Abstract: A method of manufacturing a portion of a boot shell for an ice skate that includes preparing a monolithic, two-dimensional pattern of the boot shell; positioning the monolithic, two-dimensional pattern into a three-dimensional preform of the boot shell; installing the three-dimensional preform in a mold; and consolidating the three-dimensional preform in the mold to produce the portion of the boot shell. An article of footwear for use in ice skating comprising a boot shell structured and arranged to accommodate a wearer's foot and having a medial forefoot portion, a lateral forefoot portion, a sole portion, a lateral ankle portion, a medial ankle portion, and a heel portion, the boot shell further comprising (i) a first thermoformable material having a softening point between 40° C. and 100° C., and (ii) a plurality of fibers, at least one of adjacent to or integrated within the first thermoformable material.

Abstract: A blade holder for an ice skate (e.g., for playing hockey). The ice skate comprises a skate boot for receiving a foot of a skater. The blade holder comprises a blade-retaining base to retain a blade. The blade-retaining base comprises a first material (e.g., a non-composite polymeric material). The blade holder comprises a support extending upwardly from the blade-retaining base to interconnect the blade holder and the skate boot. The support comprises a second material (e.g., a composite material) different from (e.g., stiffer than) the first material.

Abstract: A method of fabricating a formed structure with expandable polymeric shell microspheres. A first plurality of polymeric shell microspheres are heated from an unexpanded state to an expanded state to form a plurality of expanded microspheres. The plurality of expanded microspheres are mixed with an epoxy resin and a second plurality of unexpanded polymeric shell microspheres. The mixture is formed in a shape to create a preform. The preform is wrapped with fiber tape to create a wrapped preform. The wrapped preform is placed in a mold. The mold is heated and the second plurality of unexpanded microspheres expand from an unexpanded state to an expanded state. The mold is cooled and the formed structure is removed from the mold.

Abstract: A construct for a hockey blade that includes a foam core. The foam core includes a first core face, a second core face, and a core edge. A first layer of resin preimpregnated tape is wrapped continuously around the first core face, the core edge and the second core face. A thread is stitched along the first layer of preimpregnated tape. A second layer of resin preimpregnated tape wrapped continuously around the first layer of resin preimpregnated tape.

Abstract: A method of fabricating a formed structure with expandable polymeric shell microspheres. A first plurality of polymeric shell microspheres are heated from an unexpanded state to an expanded state to form a plurality of expanded microspheres. The plurality of expanded microspheres are mixed with an epoxy resin and a second plurality of unexpanded polymeric shell microspheres. The mixture is formed in a shape to create a preform. The preform is wrapped with fiber tape to create a wrapped preform. The wrapped preform is placed in a mold. The mold is heated and the second plurality of unexpanded microspheres expand from an unexpanded state to an expanded state. The mold is cooled and the formed structure is removed from the mold.

Abstract: A method of fabricating a formed structure with expandable polymeric shell microspheres. A first plurality of polymeric shell microspheres are heated from an unexpanded state to an expanded state to form a plurality of expanded microspheres. The plurality of expanded microspheres are mixed with an epoxy resin and a second plurality of unexpanded polymeric shell microspheres. The mixture is formed in a shape to create a preform. The preform is wrapped with fiber tape to create a wrapped preform. The wrapped preform is placed in a mold. The mold is heated and the second plurality of unexpanded microspheres expand from an unexpanded state to an expanded state. The mold is cooled and the formed structure is removed from the mold.

Abstract: A method of fabricating a formed structure with expandable polymeric shell microspheres. A first plurality of polymeric shell microspheres are heated from an unexpanded state to an expanded state to form a plurality of expanded microspheres. The plurality of expanded microspheres are mixed with an epoxy resin and a second plurality of unexpanded polymeric shell microspheres. The mixture is formed in a shape to create a preform. The preform is wrapped with fiber tape to create a wrapped preform. The wrapped preform is placed in a mold. The mold is heated and the second plurality of unexpanded microspheres expand from an unexpanded state to an expanded state. The mold is cooled and the formed structure is removed from the mold.

Abstract: A blade holder for an ice skate (e.g., for playing hockey). The ice skate comprises a skate boot for receiving a foot of a skater. The blade holder comprises a blade-retaining base to retain a blade. The blade-retaining base comprises a first material (e.g., a non-composite polymeric material). The blade holder comprises a support extending upwardly from the blade-retaining base to interconnect the blade holder and the skate boot. The support comprises a second material (e.g., a composite material) different from (e.g., stiffer than) the first material.

Abstract: A blade holder for an ice skate (e.g., for playing hockey). The ice skate comprises a skate boot for receiving a foot of a skater. The blade holder comprises a blade-retaining base to retain a blade. The blade-retaining base comprises a first material (e.g., a non-composite polymeric material). The blade holder comprises a support extending upwardly from the blade-retaining base to interconnect the blade holder and the skate boot. The support comprises a second material (e.g., a composite material) different from (e.g., stiffer than) the first material.

