Abstract: A fluid such as a fluidized bed or a molten bath, is heated to a temperature sufficiently high to soften a substantially rigid body of material and sufficiently low to avoid damage to the material. While maintaining the fluid at this temperature, the body is immersed in the fluid to heat the body uniformly. Pressure is applied to the heated body to form it into a desired three-dimensional configuration. The heated body is removed from the fluid either before, after, and/or while the pressure is applied. The body is allowed to cool and harden into its desired configuration. The body is preferably formed between a flexible member and a mold surface. The method may be used to form various types of material, including honeycomb core, laminated sheets of plastic, plastic tubing, and titanium. The body may be precut and indexed and secured to a mold which is immersed in the fluid with the body.

Abstract: A method of making an EMR coil assembly having a split housing including a coil-retaining body member and ring member attached thereto, the EMR coil assembly including a coil having a plurality of polyimide face sheets disposed between a polyester face sheet forming the outer wear surface of the coil and a major surface of the coil.