Abstract: A method that enables the use of a single preform-charge fixture to create preform charges suitable for creating a chiral part and its mirror image is disclosed. The method utilizes a preform charge having a flat-planar form, unlike the near net shape preform charges used in applicant's legacy methods. Two identical instances of a preform charge are fabricated from the preform-charge fixture. The first instance of the preform charge is placed, in a first orientation, in a first compression mold for fabricating a first part. The second instance of the preform charge is placed, in a second orientation, in a second compression mold for fabricating the second part. The second orientation is obtained by rotating the second instance of the flat planar preform charge 180 degrees relative to the first orientation about an axis that is parallel to a reflection axis of the first and second instance of the preform charge.

Abstract: A compression-molding tool includes “cutouts” (i.e., recesses) that are machined into the male mold portion of the tool along a boundary edge thereof. During molding, liquefied resin and fibers fill the cutouts, forming “ejection tabs” along the upper surface of the part. The ejection tabs couple the part to the male mold/plunger. The ejection tabs, along with the finished part, remain coupled to the plunger as it is withdrawn from the female mold portion, thereby releasing the finished part from the mold cavity.

Abstract: A method that enables the use of a single preform-charge fixture to create preform charges suitable for creating a chiral part and its mirror image is disclosed. The method utilizes a preform charge having a flat-planar form, unlike the near net shape preform charges used in applicant's legacy methods. Two identical instances of a preform charge are fabricated from the preform-charge fixture. The first instance of the preform charge is placed, in a first orientation, in a first compression mold for fabricating a first part. The second instance of the preform charge is placed, in a second orientation, in a second compression mold for fabricating the second part. The second orientation is obtained by rotating the second instance of the flat planar preform charge 180 degrees relative to the first orientation about an axis that is parallel to a reflection axis of the first and second instance of the preform charge.

Abstract: A method for forming a preform charge having a complex geometry includes determining a partitioning axis defining first and second portions the preform charge, each portion having a major segment and a minor segment that are not co-planar with each other, creating a fixture having segregable elements that form cavities for partially consolidating the major segments of the first and second portions, and a cavity for partially consolidating the minor segments, separately partially consolidating the major segments, and, while partially consolidating the major segments to one another, forming the minor segments and partially consolidating them to the major segments. And a fixture capable of carrying out the method.