Abstract: A method of depositing a multiphase material. The method includes providing a Continuous Multifunctional Composite (CMC) phase containing at least one continuous element in a polymeric matrix, passing the CMC phase through a feeding system containing a cutting system, producing a predetermined length of the CMC phase, providing a flow a molten polymer such that the molten polymer and the CMC phase are merged into a continuous co-extrusion nozzle so as to produce a co-extruded multiphase material, and depositing the co-extruded multiphase material onto a surface. An apparatus for depositing a multiphase material. The apparatus contains a co-extrusion nozzle, a means to introduce a CMC phase and a molten polymer into the co-extrusion nozzle, such that the molten polymer and the CMC phase are co-extruded and deposited on a surface. An article containing a CMC phase containing continuous elements embedded in a polymer resin forming a multiphase structure.

Abstract: A method of depositing a multiphase material. The method includes providing a Continuous Multifunctional Composite (CMC) phase containing at least one continuous element in a polymeric matrix, passing the CMC phase through a feeding system containing a cutting system, producing a predetermined length of the CMC phase, providing a flow a molten polymer such that the molten polymer and the CMC phase are merged into a continuous co-extrusion nozzle so as to produce a co-extruded multiphase material, and depositing the co-extruded multiphase material onto a surface. An apparatus for depositing a multiphase material. The apparatus contains a co-extrusion nozzle, a means to introduce a CMC phase and a molten polymer into the co-extrusion nozzle, such that the molten polymer and the CMC phase are co-extruded and deposited on a surface. An article containing a CMC phase containing continuous elements embedded in a polymer resin forming a multiphase structure.

Abstract: Aspects of the disclosure relate to a method for creating a solidified material using a machine tool. In some aspects, the machine tool supplies a current to an induction coil such that the induction coil generates a magnetic field. The machine tool changes the magnetic field to induce eddy currents in a first conductor surrounding a feedstock and a second conductor surrounded by the feedstock. The machine tool uses the eddy currents to cause the feedstock to transition from a solid state to a uniform malleable state regardless of the feedstock's electrical conductivity.

Abstract: A low pull force system for feeding a filament along a feed path from a source to a liquefier in a 3D printer includes a low compressive force loading drive for advancing filament from the source, a feed drive for advancing filament into the liquefier, and an in-line accumulator comprising a telescoping joint positioned in the feed path between the loading drive and the feed drive. When the telescoping joint is in a contracted position, the loading drive activates to feed filament into the feed path at a rate faster than a rate at which the feed drive advances filament into the liquefier, causing the telescoping joint to expand and accrue a slack of filament in the feed path. When the telescoping joint reaches an extended position, the loading drive deactivates while the feed drive continues to advance filament into the liquefier, and the slack of filament is consumed.

Abstract: A method of making a physical object by additive manufacturing. In the method a hardenable primary material is provided, the object is built up by successively hardening layers of the hardenable primary material, and the object is cleaned from excess material by moving the object and thereby generating a mass inertial force in the excess material. The invention facilitates the making of objects by additive manufacturing.

Abstract: Additive manufacturing apparatuses and methods are provided. A coater having a rake moves above a build platform. A sensor measures topography of the build platform. A rake control unit receives the topography, determines (based on the topography) an adjustment of the rake's inclination relative to a reference plane as the coater moves from a first position above the platform to a second position above the platform, and sends command signals to a motor based on the adjustment. The motor adjusts an inclination of the rake relative to the reference plane as the coater moves from the first position to the second position.

Abstract: A method for manufacturing an object having a polymer part, including inserting a core through a movable element via a hole passing through the movable element, inserting the polymer part in a mould, inside which the movable element is arranged, so that the polymer part is in contact with the movable element on a first side of the movable element, displacing the movable element in the mould by exerting a force, originating from the polymer part, on the movable element in such a way that the movable element slides along the core, the movable element constraining, at an entrance of the hole on the first side, at each instant and as the movable element is displaced, the position of the portion of the core in the course of being covered with polymer at this instant.

Abstract: The invention provides a method for manufacturing a 3D item (10) comprising an electrically conductive coil (140) of at least part of an electrically conductive wire (51), wherein the method comprising printing with a fused deposition modeling (FDM) 3D printer (500) 3D printable material (201), wherein the 3D printable material (201) comprises the electrically conductive wire (51), to provide the 3D item (10) comprising the electrically conductive coil (140).

