Abstract: A rotary acoustic horn. The rotary acoustic horn includes a shaft having an axial input end and an axial output end; and at least one welding portion; wherein the welding portion comprises an outer weld face that expands and contracts with the application of acoustic energy; wherein the welding portion comprises a first opposing end portion and a second opposing end portion; wherein the welding portion comprises through holes extending substantially along an axial direction of the welding portion from the first opposing end portion to the second opposing end portion; and wherein the through holes are located between the weld face and the shaft.

Abstract: A rotary acoustic horn. The rotary acoustic horn includes a shaft having an axial input end and an axial output end; and at least one welding portion; wherein the welding portion comprises an outer weld face that expands and contracts with the application of acoustic energy; wherein the welding portion comprises a first opposing end portion and a second opposing end portion; wherein the welding portion comprises through holes extending substantially along an axial direction of the welding portion from the first opposing end portion to the second opposing end portion; and wherein the through holes are located between the weld face and the shaft.

Abstract: A method of controlling a slot die comprises, while continuing to pass the extrudate through the fluid flow path and out the applicator slot, changing the position of the actuators with the controller to either increase the cross-directional thickness of the fluid flow path adjacent each of the actuators or substantially close the fluid flow path adjacent the actuators, and after changing the cross-directional thickness of the fluid flow path adjacent each of the actuators, while continuing to pass the extrudate through the fluid flow path and out the applicator slot, repositioning each of the actuators with the controller according to the set of discrete settings to resume operating the slot die with the actuators positioned according to the set of discrete settings.

Abstract: A system comprises a slot die including an applicator slot extending about a width of the slot die, wherein the applicator slot is in fluid communication with a fluid flow path through the slot die, and a plurality of actuators spaced about the width of the slot die, wherein each actuator in the plurality of actuators is operable to adjust a cross-directional thickness of the fluid flow path at its respective location to provide a local adjustment of fluid flow through the applicator slot. The system further comprises a controller configured to set the position of each actuator according to one of a plurality of discrete settings for operation of the slot die. The controller is further configured to, using fluid dynamics and a digital model of the die, predict a set of discrete settings from the plurality of discrete settings corresponding to a preselected cross-web profile for the extrudate.

Abstract: A method of controlling a slot die comprises positioning actuators of the slot die with a controller according to a first set of discrete settings, operating the slot die by passing an extrudate through the fluid flow path and out the applicator slot with the actuators positioned according to the first set of discrete settings, and while passing the extrudate through the fluid flow path and out the applicator slot, changing the positions of the actuators with the controller to create patterned features in the extrudate.

Abstract: A method of controlling a slot die comprises, while continuing to pass the extrudate through the fluid flow path and out the applicator slot, changing the position of the actuators with the controller to either increase the cross-directional thickness of the fluid flow path adjacent each of the actuators or substantially close the fluid flow path adjacent the actuators, and after changing the cross-directional thickness of the fluid flow path adjacent each of the actuators, while continuing to pass the extrudate through the fluid flow path and out the applicator slot, repositioning each of the actuators with the controller according to the set of discrete settings to resume operating the slot die with the actuators positioned according to the set of discrete settings.

Abstract: A method of controlling a slot die comprises, while continuing to pass the extrudate through the fluid flow path and out the applicator slot, changing the position of the actuators with the controller to either increase the cross-directional thickness of the fluid flow path adjacent each of the actuators or substantially close the fluid flow path adjacent the actuators, and after changing the cross-directional thickness of the fluid flow path adjacent each of the actuators, while continuing to pass the extrudate through the fluid flow path and out the applicator slot, repositioning each of the actuators with the controller according to the set of discrete settings to resume operating the slot die with the actuators positioned according to the set of discrete settings.

Abstract: Computer implemented method for making a die includes: selecting coating uniformity required to produce a particular coated product with the die and a value for one or more dimensions of the die; determining (using a mathematical model determined by regression analysis) total indicated run-out (TIR) of a die surface and dimensions of the die not having a user specified value; and machining die part or parts to the determined TIR and dimensions. A thermal treatment process for reducing the number of finishing (e.g., grinding) cycles needed to produce a desired die flatness is provided. A coating fluid rheological characteristic can be an input to the method.

Abstract: A method of controlling a slot die comprises positioning actuators of the slot die with a controller according to a first set of discrete settings, operating the slot die by passing an extrudate through the fluid flow path and out the applicator slot with the actuators positioned according to the first set of discrete settings, and while passing the extrudate through the fluid flow path and out the applicator slot, changing the positions of the actuators with the controller to create patterned features in the extrudate.

Abstract: A system comprises a slot die including an applicator slot extending about a width of the slot die, wherein the applicator slot is in fluid communication with a fluid flow path through the slot die, and a plurality of actuators spaced about the width of the slot die, wherein each actuator in the plurality of actuators is operable to adjust a cross-directional thickness of the fluid flow path at its respective location to provide a local adjustment of fluid flow through the applicator slot. The system further comprises a controller configured to set the position of each actuator according to one of a plurality of discrete settings for operation of the slot die. The controller is further configured to, using fluid dynamics and a digital model of the die, predict a set of discrete settings from the plurality of discrete settings corresponding to a preselected cross-web profile for the extrudate.

