Abstract: A support structure includes a first sheet with perforations having a front surface and a back surface and a second sheet with perforation having a front surface and a back surface. Each perforation in the first sheet and the second sheet has a portion adjacent to the front surface of the sheet that is wider than a portion of the perforation that is adjacent to the back surface of the sheet. A core made of a first material is formed between the back surface of the first sheet and the back surface of the second sheet and within the perforations to anchor the first sheet and the second sheet to the core. Molded features may be disposed on the front surfaces of the sheets and integrally formed with the core through perforations in the sheets. The support structure may be used in a horizontal base or an end-of-arm tool.

Abstract: An abrasive tool includes a first perforated sheet having a front surface and a back surface, and a second perforated sheet having a front surface and a back surface. A first layer of abrasive grains is bonded to the front surface of the first perforated sheet, and a second layer of abrasive grains is bonded to the front surface of the second perforated sheet. A core includes a first wall having an inner surface and an outer surface, a second wall having an inner surface and an outer surface, and a plurality of walls each connected to both the inner surface of the first wall and the inner surface of the second wall to space the first wall from the second wall and to form a plurality of hollow spaces within the core. The back surface of the first perforated sheet is disposed adjacent to the outer surface of the first wall and the back surface of the second perforated sheet is disposed adjacent to the outer surface of the second wall.

Abstract: An abrasive tool includes a first perforated sheet having a front surface and a back surface, and a second perforated sheet having a front surface and a back surface. A first layer of abrasive grains is bonded to the front surface of the first perforated sheet and a second layer of abrasive grains is bonded to the front surface of the second perforated sheet. A core is made of a first material, the core having a first surface and a second surface, the back surface of the first perforated sheet disposed adjacent to the first surface of the core and the back surface of the second perforated sheet disposed adjacent to the second surface of the core, the core being bonded to the first perforated sheet and the second perforated sheet by forming the core between the first perforated sheet and the second perforated sheet.

Abstract: An abrasive tool includes a base having an upper surface and a perforated sheet having a lower surface and an upper surface. A layer of abrasive grains is bonded to the upper surface of the perforated sheet. The upper surface of the base is bonded to the lower surface of the perforated sheet by a brazing material. A method of assembling an abrasive tool includes bonding the upper surface of the base and the lower surface of the perforated sheet by brazing the surfaces together and bonding a layer of abrasive grains to the upper surface of the perforated sheet.

Abstract: An abrasive tool and method for assembling same includes a first base having a front surface and a back surface and a second base having a front surface and a back surface. A first perforated sheet has a front surface and a back surface, the back surface of the first perforated sheet being bonded to the front surface of the first base. A second perforated sheet has a front surface and a back surface, the back surface of the second perforated sheet being bonded to the front surface of the second base. A first layer of abrasive grains is bonded to the front surface of the first perforated sheet, and a second layer of abrasive grains is bonded to the front surface of the second perforated sheet. The back surface of the first base is bonded to the back surface of the second base. The back surfaces of the bases may be bonded by sonic welding.