Abstract: The disclosure belongs to a technical field related to metamaterials and discloses a multi-scale three-dimensional pentamode metamaterial and an additive manufacturing method thereof. The multi-scale three-dimensional pentamode metamaterial has a body centered cubic (BCC) structure and includes a plurality of rods and a plurality of node structures. Two ends of each of the rods are connected to the node structures. Each of the rods has a cylindrical shape and is provided with a biconical through hole. From one end of the rod towards the other end of the rod, a diameter of the biconical through hole gradually decreases and then gradually increases. A chamber is formed inside each of the node structures, the biconical through hole communicates with the chamber, and the chamber is filled with a lattice structure.

Abstract: A method of depositing a multiphase material. The method includes providing a Continuous Multifunctional Composite (CMC) phase containing at least one continuous element in a polymeric matrix, passing the CMC phase through a feeding system containing a cutting system, producing a predetermined length of the CMC phase, providing a flow a molten polymer such that the molten polymer and the CMC phase are merged into a continuous co-extrusion nozzle so as to produce a co-extruded multiphase material, and depositing the co-extruded multiphase material onto a surface. An apparatus for depositing a multiphase material. The apparatus contains a co-extrusion nozzle, a means to introduce a CMC phase and a molten polymer into the co-extrusion nozzle, such that the molten polymer and the CMC phase are co-extruded and deposited on a surface. An article containing a CMC phase containing continuous elements embedded in a polymer resin forming a multiphase structure.

Abstract: The invention provides a valve disposed in a fluid supply path to control opening or closing of the supply path, configured to comprise, as components of the supply path, an inflow channel, a second channel, a first channel, and an outflow channel that are in communication with each other in sequence, in such a manner that fluid from a supply source entering the inflow channel passes through the second channel and the first channel in sequence and then flows out through the outflow channel. The valve further comprises a first valve piece and a second valve piece disposed movably in the first channel and the second channel respectively. Blocking or unblocking of the communication between the first channel and the outflow channel is controlled by movement of the first valve piece in the first channel, while blocking or unblocking of the communication between the inflow channel and the first channel via the second channel is controlled by movement of the second valve in the second channel.

Abstract: Methods and systems are disclosed for structurally analyzing and/or three-dimensional printing a part. The method may comprise receiving a model of the part for three-dimensional printing from a material comprising a matrix, receiving one or more properties for the material, and using the model, determining a print head tool path for use during the three-dimensional printing of the part. The method may also comprise determining a trajectory of at least one stiffness-contributing portion of the material based at least in part on the print head tool path, determining a performance of the part based at least in part on the one or more properties and the trajectory, and electronically outputting the performance of the part.

Abstract: A feedstock line comprises elongate filaments, a resin, and a full-length optical waveguide, comprising a full-length optical core. The full-length optical waveguide is configured such that when electromagnetic radiation enters the full-length optical core via at least one of a first full-length-optical-core end face, a second full-length-optical-core end face, or a full-length peripheral surface that extends between the first full-length-optical-core end face and the second full-length-optical-core end face, at least a portion of the electromagnetic radiation exits the full-length optical core via the full-length peripheral surface to irradiate, in an interior volume of the feedstock line, the resin that, due at least in part to the elongate filaments, is not directly accessible to the electromagnetic radiation, incident on the exterior surface of the feedstock line.

Abstract: The invention relates to a feeding carriage for a compressor machine of the type having an upper filling end through which a particulate material which is to be compressed in a mold of the compressor machine is introduced, and a lower discharging end for discharging said particulate material towards said mold. At least some of the elements forming said feeding carriage can move with respect to one another, which thereby allows modifying the geometry of at least one of said lower discharging end, said upper filling end and an intermediate portion of the supply carriage located between both ends. The invention also relates to the use of such a feeding carriage comprising the initial steps of determining optimum carriage geometry for a particulate material which is to be compressed and applying said optimum carriage geometry to the feeding carriage.

Abstract: Methods for manufacturing structures are provided. The methods include manufacturing a shell structure by additive manufacturing methods and sectioning panels with predetermined shapes from the shell structure. The panels are subsequently coupled to shell structure. Devices for performing various steps of the methods are also provided.

Abstract: A method of operating an extruder assembly to form a three-dimensional build object forms a build object quickly, with enhanced feature resolution, and with increased structural strength. The method includes positioning with at least one actuator an extruder having at least one opening defining an extrusion area through which build material can be extruded through the at least one opening. The extruder is positioned to cover a first portion of the extrusion area with a portion of an object supported on a build platen and to leave open a second portion of the extrusion area. The method further includes extruding a first continuous ribbon of build material adjacent to the object through the second portion of the extrusion area while moving the extruder along the object with the at least one actuator.

