Abstract: Methods of in-situ additively manufacturing (AM) a part include placing a blank of a decorative material onto a platform and applying an AM material onto the blank such that the blank and the AM material simultaneously contour to a shape of the platform to form the part. The AM material may be applied onto the part by an extrusion process. The blank and the AM material may be under vacuum. The blank and/or the AM material may be directly or indirectly heated while the AM material is applied onto the blank.

Abstract: Methods of in-situ additively manufacturing (AM) a part include placing a blank of a decorative material onto a platform and applying an AM material onto the blank such that the blank and the AM material simultaneously contour to a shape of the platform to form the part. The AM material may be applied onto the part by an extrusion process. The blank and the AM material may be under vacuum. The blank and/or the AM material may be directly or indirectly heated while the AM material is applied onto the blank.

Abstract: A method is provided for molding a composite sheet in an injection molding press including a female mold tool and a cooperating male mold tool. The method includes the steps of loading the composite sheet into an open mold, positioning a heating element between the composite sheet and the female mold tool to preheat the composite sheet and a cavity of the female mold tool and removing the heating element and closing the mold.

Abstract: A method is provided for molding a composite sheet in an injection molding press including a female mold tool and a cooperating male mold tool. The method includes the steps of loading the composite sheet into an open mold, positioning a heating element between the composite sheet and the female mold tool to preheat the composite sheet and a cavity of the female mold tool and removing the heating element and closing the mold.

Abstract: A mold core package for forming a molding tool includes a plurality of stacked particulate layers having a binding agent. The plurality of stacked particulate layers form sacrificial walls defining a mold cavity. A sacrificial displacement line and a sacrificial displacement body extend from the mold core package and are adapted to displace a molten material applied to the mold core package.

Abstract: A mold core package for forming a molding tool includes a plurality of stacked particulate layers having a binding agent. The plurality of stacked particulate layers form sacrificial walls. An elongate sacrificial displacement line extends through the mold core package adjacent a forming surface of the mold core package. A mold cavity is defined by the stacked particulate layers.

Abstract: An active bolster for automotive crash protection has front and back walls with their outer peripheral edges sealed together to provide a bladder chamber therebetween. A gas source supplies an expansion gas to inflate the bladder chamber during a crash. The back wall has a pleated section comprising a plurality of generally-parallel rows of generally-circumferential pleats that unfold during inflation. The unfolding of the pleats controls a deployment trajectory of the front wall, and the pleats have an undulating transverse curve length corresponding to a maximum trajectory of the front wall. The pleated section further comprises a plurality of transverse ribs joining adjacent pleats in selected locations to reduced the unfolding during inflation to provide a modified deployment trajectory.

Abstract: A molding assembly for making molded parts includes a molding tool having conformal fluid lines that follow contours of a molding surface of the molding tool. The conformal fluid lines are defined in the molding tool during casting by sacrificial displacement lines formed by a three-dimensional printer. A temperature control station is coupled to the molding tool and includes a heating and cooling fluid. A valve station regulates fluid flow to the molding tool.

Abstract: A mold core package for forming a molding tool includes a plurality of stacked particulate layers having a binding agent. The plurality of stacked particulate layers form sacrificial walls defining a mold cavity. A sacrificial displacement line and a sacrificial displacement body extend from the mold core package and are adapted to displace a molten material applied to the mold core package.

Abstract: A mold core package for forming a molding tool with a removable insert includes a plurality of stacked particulate layers having a binding agent. The plurality of stacked particulate layers form molding pattern walls that generally define a base mold cavity and an insert mold cavity defining a mold surface. A sacrificial displacement line extends through the insert mold cavity closely following contours of the mold surface.

Abstract: A mold core package for forming a molding tool includes a plurality of stacked particulate layers having a binding agent. The plurality of stacked particulate layers form sacrificial walls. An elongate sacrificial displacement line extends through the mold core package adjacent a forming surface of the mold core package. A mold cavity is defined by the stacked particulate layers.

Abstract: An active bolster for an automotive vehicle has base wall for mounting against a rigid structure of the vehicle. A front wall overlies the base wall and forms an interior trim piece of the vehicle. The base wall has a first surface facing the front wall, and the front wall has a second surface facing the base wall. The base wall and front wall are joined around a closed perimeter to form an inflatable bladder with an initial open space between the first and second surfaces. The base wall includes a wide rib projecting from the first surface continuously along the closed perimeter, the wide rib having a minimum radial width along the closed perimeter equal to a first predetermined radial width. The front wall includes a plurality of narrow ribs projecting concentrically from the second surface continuously along the closed perimeter.

Abstract: An active bolster for an automotive vehicle has base wall for mounting against a rigid structure of the vehicle. A front wall overlies the base wall and forms an interior trim piece of the vehicle. The base wall has a first surface facing the front wall, and the front wall has a second surface facing the base wall. The base wall and front wall are joined around a closed perimeter to form an inflatable bladder with an initial open space between the first and second surfaces. The base wall includes a wide rib projecting from the first surface continuously along the closed perimeter, the wide rib having a minimum radial width along the closed perimeter equal to a first predetermined radial width. The front wall includes a plurality of narrow ribs projecting concentrically from the second surface continuously along the closed perimeter.

Abstract: An in-vehicle coffee maker includes a coffee mug and a brewing station that receives the mug, and has a lid that secures the mug therein. A pump supplies water to the lid from a water reservoir via a water line. A heating element heats the water to a predetermined temperature. The mug includes a mug portion, a drink cap, and a pod retainer. The drink cap includes a pod chamber to hold coffee grounds, and the pod retainer secures the coffee grounds therein. The pod retainer includes a opening for water to pass through, into the pod chamber, which in turn includes an opening for water to drain downward into the mug. The lid of the brewing station includes a nozzle that forms a sealed engagement with the opening in the pod retainer so water supplied from the reservoir to the lid flows into the pod chamber.