Abstract: A method for texturizing a workpiece uses a die assembly installed within a press having a press ram. The method includes (a) delivering the workpiece onto a center die plate; (b) forcing the press ram against an upper die plate mounted above the center die plate to descend a first contact surface associated with the upper die plate and a plurality of blades mounted to the upper die plate toward the center die plate; (c) actuating horizontal movement of the blades; (d) driving the blades down into the workpiece; and (e) contacting the first contact surface to a second contact surface associated with the center die plate to descend the center die plate in unison with the upper die plate.

Abstract: A method of assembling a brake pad includes impaling a first layer of a preformed multi-layer friction pad on piercing members of a rotor facing surface of a brake pad backing plate. A shim is concurrently assembled to a caliper facing surface of the backing plate.

Abstract: The present invention is a laminate sheet having two laminae. The first lamina is a relatively hard material having first and second surfaces. The first surface has a plurality of raised and generally pointed piercing structures, each structure having a tip. The second lamina is graphite foil material, which is mated to the relatively hard material, such that at least some of the piercing structures pierce the graphite foil material. In one embodiment, the first lamina has no performations and is uniformly smooth. In another embodiment, the second surface also has a plurality of piercing structures and a third lamina comprising graphite foil is mated to the second surface.

Abstract: A brake backing plate includes first and second sheet metal stampings. Each sheet metal stamping has a respective textured face with a plurality of integrally formed piercing members. A solid non-porous metal core is sandwiched between the first sheet metal stamping and the second sheet metal stamping. The piercing members of the first sheet metal stamping penetrate into the metal core, and the piercing members of the second sheet metal stamping penetrate into the metal core, to secure the first sheet metal stamping, the second sheet metal stamping, and the metal core together.

Abstract: A method for additive manufacturing of a three-dimensional object includes: a) identifying a set of sequentially extending planar cross-sectional shapes of the three-dimensional object; b) cutting a metal sheet into a plurality of planar metal pieces, each metal piece cut to a metal piece shape corresponding to a respective one of the cross-sectional shapes, wherein the metal sheet has a first face with a first plurality of barbs extending therefrom, and an opposed second face with a second plurality of barbs extending therefrom; c) cutting a substrate sheet into a plurality of planar substrate pieces, each substrate sheet cut to a substrate piece shape corresponding to a respective one of the cross-sectional shapes; and d) positioning the metal pieces and the substrate pieces in facing relation in an alternating pattern and in sequential order, and pressing the metal pieces and substrate pieces together to force the barbs to penetrate the substrate pieces.

Abstract: A material includes a sheet of metal having a first face and an opposed second face, and a metal grain direction. The first face is textured with a first set of texturing features. Each texturing feature of the first set includes, respectively, a groove cut into the first face and extending along a groove axis, and a barb extending from the groove and away from the first face. The texturing features of the first set are arranged in a plurality of rows, and the groove axes of the texturing features in a given row extend generally parallel to the given row. The rows are generally non-perpendicular to the grain direction.

Abstract: A process for producing a textured laminate sheet includes a) positioning a substrate material adjacent a barbed face of a metal sheet. The barbed face has a plurality of barbs, and the metal sheet has an opposed face opposite the barbed face. The process further includes b) forcing the metal sheet and the substrate material together to impale the substrate material on the barbs and secure the substrate material and the metal sheet together as a laminate sheet, and c) debossing the opposed face to form a plurality of depressions in the laminate sheet and texture the laminate sheet.

Abstract: A method for additive manufacturing of a three-dimensional object includes: a) identifying a set of sequentially extending planar cross-sectional shapes of the three-dimensional object; b) cutting a metal sheet into a plurality of planar metal pieces, each metal piece cut to a metal piece shape corresponding to a respective one of the cross-sectional shapes, wherein the metal sheet has a first face with a first plurality of barbs extending therefrom, and an opposed second face with a second plurality of barbs extending therefrom; c) cutting a substrate sheet into a plurality of planar substrate pieces, each substrate sheet cut to a substrate piece shape corresponding to a respective one of the cross-sectional shapes; and d) positioning the metal pieces and the substrate pieces in facing relation in an alternating pattern and in sequential order, and pressing the metal pieces and substrate pieces together to force the barbs to penetrate the substrate pieces.

