Abstract: An apparatus and process for forming a predetermined three-dimensional (3D) object, in particular to an apparatus and method for making of a predetermined 3D object including an outer finished show surface without the use of post processing steps, and selectively printing three-dimension features onto another surface without compromising the integrity of the outer finished surface quality. A build platform of the apparatus includes a smooth surface to disperse deposited materials into a highly uniform base layer with exceptional surface quality on the interface between the deposited material and the build platform. The apparatus and process have the ability to produce an exceptionally smooth surface capable of achieving automotive standards for exterior components without the use of post-processing.

Abstract: Impregnated veil and compression molding process of reinforcing fiber pre-impregnated continuous and discontinuous thermoset and thermoplastic materials. Veils are incorporated within the process, filming or laminating stages of the pre-pregging, either hotmelt or solvent based processes, in a variety of chosen resins. The veils help to improve visual part quality, reduce fiber splitting, and provide an isolating material in applications where incompatible materials must exist.

Abstract: An apparatus and process for forming a predetermined three-dimensional (3D) object, in particular to an apparatus and method for making of a predetermined 3D object including an outer finished show surface without the use of post processing steps, and selectively printing three-dimension features onto another surface without compromising the integrity of the outer finished surface quality. A build platform of the apparatus includes a smooth surface to disperse deposited materials into a highly uniform base layer with exceptional surface quality on the interface between the deposited material and the build platform. The apparatus and process have the ability to produce an exceptionally smooth surface capable of achieving automotive standards for exterior components without the use of post-processing.

Abstract: A process for molding a hollow structure comprising the steps of: a. Forming a mandrel in a shape of a proposed cavity from a water-soluble substance capable of withstanding temperatures and pressures from a predetermined compression molding process; b. Positioning the mandrel in a suitable mold for forming an article which includes the mandrel within the article; and, c. Removing the mandrel by loosening and dissolving the mandrel with a water solution, thereby creating a cavity in the article.

Abstract: A modified compression moulding arrangement where the compression moulding tool has been modified to allow for the use of pre-impregnated pre-form sheets in order to produce class A automotive structural parts in high volume. The pre-impregnated pre-form has continuous un-chopped fibers that extend across an entire length of the pre-impregnated pre-form. The pre-impregnated pre-form is then placed in an open compression moulding tool that has a bottom half and a top half that are movable between an open position and a closed position. When the mould tool is in the closed position, the top half and bottom half create a forming cavity that is defined by a forming surface of the top half and a forming surface of the bottom half. The forming surface of the bottom half has a boundary defined by a run-off edge and an upshear that is necessary for forming a class A structural automotive component using pre-impregnated pre-form material.

Abstract: Impregnated veil and compression molding process of reinforcing fiber pre-impregnated continuous and discontinuous thermoset and thermoplastic materials. Veils are incorporated within the process, filming or laminating stages of the pre-pregging, either hotmelt or solvent based processes, in a variety of chosen resins. The veils help to improve visual part quality, reduce fiber splitting, and provide an isolating material in applications where incompatible materials must exist.

Abstract: End of arm tooling system and a method for manufacture is provided. The end or arm tooling system provides automated material handling, part manipulation, pre-forming and transferring of a pre-impregnated carbon fiber material. A robot is connected to end of arm tooling for automated material handling and transfer operations from at least a lower preform tool system where light compression is applied to a molding press. The end or arm tooling system includes a cured silicone membrane as well as vacuum and air blow off, allowing for robotically preforming, picking up and dropping-off pre-impregnated carbon fiber materials which are notoriously sticky and difficult to handle.

Abstract: End of arm tooling system and a method for manufacture is provided. The end or arm tooling system provides automated material handling, part manipulation, pre-forming and transferring of a pre-impregnated carbon fiber material. A robot is connected to end of arm tooling for automated material handling and transfer operations from at least a lower preform tool system where light compression is applied to a molding press. The end or arm tooling system includes a cured silicone membrane as well as vacuum and air blow off, allowing for robotically preforming, picking up and dropping-off pre-impregnated carbon fiber materials which are notoriously sticky and difficult to handle.

Abstract: A modified compression moulding arrangement where the compression moulding tool has been modified to allow for the use of pre-impregnated pre-form sheets in order to produce class A automotive structural parts in high volume. The pre-impregnated pre-form has continuous un-chopped fibers that extend across an entire length of the pre-impregnated pre-form. The pre-impregnated pre-form is then placed in an open compression moulding tool that has a bottom half and a top half that are movable between an open position and a closed position. When the mould tool is in the closed position, the top half and bottom half create a forming cavity that is defined by a forming surface of the top half and a forming surface of the bottom half. The forming surface of the bottom half has a boundary defined by a run-off edge and an upshear that is necessary for forming a class A structural automotive component using pre-impregnated pre-form material.