Abstract: A screw-moving assembly (100) for a screw assembly (903), the screw-moving assembly (100) comprising: a screw-moving actuator (102); and a bias-adjustment mechanism (104); wherein the screw-moving actuator (102) and the bias-adjustment mechanism (104) are configured to connect to the screw assembly (903); the screw-moving actuator (102) is configured to transmit, in use, a screw-translation force (112) to a longitudinal central axis (905) of the screw assembly (903); and the bias-adjustment mechanism (104) is configured to transmit, in use, a biasing force (114) to the longitudinal central axis (905) of the screw assembly (903).

Abstract: When an injection member such as a screw injecting a molten material into a mold is attached to an injection molding machine, a buffer spacer is provided between the injection member and a power transmission member such as an injection shaft sleeve transmitting forward/backward moving power to the injection member. Then, the buffer spacer is fixed to the power transmission member by a bolt.

Abstract: A fused deposition modeling (FDM) extrusion head is configured to receive control signals from a controller. The FDM extrusion head receives a stream of thermofusible material into an input channel; forces the stream of thermofusible material into a liquefier channel using a mechanical driver; heats the stream of thermofusible material within the liquefier channel to a specified temperature above melting point of the thermofusible material; and receives the heated thermofusible material from an outlet of the liquefier channel and expels the heated thermofusible material through an extrusion tip.

Abstract: A method of forming a three-dimensional object, comprises providing a carrier and an optically transparent member having a build surface, the carrier and the build surface defining a build region therebetween; filling the build region with a polymerizable liquid; irradiating the build region through the optically transparent member to form a solid polymer from the polymerizable liquid while concurrently advancing the carrier away from the build surface to form the three-dimensional object from the solid polymer, while also concurrently: (i) continuously maintaining a dead zone of polymerizable liquid in contact with the build surface, and (ii) continuously maintaining a gradient of polymerization zone between the dead zone and the solid polymer and in contact with each thereof, the gradient of polymerization zone comprising the polymerizable liquid in partially cured form. Apparatus for carrying out the method is also described.

Abstract: An apparatus for forming an object by an additive process, commonly referred to as 3-D printing, is provided. The apparatus includes a filament comprising a series of irregularities along the length of the filament, a nozzle depositing a layer of melted material onto a surface and a feeder feeding the filament to the nozzle. A heating element melts the filament and a controller controls the position of the nozzle in a plane to control the configuration of the layer of melted material deposited by the nozzle. Additionally, a method for forming polymer filament used in 3-D printing devices is also provided. The method includes the steps of melting a polymer, selecting an extrusion characteristic calculated to induce a polymer flow instability and extruding the melted polymer using the selected extrusion characteristic to produce an extrusion having distortions created by the polymer flow instability.

Abstract: A 5D printer, which additively manufactures an object, includes an extruder that can move linearly along three orthogonal axes and rotationally around at least one of the axes with respect to the object while depositing a material. A gantry is movable along X, Y and Z axes, and a trunnion table movable about A and B axes is mounted on the gantry. A platen is mounted on the trunnion table, and the extruder deposits the material on the platen while moving the gantry and trunnion table. A model of the object is analyzed to produce a stress tensor for the object, and the depositing is according to the stress tensor.

Abstract: A system, method and apparatus are provided for a fishing lure made with sugar. The system includes a mixing vat, a mixing mechanism, a mold, and a pump. The vat contains a mixture that includes resin, plasticizer, stabilizer, oil, and sugar. The mixing mechanism mixes the mixture in the vat. The mold forms a fishing lure of a desired shape. The pump pumps the mixture from the vat into the mold.

Abstract: A composition comprising a plurality of cell aggregates for use in the production of engineered organotypic tissue by organ printing. A method of making a plurality of cell aggregates comprises centrifuging a cell suspension to form a pellet, extruding the pellet through an orifice, and cutting the extruded pellet into pieces. Apparatus for making cell aggregates comprises an extrusion system and a cutting system. In a method of organ printing, a plurality of cell aggregates are embedded in a polymeric or gel matrix and allowed to fuse to form a desired three-dimensional tissue structure. An intermediate product comprises at least one layer of matrix and a plurality of cell aggregates embedded therein in a predetermined pattern. Modeling methods predict the structural evolution of fusing cell aggregates for combinations of cell type, matrix, and embedding patterns to enable selection of organ printing processes parameters for use in producing an engineered tissue having a desired three-dimensional structure.

