pattern to create scanned data. The scanned data can then be used to machine a face of the stripper shoe that is the mirror image of the selected pattern.

Abstract: The invention provides a device for injecting a resin into at least one fiber layer of a fiber-reinforced product (5) to be manufactured, comprising a mold (2, 3) having a mold cavity (4) that is surrounded by a mold wall for abutment of the product thereagainst in the closed condition of the mold. A rigid part (3a, 3b, 3c, 3d) of the mold wall is movable with respect to another part of the mold wall in the closed condition of the mold so as to ensure a continued abutment of the movable part of the mold wall with the products when shrinkage of the resin caused by curing thereof takes place subsequent to the injection process.

Abstract: Molded articles are described herein having a surface feature thereon, the articles being formed so as to include a polymeric composite material having reinforcing fibers in a polymeric matrix material. The surface feature(s) is created during heat molding of the polymeric composite material to form the article and the surface feature(s) include the polymeric matrix material and the reinforcing fibers therein.

Abstract: A purpose is to provide a tubular body soundproof cover and a covered tubular body, for which elastic deformation of the tubular body is unlikely to be inhibited. The tubular body soundproof cover includes a sound absorbing layer arranged on outside in an axially perpendicular direction of a tubular body having tubular body side curved sections; a skin layer arranged on outside in the axially perpendicular direction of the sound absorbing layer; and cover side curved sections arranged on outside in the axially perpendicular direction of the tubular body side curved sections, including at least a portion of the sound absorbing layer and at least a portion of the skin layer. The cover side curved sections have non-adherent sections in which the sound absorbing layer and the skin layer are not bonded over the entire circumferential length.

Abstract: A method for use in manufacturing a ceramic matrix composite article includes assembling a ceramic fiber sheet between a tool and a die, where the tool is conformable to the shape of the die and the melting point of the die is greater than the melting point of the tool. The assembly is then heated to soften the tool. At least one of the tool, the die or a separate inflatable member is then pressurized to conform the tool and the ceramic fiber sheet to the die. Next, the assembly is cooled and the pressure is vented before removal of the tool and ceramic fiber sheet from the die. A preceramic resin with a catalyst is then applied to the ceramic fiber sheet and cured at a curing temperature that is below the melting point of the tool, to form a preform. The tool is then removed from the preform.

Abstract: A ball striking device has a head that includes a metal face configured for striking a ball, a rearwardly extending metal band, a top piece, and a bottom piece. The metal band has a first end extending from one side of the face, a second end extending from the opposite side of the face, and a rear portion extending between the first and second ends and defining at least a portion of the rear periphery of the head. The top piece and the bottom piece are non-metallic or substantially non-metallic. The top piece is connected to the top side of the metal band and forms at least a portion of a top side of the head, and the bottom piece is connected to the bottom side of the metal band and forms at least a portion of a bottom side of the head. The top piece and the bottom piece are separated by the metal band.

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: An inflatable compaction tool for consolidating a composite material inside a faceted hollow or tubular mold for a composite part is made from an elastic material. The compaction tool includes relatively flat wall segments conjoined by corner segments that define a sealed chamber. The wall segments curve away from the mold surface toward the midpoint of each wall segment, so that as a pressurized fluid is introduced into the compaction tool, a component of the force exerted on the tool interior surface is transmitted through the wall segments toward the corner segments. Thus, during initial inflation, the corner segments are forced toward the corner regions of the mold before the wall segments contact the composite material, firmly compressing the composite material into the corner regions of the mold before the friction of the wall segments against the composite material inhibits expansion of the corner segments into the mold corner regions.

Abstract: A method of forming a composite article from a work piece at elevated temperatures and pressures. The method steps include disposing within a pressure chamber the work piece in contact with a mold, disposing a substantially incompressible medium in the chamber so that the medium is capable of transferring a substantially uniform predetermined pressure to the surface of the work piece, disposing within the substantially incompressible medium a fluid filled elastomeric vessel in fluid communication with a source of high pressure fluid so that the vessel is capable of causing a substantially uniform predetermined fluid pressure to the substantially incompressible medium, and causing the vessel to produce a pressure in the range of 400 to 20000 psi (2.8 to 138 MPa) to be applied to the substantially incompressible medium.

