Abstract: A composite panel comprises a first skin and a second skin. A core is arranged between and attached to the first skin and the second skin. The core includes Z zones that are 3D printed using a thermoplastic material. Each of the Z zones abuts and is connected to another one of the Z zones. Each of the Z zones has one of D densities and at least one of the Z zones had a different density that another one of the Z zones. Z and D are integers greater than one.

Abstract: A composite fusion filament is disclosed that includes a polymer encasement and one or more mesogenic reinforcement bodies contained within the polymer encasement. The polymer encasement is comprised of a thermoplastic polymer, which has a melting temperature, and each of the one or more mesogenic reinforcement bodies is comprised of a thermotropic liquid crystal polymer, which has a clearing temperature. The melting temperature of the thermoplastic polymer included in the polymer encasement is less than the clearing temperature of the thermotropic liquid crystal polymer included in the one or more mesogenic reinforcement bodies. Additionally, the thermotropic liquid crystal polymer of each mesogenic reinforcement body has a plurality of organized crystalline fibrils that are aligned lengthwise along a longitudinal axis of the polymer encasement. A method of using the composite fusion filament to form a bond with a substrate that includes a thermoplastic polymer is also disclosed.

Abstract: A fused filament deposition head is employed for depositing filament materials on workpieces to join the workpieces together. The workpieces can be of an automotive application, aerospace application, or something else. The fused filament deposition head, in an example, has a feed end, a dispensing end, and a heater. The feed end introduces more than one filament in the fused filament deposition head, as demanded in the larger application. The dispensing end delivers materials of the filaments to the underlying workpieces. The materials are delivered together. The heater serves to heat the filaments as they travel through the fused filament deposition head. The filaments can include a filament having a core portion of liquid-crystal polymer material.

Abstract: A method of joining workpieces includes the steps of bringing a first workpiece and a second workpiece together, induction heating a susceptor material, and pressing the workpieces together. Each workpiece may include a thermoplastic material, and the workpieces are brought together at a joint interface so that a protrusion of the first workpiece is aligned with a receptacle of the second workpiece. The susceptor material is in contact with the thermoplastic material of the first workpiece during heating such that the thermoplastic material of the first workpiece softens. The step of pressing is performed while the thermoplastic material of the first workpiece is softened, thereby reshaping the first workpiece where the susceptor material is in contact with the thermoplastic material of the first workpiece. The protrusion is deformed to form an interlock with the receptacle at the joint interface.

Abstract: A method of joining a first workpiece substrate and a second workpiece substrate is disclosed in which a local mold tool is positioned into contact with the first workpiece substrate and the second workpiece substrate. The local mold tool defines a mold cavity and encloses an edge portion of the first workpiece substrate and an edge portion of the second workpiece substrate such that the edge portion of the first workpiece substrate and the edge portion of the second workpiece substrate are contained within the mold cavity. Once the local mold tool is positioned, a liquid polymer molding compound is injected into the mold cavity. The liquid polymer molding compound is hardened in the mold cavity into a polymer joint that adheres the edge portion of the first workpiece substrate and the edge portion of the second workpiece substrate together.

Abstract: A method of joining workpieces includes the steps of bringing a first workpiece and a second workpiece together, induction heating a susceptor material, and pressing the workpieces together. Each workpiece may include a thermoplastic material, and the workpieces are brought together at a joint interface so that a protrusion of the first workpiece is aligned with a receptacle of the second workpiece. The susceptor material is in contact with the thermoplastic material of the first workpiece during heating such that the thermoplastic material of the first workpiece softens. The step of pressing is performed while the thermoplastic material of the first workpiece is softened, thereby reshaping the first workpiece where the susceptor material is in contact with the thermoplastic material of the first workpiece. The protrusion is deformed to form an interlock with the receptacle at the joint interface.

Abstract: A fused filament deposition head is employed for depositing filament materials on workpieces to join the workpieces together. The workpieces can be of an automotive application, aerospace application, or something else. The fused filament deposition head, in an example, has a feed end, a dispensing end, and a heater. The feed end introduces more than one filament in the fused filament deposition head, as demanded in the larger application. The dispensing end delivers materials of the filaments to the underlying workpieces. The materials are delivered together. The heater serves to heat the filaments as they travel through the fused filament deposition head. The filaments can include a filament having a core portion of liquid-crystal polymer material.

Abstract: A composite fusion filament is disclosed that includes a polymer encasement and one or more mesogenic reinforcement bodies contained within the polymer encasement. The polymer encasement is comprised of a thermoplastic polymer, which has a melting temperature, and each of the one or more mesogenic reinforcement bodies is comprised of a thermotropic liquid crystal polymer, which has a clearing temperature. The melting temperature of the thermoplastic polymer included in the polymer encasement is less than the clearing temperature of the thermotropic liquid crystal polymer included in the one or more mesogenic reinforcement bodies. Additionally, the thermotropic liquid crystal polymer of each mesogenic reinforcement body has a plurality of organized crystalline fibrils that are aligned lengthwise along a longitudinal axis of the polymer encasement. A method of using the composite fusion filament to form a bond with a substrate that includes a thermoplastic polymer is also disclosed.