Abstract: A cassette is provided for use within the build chamber of the powder forming apparatus for dispensing powders within the build chamber without the need for opening and closing the building chamber for dispensing such powders.

Abstract: Various embodiments related to three dimensional printers, and reinforced filaments, and their methods of use are described. In one embodiment, a void free reinforced filament is fed into an conduit nozzle. The reinforced filament includes a core, which may be continuous or semi-continuous, and a matrix material surrounding the core. The reinforced filament is heated to a temperature greater than a melting temperature of the matrix material and less than a melting temperature of the core prior to drag the filament from the conduit nozzle.

Abstract: An apparatus for controlling the rate of flow of fluid mold material comprising: a manifold, a valve pin having a pin axis, a pin connector and a stem, the valve pin being drivable into and out of open and closed positions relative to the gate, an electric actuator comprising an electric motor comprised of a motor housing that houses a drive shaft having a drive gear and a drive axis, a transmission comprised of a gear shaft, the drive gear and the transmission gear being drivably interconnected and arranged such that the drive axis and the gear axis are non-coaxially mounted or disposed relative to each other, wherein one or the other of the motor housing or the transmission housing are removably attached to a top clamping or mounting plate that is mounted upstream of the manifold and fixedly interconnected to a mold.

Abstract: An apparatus for producing a non-woven product is disclosed. The apparatus is located substantially within an enclosure and includes a mold or former and at least two moveable material application heads. A controller controls various elements located within or connected to the enclosure. The footprint of the enclosure is smaller than 2 m×2 m.

Abstract: An apparatus (100) for performing a multi-layer construction method using cementitious material has a reservoir (4) for containing cementitious material. The reservoir (4) is coupled to a print head (6) with a delivery nozzle (13). The delivery nozzle (13) can be moved by a robotic arm assembly (1) to index the nozzle (13) along a predetermined path. Flow of the cementitious material from the reservoir (4) to the nozzle (13) and to extrude the material out of the nozzle (13) is controlled in conjunction with indexing of the nozzle (13). A support material, an accelerating agent and a cartilage material may also be deposited from the print head (6).

Abstract: Injection molding system (20, 220, 320, 420) having hydraulic circuit (50, 250, 350, 450) for motivating hydraulic actuator (36, 38) comprising: pump motor (52); and digital displacement pump (54, 354A, 354B, 454A, 454B) having: piston assemblies (102A, 102B, 102C, 102D) actuatable by pump motor (52), piston assembly including: pair of inlet and outlets operable to be individually opened and closed at selective rate independently of actuation of each piston assembly; at least one hydraulic actuator (36, 38) operably coupled on each of rod side (64, 66) and cylinder side (58, 74) to first subset of the plurality of piston assemblies (102B, 102D) and second subset of the plurality of piston assemblies (102A, 102C), respectively.

Abstract: The apparatus (100) includes a die head (118) for extruding a main comestible material to form an extrudate body. A plurality of nozzles (160, FIG. 7) is located within the die head for introducing a comestible fluid into the extrudate body to form a plurality of filled capillaries. A control system (182) is capable of selectively connecting at least one of the nozzles to any one of at least two different fluid filling sources (150A, 15 OB). The control system may be capable of connecting each of the nozzles independently to different fluid sources or the nozzles may be arranged into two or more groups of flu idly interconnected nozzles that can each be independently switched between different fluid sources. The apparatus can be used to form products in which the fillings in the capillaries are varied or in which an image is formed in cross section. The apparatus can also be used to switch production between products having different fillings without stopping extrusion.

Abstract: The present invention relates to a method for producing three-dimensional objects based on computer-provided data, whereby a material is deposited in layers in a process chamber and the material is selectively solidified and/or bonded using a bonding apparatus and/or a solidifying apparatus in the process chamber, these steps being repeated. A conveyance of the material proceeds during the build process and proceeds continuously, sequentially and evenly up to an unpacking position.

Abstract: Branched end reactants having two or three functional groups at the ends are disclosed. The branched end reactants are used to prepare crosslinked hydrogel tissue adhesives, which have a good balance of mechanical properties in an aqueous environment. Kits comprising the branched end reactants and methods for applying a coating to an anatomical site on tissue of a living organism are also disclosed.