Abstract: A method for texturizing a workpiece uses a die assembly installed within a press having a press ram. The method includes (a) delivering the workpiece onto a centre die plate; (b) forcing the press ram against an upper die plate mounted above the centre die plate to descend a first contact surface associated with the upper die plate and a plurality of blades mounted to the upper die plate toward the centre die plate; (c) actuating horizontal movement of the blades; (d) driving the blades down into the workpiece; and (e) contacting the first contact surface to a second contact surface associated with the centre die plate to descend the centre die plate in unison with the upper die plate.

Abstract: A workpiece includes a material with a face and a first plurality of barbs and a second plurality of barbs extending integrally from the face. Each barb has a height above the face. The barbs of the first plurality are at least 10% higher than the barbs of the second plurality. The first plurality of barbs includes at least 10% of the barbs on the face and the second plurality of the barbs includes at least 10% of the barbs on the face. The barbs of the second plurality of barbs are bent and pointed.

Abstract: A method for texturizing a workpiece uses a die assembly installed within a press having a press ram. The method includes (a) delivering the workpiece onto a center die plate; (b) forcing the press ram against an upper die plate mounted above the center die plate to descend a first contact surface associated with the upper die plate and a plurality of blades mounted to the upper die plate toward the center die plate; (c) actuating horizontal movement of the blades; (d) driving the blades down into the workpiece; and (e) contacting the first contact surface to a second contact surface associated with the center die plate to descend the center die plate in unison with the upper die plate.

Abstract: The invention provides an adhesive support article for supporting a body part of a user. A single-sided stretchable adhesive tape blank is precut into a sheet having a central anchoring portion and a plurality of outwardly extending fingers. The sheet is marked with visual indicators to guide the user of the support article for applying the central anchoring portion onto a first exterior surface of the body part and for stretching the fingers before adhering them at a predetermined distance away from the central anchoring portion. The adhesive support article can also be provided in a support system with at least one corresponding body landmark article, providing further guidance for applying the support article to the desired body part.

Abstract: A method for texturizing a workpiece uses a die assembly installed within a press having a press ram. The method includes (a) delivering the workpiece onto a center die plate; (b) forcing the press ram against an upper die plate mounted above the center die plate to descend a first contact surface associated with the upper die plate and a plurality of blades mounted to the upper die plate toward the center die plate; (c) actuating horizontal movement of the blades; (d) driving the blades down into the workpiece; and (e) contacting the first contact surface to a second contact surface associated with the center die plate to descend the center die plate in unison with the upper die plate.

Abstract: A workpiece includes a material with a face and a first plurality of barbs and a second plurality of barbs extending integrally from the face. Each barb has a height above the face. The barbs of the first plurality are at least 10% higher than the barbs of the second plurality. The first plurality of barbs includes at least 10% of the barbs on the face and the second plurality of the barbs includes at least 10% of the barbs on the face. The barbs of the second plurality of barbs are bent and pointed.

Abstract: The invention provides an adhesive support article for supporting a body part of a user. A single-sided stretchable adhesive tape blank is precut into a sheet having a central anchoring portion and a plurality of outwardly extending fingers. The sheet is marked with visual indicators to guide the user of the support article for applying the central anchoring portion onto a first exterior surface of the body part and for stretching the fingers before adhering them at a predetermined distance away from the central anchoring portion. The adhesive support article can also be provided in a support system with at least one corresponding body landmark article, providing further guidance for applying the support article to the desired body part.

Abstract: A brake backing plate is provided in which a non-compressible core material is sandwiched between two sheet metal stampings to make a lightweight, composite brake backing plate. Each of the stampings has a textured face with a plurality of integrally formed piercing members. By rolling or pressing, the piercing members of the textured faces are fully embedded in the core material, and thus lock the stampings and the core material together.

Abstract: A brake backing plate includes first and second sheet metal stampings. Each sheet metal stamping has a respective textured face with a plurality of integrally formed piercing members. A solid non-porous metal core is sandwiched between the first sheet metal stamping and the second sheet metal stamping. The piercing members of the first sheet metal stamping penetrate into the metal core, and the piercing members of the second sheet metal stamping penetrate into the metal core, to secure the first sheet metal stamping, the second sheet metal stamping, and the metal core together.

Abstract: A process is provided for making stiff, lightweight laminate materials. At least one sheet of textured lamina having raised pointed structures is forced against a softer plain lamina so as to embed the structures therein. The pointed structures raised from grooves carved into the surface of the sheet material by means of a set of teeth carried on a knife element. The pointed structures may pierce through the softer lamina such that the protruding tips may be bent over or clinched to prevent their easy withdrawal. Two such texturized lamina may be used to sandwich and pierce through the softer lamina and are co-clinched by the other. In this way a light and stiff laminate is created.