Abstract: A complex-shaped, three-dimensional fiber reinforced composite structure may be formed by using counteracting pressures applied to a structural lay-up of wetted fibers. The wetted fibers are arranged on pressurizable members and may be configured to include internal structural features, such as shear webs. A reinforcement stiffener may be located adjacent to at least one of the pressurizable members and the wetted fibers that form the internal structural feature. The reinforcement stiffener includes a modulus of elasticity that is substantially higher than a modulus of elasticity of the resin used to wet the fibers. In one embodiment, the reinforcement stiffener may be received in a pocket of one of the pressurizable members and may include a releasing agent that permits removal of the stiffener after the composite structure has been pressurized and cured.

Abstract: A method of making a composite material article includes, in an exemplary embodiment, providing a pre-impregnated preform formed from a plurality of reinforcing fibers and a polymer matrix, positioning the preform on a flat base plate, positioning a pressure bladder on top of the preform, and positioning a bridge tool above the pressure bladder. The bridge tool includes a top plate and at least one support member. The support members are coupled to the base plate with the top plate spaced above the pressure bladder. The method also includes enclosing the preform and bridge tool inside a vacuum bag by sealingly attaching the vacuum bag to the base plate, drawing a vacuum in the vacuum bag to remove air and volatiles from the preform, and then applying pressure to the preform by inflating the pressure bladder to consolidate the preform.

Abstract: A method for centralising and retaining a molded end coil (20) in a magnet former (12) which includes an oversleeve (24) for retaining the end coil in position, the radially outer (A2) surface of the end coil being of lesser diameter than the radially inner surface of the oversleeve.

Abstract: An optofluidic lithography system including a membrane, a microfluidic channel, and a pneumatic chamber is provided. The membrane may be positioned between a pneumatic chamber and a microfluidic channel. The microfluidic channel may have a height corresponding to a displacement of the membrane and have a fluid flowing therein, the fluid being cured by light irradiated from the bottom to form a microstructure. The pneumatic chamber may induce the displacement of the membrane depending on an internal atmospheric pressure thereof.

Abstract: An apparatus for forming a hollow FRP article by internal pressure molding includes a vacuum chamber, a forming die positioned in the vacuum chamber, a vacuum-chamber opening/closing mechanism, a composite-body support device for supporting a composite body without making the composite body come into contact with the forming die in a state where the forming die is opened by the vacuum-chamber opening/closing mechanism, the composite body including an airtight internal-pressure holding tube and a prepreg fitted on said airtight internal-pressure holding tube, an evacuation system for evacuating the vacuum chamber, an internal-pressure supplying device for applying pressure to an inside of the internal-pressure holding tube, and a controller for actuating the vacuum-chamber opening/closing mechanism to clamp the forming die to thereby bring the forming die and the composite body into intimate contact with each other.

Abstract: One method of forming a part includes deforming a shape memory polymer from a permanent shape into a temporary shape, where the permanent shape of the shape memory polymer is a predetermined part shape and the temporary shape is a shape larger than the predetermined part shape. The shape memory polymer in each of the permanent shape and the temporary shape defines a cavity therein. The method further includes introducing a molding material into the cavity of the shape memory polymer, and reverting the shape memory polymer back into its permanent shape. Other methods for forming the part are also disclosed herein.

Abstract: Apparatus and methods for molding composite bodies into composite parts using pressure. A lower inflexible mold is combined with an elastic upper mold layer to form a molding cavity in which the composite body to be molded is placed. An elastic pressure layer is used in combination with the upper mold layer to form a pressure chamber. A flexible expansion control layer is used to limit the increase in surface area of the pressure layer during pressurization. A perimeter retention lock is provided to prevent the perimeters of the elastic and flexible layers from moving inward or away from the lower mold during application of pressure to the pressure chamber.

Abstract: A method of manufacturing a multi-layer panel having a curved reflective and/or transmitting facing layer that includes the steps of increasing and/or decreasing pressure on a side of a thin membrane to form a pressure differential across the thin membrane that causes the thin membrane to deform to a required shape; applying a first layer of material to an outer surface of the thin membrane while the thin membrane is maintained in the required shape by the increase and/or decrease in pressure, and allowing the first layer of material to cure for a pre-determined time.