Abstract: A method of controlling a slot die comprises, while continuing to pass the extrudate through the fluid flow path and out the applicator slot, changing the position of the actuators with the controller to either increase the cross-directional thickness of the fluid flow path adjacent each of the actuators or substantially close the fluid flow path adjacent the actuators, and after changing the cross-directional thickness of the fluid flow path adjacent each of the actuators, while continuing to pass the extrudate through the fluid flow path and out the applicator slot, repositioning each of the actuators with the controller according to the set of discrete settings to resume operating the slot die with the actuators positioned according to the set of discrete settings.

Abstract: A cutting tool assembly using a machined tool operating in a plunge mode of electrical discharge machining to make microreplicated features in a work piece having a complex surface. The microreplicated features can be non-adjacent and can have any geometric configuration and micron-scaled dimensions, as determined by the microstructured features in the tool. The machined work piece can be used as a master tool in order to make microreplicated articles such as optical films, friction control films, plasma display panel molds, or micro-fasteners.

Abstract: A method includes placing a conductive mold in a first bath of electroforming solution, the solution including metal and having a selected temperature. A current is provided to the electroforming solution so that metal deposits onto the mold, thereby forming an electroformed element on the mold, the electroformed element and the mold being a composite assembly. The method further includes removing the composite assembly from the electroforming solution and transferring the composite assembly to a second bath having the same selected temperature. Thereafter, the electroformed element is separated from the mold while the composite assembly is in the second bath.

Abstract: Methods and apparatus for orthodontic treatment planning that involve determining an initial position of an orthodontic structure, determining an altered position, and generating response surface data using a mathematical relationship between the positions. The mathematical relationship may be defined by a number of parameters useful for determining one or more of the stress, strain, force, and moment associated with movement of the orthodontic structure. The mathematical relationship between the initial position and the altered position may be defined using a finite element analysis, empirically determined, or using other computational methodologies such as a finite difference methodology. The mathematical relationship may also be defined using an analytical methodology, such as elasticity and/or plasticity methodologies.

Abstract: The disclosure is directed to a cutting tool assembly used for creating grooves in a microreplication tool. The cutting tool assembly includes a mounting structure and multiple diamonds aligned in the mounting structure to a tolerance of less than 10 microns. For example, first and second tool shanks having first and second diamond tips can be positioned in the mounting structure such that a cutting location of the first diamond tip is identical to a cutting location of the second diamond tip. However, the second diamond tip may be a defined distance further away from the mounting structure than the first diamond tip, or the second diamond tip may have a different shape than the first diamond tip. In this manner, the first diamond tip may cut a groove into a work piece and the second diamond tip may cut a sub-feature into the groove to create a multi-featured groove.

Abstract: In one embodiment, a computer implemented system and method for selecting dimensions of a die is disclosed. The method may include prompting a user to select a coating uniformity required to produce a particular coated product with the die. The user may also be prompted to select a slot height of the die. In some embodiments, the user may specify a value for one or more dimensions of the die. The method may then determine the total indicated run-out (TIR) of the coated product as a function of the dimensions of the die not having a user specified value. In certain embodiments, the method provides a thermal treatment process for reducing the number of finishing (e.g., grinding) cycles needed to produce a desired die flatness. In another embodiment, a computer implemented method for designing a coating die to achieve a desired coating uniformity with a particular coating fluid having a specified rheological characteristic is disclosed.

Abstract: A method includes placing a conductive mold in a first bath of electroforming solution, the solution including metal and having a selected temperature. A current is provided to the electroforming solution so that metal deposits onto the mold, thereby forming an electroformed element on the mold, the electroformed element and the mold being a composite assembly. The method further includes removing the composite assembly from the electroforming solution and transferring the composite assembly to a second bath having the same selected temperature. Thereafter, the electroformed element is separated from the mold while the composite assembly is in the second bath.

Abstract: In one embodiment, a cutting tool assembly used for creating grooves in a microreplication tool is described. The cutting tool assembly includes a mounting structure and multiple diamonds mounted in the mounting structure. For example, first and second tool shanks having first and second diamond tips can be positioned in the mounting structure such that a cutting location of a diamond cutting tip of the first tool shank is a defined distance from a cutting location of a diamond cutting tip of the second tool shank. The defined distance may correspond to an integer number of pitch spacings, and may be accurate to within a tolerance of less than approximately 10 microns.

Abstract: The invention is directed to a cutting tool assembly that include multiple diamonds to define multiple cutting tips. A first diamond is positioned in the cutting tool assembly to create a first groove in a microreplication tool and a second diamond is positioned in the cutting tool assembly to create a second groove the microreplication tool, wherein the first and second grooves define integer pitch spacing of a microreplication structure to be created using the microreplication tool. In addition, a third diamond is positioned in the cutting tool assembly between the first and second diamonds to create a land feature in the microreplication tool between the first and second grooves. The invention can improve land feature creation by using a third diamond tip, rather than leaving the land features untooled and defined by the original untooled surface of micro-replication tool.

Abstract: A cutting tool assembly using a machined tool operating in a plunge mode of electrical discharge machining to make microreplicated features in a work piece having a complex surface. The microreplicated features can be non-adjacent and can have any geometric configuration and micron-scaled dimensions, as determined by the microstructured features in the tool. The machined work piece can be used as a master tool in order to make microreplicated articles such as optical films, friction control films, plasma display panel molds, or micro-fasteners.