Abstract: A method of making a composite sheet material, comprising: applying (102) an opaque layer of opaque material (12), for example aluminium, to a first side of a layer of fibrous material (10); applying (104) a layer of transparent or translucent plastics material (14) on a side of the opaque material opposite the layer of fibrous material. The side of the layer of opaque material is viewable through the layer of plastics material. The opaque layer is a different colour to the colour of the fibrous material. The opaque layer and the layer of plastics material cooperate to provide the composite sheet material with a coloured appearance. The layer of opaque material is coated on the first side of the fibrous layer so that contours of the side of the opaque material correspond to the shape of the first side of the fibrous material layer.

Abstract: A method of fabricating a formed structure with expandable polymeric shell microspheres. A first plurality of polymeric shell microspheres are heated from an unexpanded state to an expanded state to form a plurality of expanded microspheres. The plurality of expanded microspheres are mixed with an epoxy resin and a second plurality of unexpanded polymeric shell microspheres. The mixture is formed in a shape to create a preform. The preform is wrapped with fiber tape to create a wrapped preform. The wrapped preform is placed in a mold. The mold is heated and the second plurality of unexpanded microspheres expand from an unexpanded state to an expanded state. The mold is cooled and the formed structure is removed from the mold.

Abstract: A construct for a hockey blade that includes a foam core. The foam core includes a first core face, a second core face, and a core edge. A first layer of resin preimpregnated tape is wrapped continuously around the first core face, the core edge and the second core face. A thread is stitched along the first layer of preimpregnated tape. A second layer of resin preimpregnated tape wrapped continuously around the first layer of resin preimpregnated tape.

Abstract: A method of fabricating a formed structure with expandable polymeric shell microspheres. A first plurality of polymeric shell microspheres are heated from an unexpanded state to an expanded state to form a plurality of expanded microspheres. The plurality of expanded microspheres are mixed with an epoxy resin and a second plurality of unexpanded polymeric shell microspheres. The mixture is formed in a shape to create a preform. The preform is wrapped with fiber tape to create a wrapped preform. The wrapped preform is placed in a mold. The mold is heated and the second plurality of unexpanded microspheres expand from an unexpanded state to an expanded state. The mold is cooled and the formed structure is removed from the mold.

Abstract: A method of fabricating a formed structure with expandable polymeric shell microspheres. A first plurality of polymeric shell microspheres are heated from an unexpanded state to an expanded state to form a plurality of expanded microspheres. The plurality of expanded microspheres are mixed with an epoxy resin and a second plurality of unexpanded polymeric shell microspheres. The mixture is formed in a shape to create a preform. The preform is wrapped with fiber tape to create a wrapped preform. The wrapped preform is placed in a mold. The mold is heated and the second plurality of unexpanded microspheres expand from an unexpanded state to an expanded state. The mold is cooled and the formed structure is removed from the mold.

Abstract: A construct for a hockey blade that includes a foam core. The foam core includes a first core face, a second core face, and a core edge. A first layer of resin preimpregnated tape is wrapped continuously around the first core face, the core edge and the second core face. A thread is placed along the first layer of preimpregnated tape. A second layer of resin preimpregnated tape wrapped continuously around the first layer of resin preimpregnated tape.

Abstract: A method of fabricating a formed structure with expandable polymeric shell microspheres. A first plurality of polymeric shell microspheres are heated from an unexpanded state to an expanded state to form a plurality of expanded microspheres. The plurality of expanded microspheres are mixed with an epoxy resin and a second plurality of unexpanded polymeric shell microspheres. The mixture is formed in a shape to create a preform. The preform is wrapped with fiber tape to create a wrapped preform. The wrapped preform is placed in a mold. The mold is heated and the second plurality of unexpanded microspheres expand from an unexpanded state to an expanded state. The mold is cooled and the formed structure is removed from the mold.

Abstract: A method of fabricating a formed structure with expandable polymeric shell microspheres. A first plurality of polymeric shell microspheres are heated from an unexpanded state to an expanded state to form a plurality of expanded microspheres. The plurality of expanded microspheres are mixed with an epoxy resin and a second plurality of unexpanded polymeric shell microspheres. The mixture is formed in a shape to create a preform. The preform is wrapped with fiber tape to create a wrapped preform. The wrapped preform is placed in a mold. The mold is heated and the second plurality of unexpanded microspheres expand from an unexpanded state to an expanded state. The mold is cooled and the formed structure is removed from the mold.

Abstract: A construct for a hockey blade that includes a foam core. The foam core includes a first core face, a second core face, and a core edge. A first layer of resin preimpregnated tape is wrapped continuously around the first core face, the core edge and the second core face. A thread is stitched along the first layer of preimpregnated tape. A second layer of resin preimpregnated tape wrapped continuously around the first layer of resin preimpregnated tape.