Abstract: In a process for making a bonded article having a rigid foam core and a cured fiber-impregnated resin composite skin external of the foam core, a skin of a curable fiber-impregnated resin composite material is overlayed onto a shaped rigid foam core formed of a resin material that below is thermoelastic point is inflexible to expansion by internal gas expansion and below it thermoelastic point has a positive coefficient of thermal expansion. The composite material is chosen to have a cure temperature that is below the thermoelastic temperature of the foam core material. The foam core having the skin thereon is loaded into the cavity of a mold. The mold is closed, secured and heated to the cure temperature of the fiber-impregnated resin composite material to cure the fiber-impregnated resin composite material and to thermally expand the foam core via its positive coefficient of thermal expansion.

Abstract: Polymerized foam material in flat billet form is enclosed in a heat-retaining envelope and heated to forming temperature then promptly loaded into an innovative unheated forming press and accurately formed before cooling below forming temperature. The heat-retaining envelope has an expansive skin on one side and a contractive skin on the other side to facilitate bending without wrinkling or other distortion. The forming press utilizes a rigid male form punch and a spring-tensioned elastic belt, supported on a pair of variably-spaced rollers, initially presenting a flat compliant surface upon which the heated workpiece is placed. Pressure from the form punch progressively deflects the workpiece and the belt, which becomes a compliant mold member conforming itself and the workpiece progressively around the form punch to yield an article of required carved shape, free of wrinkles or tool creep distortions.

Abstract: An essentially cylindrical, light weight, composite fastener formed of an interior cylindrical core member, a cone-shaped molded insert plug member in the first or head end of the core, and an exterior cup-shaped overwrap member. Threads are formed at the second or threaded end of the fastener. All of the components are fabricated of an organic resin material with high-modulus fibers embedded therein. The fibers of the exterior member are long and continuous while the fibers of the other members are short and chopped. All the fibers are essentially parallel with the axis of the fastener. The resin material is preferably polyetheretherketone and the fibers are preferably graphite. Also disclosed is the method of manufacturing the above described fastener.