Abstract: Injection molding system (20, 220, 320, 420) having hydraulic circuit (50, 250, 350, 450) for motivating hydraulic actuator (36, 38) comprising: pump motor (52); and digital displacement pump (54, 354A, 354B, 454A, 454B) having: piston assemblies (102A, 102B, 102C, 102D) actuatable by pump motor (52), piston assembly including: pair of inlet and outlets operable to be individually opened and closed at selective rate independently of actuation of the each piston assembly; at least one hydraulic actuator (36, 38) operably coupled on each of rod side (64, 66) and cylinder side (58, 74) to first subset of the plurality of piston assemblies (102B, 102D) and second subset of the plurality of piston assemblies (102A, 102C), respectively.

Abstract: A hand operated injection molding apparatus constructed from prefabricated sub-assemblies and a desired mold clamping means attached to a main support structure, and then electrically integrated with each other

Abstract: A system for building a three-dimensional object with a layer-based additive technique, the system comprising a controller configured to receive build sequence data for the three-dimensional object, a head assembly in signal communication with the controller and configured to form a plurality of layers of the three-dimensional object based on the build sequence data, and an insert placement apparatus in signal communication with the controller and configured to place at least one insert in the plurality of formed layers based on the build sequence data.

Abstract: Apparatus for controlling the rate of flow of fluid material through an injection molding flow channel leading to a gate of a mold cavity, the apparatus comprising: a pin having a longitudinal length being adapted for back and forth axial movement through the flow channel; the pin having a protrusion having a maximum diameter circumferential surface; the channel having an interior surface complementary to the maximum diameter circumferential surface of the protrusion; the pin being slidable to a position within the channel such that the maximum diameter circumferential surface of the protrusion forms a seal with the complementary interior surface portion of the channel to stop flow of the fluid material, an electrically powered actuator interconnected to and controllably driving the pin through the channel.

Abstract: A superabrasive grain setting apparatus for arranging superabrasive grains on a surface of a manufacturing mold used in manufacturing a grinding tool includes a grip and raising mechanism for gripping the mold in a horizontal state and for turning the mold to a vertical state. A six-axis control robot is composed of a base arm mechanism with three controlled axes and a wrist unit with three controlled axes attached to the base arm mechanism. A superabrasive grain supply device has a grain storage for storing the superabrasive grains and a grain separation mechanism for separating the superabrasive grains in the grain storage one by one to a suction position. A suction nozzle is detachably mounted on an endmost arm of the robot and provided with a bent nose portion for drawing a grain of superabrasive to a nozzle end thereof at the suction position.

Abstract: A power supply device for supplying an electric power to a servo amplifier is configured by an AC/DC converter and a power accumulating device. Among a molding cycle, during a process where an amount of consumed power is small, a DC voltage is supplied to the servo amplifier from the AC/DC converter and a power is accumulated in the power accumulating device. In a process such as an injection process where a large power is required, a high DC voltage is supplied to the servo amplifier from the power accumulating device in place of the AC/DC converter.

Abstract: A superabrasive grain setting apparatus is provided for arranging superabrasive grains on a surface of a manufacturing mold used in manufacturing a grinding tool. The apparatus comprises a grip and raising mechanism for gripping the mold in a horizontal state and for turning the mold to a vertical state; a six-axis control robot composed of a base arm mechanism with three controlled axes and a wrist unit with three controlled axes attached to the base arm mechanism; a superabrasive grain supply device having a grain storage for storing the superabrasive grains and a grain separation mechanism for separating the superabrasive grains in the grain storage one by one to a suction position; and a suction nozzle detachably mounted on an endmost arm of the robot and provided with a bent nose portion for drawing a grain of superabrasive to a nozzle end thereof at the suction position.

Abstract: A solid free form fabrication (SFF) system and method is used to fabricate a three-dimensional structure in a continuous manner from successive layers of feedstock material. The system includes a gas shielding structure that is configured to protect a targeted region from oxidation. The system further includes a positioning arm coupled to the deposition head and moveable to align the deposition head with a targeted region of the three-dimensional structure and a plurality of control components coupled to the positioning arm for controlling a position of the positioning arm and operation of the deposition head. The gas shielding structure is formed as either a parallelepiped structure or a half disc structure and may be conformable to at least one surface of the three-dimensional structure.

Abstract: Embodiments of the present invention teach a method of controlling a screw in a two-stage injection unit and a system for implementing the method. For example, a method of controlling a screw in a two-stage injection unit, the method executable at a computing apparatus associated with the two-stage injection unit is disclosed. The method comprises receiving an indication of an operational parameter associated with the screw of the two-stage injection unit; based on the indication of the operational parameter, determining a target speed (STARGET) for the screw, the target speed (STARGET) being sufficient to enable the screw to produce a required amount of material in a molten state; causing the screw to rotate at the target speed (STARGET), thereby causing the screw to operate in a substantially continuous manner.

