Abstract: A method includes forming a mesh member, forming hinges in the mesh member to form a blank, placing the blank into a mold, and forming a product from the mesh member in the mold. The mesh member comprises a set of filaments of polymeric material, where at least two members of the set of filaments are looped and bonded to each other.

Abstract: An assembly is provided with a unitary mesh of expanded thermoplastic resin strands with an aperture formed therein. The assembly is further provided with a trim cord inserted within the aperture of the unitary mesh. The trim cord is installed into the aperture by one of more of: the trim cord is inserted into the aperture, the trim cord is welded to the unitary mesh of expanded thermoplastic resin strands, or a first segment of expanded thermoplastic resin strands is welded to a second segment of expanded thermoplastic resin strands at least partially over the aperture.

Abstract: A vehicle seat cushion is formed by depositing filaments of a thermoplastic to form a mesh member while embedding straight strands of thermoplastic into the mesh member. The straight strands modify a property of the mesh member, such as crush resistance. The strands may have barbs to improve mechanical bonding. The filaments may be deposited directly onto a conveyor or, alternatively, may be deposited into molds which travel along the conveyor.

Abstract: An assembly is provided with a funnel having one or more side walls extending from an entrance to an outlet, and a liner having one or more elastic panels, with the liner extending over an inner surface of the one or more side walls. A system is provided with the assembly, a die, a fluid bath, and at least one hose to direct fluid from the fluid bath onto the liner of the assembly. A method includes covering an inner surface of a funnel with a liner comprising one or more elastic panels, wetting the liner, and forming a stranded mesh material member by extruding material from a die and through the funnel. A stranded mesh material member is provided and formed using the method.

Abstract: A method is provided with a stranded mesh material blank inserted into a cavity of a tool assembly shaped to form a cushion member. Fluid is circulated above a first temperature threshold through a series of apertures defined in a forming surface of the tool assembly and into the cavity thereby softening the blank and conforming a shape of the blank to the forming surface. Fluid is circulated below a second temperature threshold through the series of apertures in the forming surface and into the cavity thereby setting the shape of the blank to the forming surface and forming a cushion member. A cushion for a seat assembly is provided by a stranded mesh material member. A system is provided with a first tool, a second tool, and one or more inlet manifolds.

Abstract: A method is provided with positioning a stranded mesh material blank and a flexible sheet into a tool assembly, heating and softening the blank and/or the sheet; circulating fluid through the tool assembly to move the flexible sheet towards the blank to form a stranded mesh material member, and removing the member from the tool assembly. A system is provided with a tool assembly, a fluid flow device, a heater, and a controller to provide fluid to the tool assembly to move the flexible sheet towards the stranded mesh material blank to form a stranded mesh material member. A vehicle interior component is provided with a stranded mesh material member and a flexible layer bonded to the surface of the member.

Abstract: A method is provided with a stranded mesh material blank inserted into a cavity of a tool assembly shaped to form a cushion member. Fluid is circulated above a first temperature threshold through a series of apertures defined in a forming surface of the tool assembly and into the cavity thereby softening the blank and conforming a shape of the blank to the forming surface. Fluid is circulated below a second temperature threshold through the series of apertures in the forming surface and into the cavity thereby setting the shape of the blank to the forming surface and forming a cushion member. A cushion for a seat assembly is provided by a stranded mesh material member. A system is provided with a first tool, a second tool, and one or more inlet manifolds.

Abstract: An assembly is provided with a funnel having one or more side walls extending from an entrance to an outlet, and a liner having one or more elastic panels, with the liner extending over an inner surface of the one or more side walls. A system is provided with the assembly, a die, a fluid bath, and at least one hose to direct fluid from the fluid bath onto the liner of the assembly. A method includes covering an inner surface of a funnel with a liner comprising one or more elastic panels, wetting the liner, and forming a stranded mesh material member by extruding material from a die and through the funnel. A stranded mesh material member is provided and formed using the method.

Abstract: A cushion, a manufacturing apparatus, and a method of manufacture. The cushion comprises a mesh member that comprises a set of filaments. Each member of the set of filaments is looped and bonded to at least one other member of the set of filaments. The mesh member defines a first side that comprises a repeating non-planar profile.

Abstract: A system and method of forming a filament mesh structure. The filament mesh structure is placed in a cavity of a mold assembly. Liquid above a first temperature threshold is added to the cavity, thereby softening the filament mesh structure and conforming a shape of the filament mesh structure to a forming surface of the mold assembly. The filament mesh structure is cooled in the mold assembly to set the shape.

Abstract: A cushion and system and method of manufacturing a cushion. The cushion includes a layer that is disposed on a side of a filament mesh structure that comprises a set of filaments. Each member of the set of filaments is looped and bonded to at least one other member of the set of filaments. The layer is bonded to at least some members of the set of filaments.

Abstract: An assembly is provided with a funnel having one or more side walls extending from an entrance to an outlet, and a liner having one or more elastic panels, with the liner extending over an inner surface of the one or more side walls. A system is provided with the assembly, a die, a fluid bath, and at least one hose to direct fluid from the fluid bath onto the liner of the assembly. A method includes covering an inner surface of a funnel with a liner comprising one or more elastic panels, wetting the liner, and forming a stranded mesh material member by extruding material from a die and through the funnel. A stranded mesh material member is provided and formed using the method.

Abstract: A body of extruded polymer fibers formed and welded together in a three-dimensional shape with a fastener comprising a stake inserted into the body. The stake comprises a head that secures the fastener to the body. The body comprises extruded polymer filaments randomly oriented and bonded together to form a three-dimensional mesh structure. The polymer stake extends from a plate through a first side toward a second side of the body to a location on the surface of the body or a location within the body. A portion of the filaments is disposed between the first side of the body and the head. A method of attaching the fastener to the body comprises inserting the stake, forming the head, and attaching the head to the body.

Abstract: A seat cushion formed from a body comprising a plurality of extruded polymer filaments randomly connected to form a first three-dimensional mesh structure formed by the extruded polymer filaments. The body is formed by heating an area of the body with an ultrasonic tool that modifies a portion of the extruded polymer filaments to form a second three-dimensional structure comprising a second shape that is different than the first shape. A skin of extruded polymer film is welded to the body of extruded polymer filaments. A second body of a plurality of extruded polymer filaments randomly connected to form a second three-dimensional mesh structure formed by the extruded polymer filaments is welded to the first body. A method is disclosed for modifying the bodies with an ultrasonic tool to shape or weld the bodies.

Abstract: A method is provided with a stranded mesh material blank inserted into a cavity of a tool assembly shaped to form a cushion member. Fluid is circulated above a first temperature threshold through a series of apertures defined in a forming surface of the tool assembly and into the cavity thereby softening the blank and conforming a shape of the blank to the forming surface. Fluid is circulated below a second temperature threshold through the series of apertures in the forming surface and into the cavity thereby setting the shape of the blank to the forming surface and forming a cushion member. A cushion for a seat assembly is provided by a stranded mesh material member. A system is provided with a first tool, a second tool, and one or more inlet manifolds.