Abstract: A sheet of aluminum is formed to a mold by applying gas pressure. Thermoplastic resin is heated and applied to the aluminum in a selected pattern through a nozzle. In one embodiment, the thermoplastic resin is applied to the aluminum sheet in a hexagonal pattern that transitions to a columnar pattern. In a further embodiment microballons or micro-spheres are added to the heated thermoplastic resin to reduce viscosity. A backing layer of aluminum sheet is formed to the patterned resin composite. Gas forming of the aluminum sheet results in aspect ratios of up to 0.6, and the sheet maintains a clean surface that directly bonds to the applied resin.

Abstract: A surface structure including a skin (13) a build-up (18) and a backing (20). A skin is formed and a build-up layer is applied to the skin. In one embodiment, gas pressure is applied to form the skin in a single-sided die. A nozzle on a five-axis arm then applies resin to the skin in a selected pattern. The selected pattern may form a hexagonal “honeycomb” cell structure, for example, to support the skin and may transition to a columnar cell structure for better crush resistance. The hexagonal-to-columnar structure provides superior crush resistance in automotive body panels, for example, and improved solar energy concentration in solar energy applications.

Abstract: An apparatus for forming a surface structure. The apparatus forms a skin to a single-sided die by applying gas pressure to a skin preform placed between the die and a cap that confines the gas against the skin preform. The apparatus also has a dispensing apparatus that is movable in relation to the surface of the skin/die. In one embodiment the dispensing apparatus is a heated nozzle on a crane arm that has five axis of movement with respect to the surface of the die. The nozzle dispenses fluid plastic, for example, in a selected pattern and at a selected height on the skin.

Abstract: An aluminum-thermoplastic composite surface structure. A sheet of aluminum is formed to a single-sided mold by heating the sheet and applying a ramp of gas pressure. A thermoplastic resin is heated and microballons are added to the resin to lower the viscosity of the resin, which is applied through a nozzle in a hexagonal pattern on the formed aluminum sheet. Upon cooling, the composite resin forms a honeycomb pattern. The hexagonal pattern transitions to a columnar pattern, and a backing layer of aluminum sheet is gas pressure formed to the resin composite. Gas forming of the aluminum sheet results in aspect ratios of up to 0.6, and the sheet maintains a clean surface that bonds to the applied resin.