Abstract: A three-dimensional lattice includes a stabilizing grid having grid warp strands and grid weft strands crossing the grid warp strands. Grid cells are defined by adjacent grid warp strands and adjacent grid weft strands intersecting the adjacent grid warp strands. A projecting net has net warp strands and net weft strands crossing the net warp strands. Each subnet in a plurality of subnets uniquely corresponds to a corresponding grid cell. Each subnet includes a net warp strand portion intersecting both of the grid weft strands that define the corresponding grid cell. Each subnet includes a net weft strand portion intersecting both of the grid warp strands that define the corresponding grid cell. The net warp strand portion and the net weft strand portion of each subnet are spaced from a minimum surface defined by the corresponding grid cell.

Abstract: An assembly for a vehicle includes a first member including a plurality of elastically deformable locating protrusions extending outward, and a second member defining a cavity extending inward and including a plurality of elastically deformable compression features disposed within the cavity. The locating protrusions of the first member are disposed within the cavity of the second member in press fit engagement with the compression features of the second member to secure the first member relative to the second member. The average of the elastic deformation between all of the locating protrusions of the first member and all of the compression features of the second member precisely aligns the first member relative to the second member. The assembly may include but is not limited to a multiple unit battery pack, a multiple unit fuel cell pack, a dashboard assembly or adjoining body panels.

Abstract: A number of variations may include a product comprising: component structure having at least one surface and at least one protrusion, wherein the component structure comprises a thermoplastic polymer material and a filler, and wherein the surface and protrusion are constructed and arranged such that the component structure is substantially free of sink.

Abstract: An assembly for a vehicle includes a first member including a plurality of elastically deformable locating protrusions extending outward, and a second member defining a cavity extending inward and including a plurality of elastically deformable compression features disposed within the cavity. The locating protrusions of the first member are disposed within the cavity of the second member in press fit engagement with the compression features of the second member to secure the first member relative to the second member. The average of the elastic deformation between all of the locating protrusions of the first member and all of the compression features of the second member precisely aligns the first member relative to the second member. The assembly may include but is not limited to a multiple unit battery pack, a multiple unit fuel cell pack, a dashboard assembly or adjoining body panels.

Abstract: An assembly for a vehicle includes a first member including a plurality of elastically deformable locating protrusions extending outward, and a second member defining a cavity extending inward and including a plurality of elastically deformable compression features disposed within the cavity. The locating protrusions of the first member are disposed within the cavity of the second member in press fit engagement with the compression features of the second member to secure the first member relative to the second member. The average of the elastic deformation between all of the locating protrusions of the first member and all of the compression features of the second member precisely aligns the first member relative to the second member. The assembly may include but is not limited to a multiple unit battery pack, a multiple unit fuel cell pack, a dashboard assembly or adjoining body panels.

Abstract: Methods for improving adhesion between a shape memory alloy and a polymeric material include functionalizing a surface of the shape memory polymer with a phosphorous containing compound or an organosilane coupling agent. Other methods include surface texturing the shape memory alloy surface, independently or in combination with the functionalization.

Abstract: A method of making a polymeric article is disclosed. The method includes unrolling a thermoplastic sheet material from a roll. The method also includes heating the thermoplastic sheet to a temperature sufficient to soften the thermoplastic sheet. The method further includes feeding the thermoplastic sheet, a first continuous support structure, and a second continuous support structure to at least two calendering rolls. Still further, the method includes embedding the first continuous support structure and the second continuous support structure into the thermoplastic sheet using the at least two calendering rolls to form a reinforced sheet; and over-molding the reinforced sheet to form the polymeric article.

Abstract: A method for making a nanocomposite material includes introducing a solution including a nanofiller material and a supercritical fluid into a molten polymeric material within an extruder. The supercritical fluid is caused to substantially instantaneously convert to a gas phase, thereby forming the nanocomposite material having the nanofiller material substantially homogeneously dispersed therein.

Abstract: Methods for improving adhesion between a shape memory alloy and a polymeric material include functionalizing a surface of the shape memory polymer with a phosphorous containing compound or an organosilane coupling agent. Other methods include surface texturing the shape memory alloy surface, independently or in combination with the functionalization.

Abstract: A method of making a polymeric article includes embedding a continuous support structure into a polymeric material to form a reinforced sheet, and over-molding the reinforced sheet to form the polymeric article.

Abstract: A method for making a nanocomposite material includes introducing a solution including a nanofiller material and a supercritical fluid into a molten polymeric material within an extruder. The supercritical fluid is caused to substantially instantaneously convert to a gas phase, thereby forming the nanocomposite material having the nanofiller material substantially homogeneously dispersed therein.