Abstract: A load determining device for an electrically-operated injection molding machine in which a load exerted on a movable part is detected based on the motor current or by an observer, with removing the influence of motor temperature. Upon start of continuous molding, a maximum load detected during retreat motion of an ejector or movable part is stored as a reference value Lr0. In every molding cycle, a maximum detected load Lra during the retraction of the ejector is determined. In the next molding cycle, load La detected during advance of the ejector is corrected based on the reference value Lr0 and the maximum detected load Lra to eliminate the influence of motor temperature rise, thereby determining the load Lfx(n) during the advance of the ejector. When there occurs a change in temperature of the ejector driving motor, the load detected based on the motor current or by the observer varies even if the actual ejector load is constant.

Abstract: Injection-molding materials comprised of polycarbonate can be processed into optically isotropic films in a chill roll extrusion method. The optically isotropic films for protecting data carriers (CD-ROMS) from becoming scratched, or they are used as supporting materials for the information layer.

Abstract: An installation for the treatment and further processing of thermoplastics comprises a screw-type compounding unit, downstream of which is disposed an intermittently drivable processing unit. Provision is made for a control unit which is connected with a drive of the screw-type compounding unit and with the drive of a metering device and with a drive of the processing unit. The control unit is designed for triggering the drives by the cycle time of the processing unit, the drives having identical run-up times and identical deceleration times.

Abstract: An electrospinning apparatus including a spinning dope main tank, a metering pump, a nozzle block, a collector positioned at the lower end of the nozzle block for collecting spun fibers, a voltage generator, a plurality of units for transmitting a voltage generated by the voltage generator to the nozzle block and the collector, said electrospinning apparatus containing a spinning dope drop device positioned between the metering pump and the nozzle block, the spinning dope drove device having (i) a sealed cylindrical shape, (ii) a spinning dope inducing tube and a gas inletting tube for receiving gas through its lower end and having its gas inletting part connected to a filter aligned side-by-side at the upper portion of the spinning dope drop device, (iii) a spinning dope discharge tube extending from the lower portion of the spinning dope drop device and (iv) a hollow unit for dropping the spinning dope from the spinning dope inducing tube formed at the middle portion of the spinning dope drop device.

Abstract: The present invention provides a process and system for the manufacture of wood-based composites that implement feedback adjusted in-line addition of a curing accelerator/catalyst to a thermosetting resin adhesive based on at least one of: present moisture content of the wood substrate being bonded and the temperature of the wood substrate being bonded.

Abstract: The present invention provides a hydraulic actuating mechanism of an injection molding machine, in which a plurality of hydraulic actuators are driven by one hydraulic pump, wherein the hydraulic pump of the hydraulic actuating mechanism is a variable discharge pump having the maximum necessary delivery capacity at least for each of the hydraulic actuators at the time of the highest rotational speed of the pump; the discharged fluid pressure is controlled by a discharge cutoff function of a pressure compensator ancillary to the variable discharge pump; and the pump is driven by a motor whose rotation can be controlled in a stepless mode.

Abstract: An innovative robotic foam application process that integrates system communications, non-contact vehicle insertion point locations, and applications controls to accurately dispense a two-component structural foam at a high volume and flow rate. The process begins by first inserting a baffle within the support structure. After an electrocoat application and bake, the baffles expand and are sealed within the support structure to form cavities having a fill hole. A hydraulic driven robotic dispensing system equipped with a high-pressure static mixer senses the respective fill hole, moves a robotic arm to a location sensed, and injects a high volume of mixed two-component viscous material within each of the respective located fill holes at a high fill rate. After dispensing, the viscous material undergoes an exothermic curing reaction to cure and is expanded to substantially fill each cavity.

Abstract: A pair of hoses connects directly from the feed pumps to the extruder without utilizing a PCV (pressure compensating valve). Each feed unit has automatic air pressure relief through a solenoid valve on top of the feed unit so that the unit does not stall at full static line pressure. When the dispense valve at the extruder is shut off, air pressure to the air motor is dumped. A pair of electric eyes is utilized—the first signals the pump (by providing pressurized air) to provide pressure while the second actually opens the extruder when the article to be coated comes into position. The first valve is located only a short distance ahead of the second valve so that the line pressure does not have a chance to exceed the dynamic pressure before the extruder opens.