Abstract: A mold core package for forming a molding tool includes a plurality of stacked particulate layers having a binding agent. The plurality of stacked particulate layers form sacrificial walls defining a mold cavity. A sacrificial displacement line and a sacrificial displacement body extend from the mold core package and are adapted to displace a molten material applied to the mold core package.

Abstract: A mold core package for forming a molding tool includes a plurality of stacked particulate layers having a binding agent. The plurality of stacked particulate layers form sacrificial walls. An elongate sacrificial displacement line extends through the mold core package adjacent a forming surface of the mold core package. A mold cavity is defined by the stacked particulate layers.

Abstract: A mold core package for forming a molding tool includes a plurality of stacked particulate layers having a binding agent. The plurality of stacked particulate layers form sacrificial walls. An elongate sacrificial displacement line extends through the mold core package adjacent a forming surface of the mold core package. A mold cavity is defined by the stacked particulate layers.

Abstract: A mold core package for forming a molding tool with a removable insert includes a plurality of stacked particulate layers having a binding agent. The plurality of stacked particulate layers form molding pattern walls that generally define a base mold cavity and an insert mold cavity defining a mold surface. A sacrificial displacement line extends through the insert mold cavity closely following contours of the mold surface.

Abstract: A molding assembly for making molded parts includes a molding tool having conformal fluid lines that follow contours of a molding surface of the molding tool. The conformal fluid lines are defined in the molding tool during casting by sacrificial displacement lines formed by a three-dimensional printer. A temperature control station is coupled to the molding tool and includes a heating and cooling fluid. A valve station regulates fluid flow to the molding tool.

Abstract: A mold core package for forming a molding tool includes a plurality of stacked particulate layers having a binding agent. The plurality of stacked particulate layers form sacrificial walls defining a mold cavity. A sacrificial displacement line and a sacrificial displacement body extend from the mold core package and are adapted to displace a molten material applied to the mold core package.

Abstract: A method of making a molded part, including forming a liquid aggregate from a mixture of ground aggregate and a fluid. A fungal inoculum and the liquid aggregate are injected into a first mold cavity. The first mold cavity is sealed against a second mold cavity. Live mycelium is grown from the fungal inoculum to fill the first and second mold cavities. The live mycelium is cured to terminate further growth and develop a formed substrate.

Abstract: A method of making a hardened elongate structure, including growing a live mycelium mat having branching hyphae. The live mycelium mat is layered to form a multi-layered structure. The hyphae are allowed to grow inward into the multi-layered structure such that the hyphae are interwoven throughout the multi-layered structure. The multi-layered structure is cured to terminate mycelium growth.

Abstract: A method of making a molded part, including adding a fungal inoculum with a liquid aggregate to form a mixture. The mixture is inserted into a mold cavity. The mold cavity is covered with a cover. Live mycelium is grown from the mixture that fills the mold cavity and physically couples with the cover. The live mycelium is heated to terminate further growth and develop a composite component made of mycelium and the cover.

Abstract: A method of making a molded part, including forming a liquid aggregate from a mixture of finely ground aggregate and a fluid. A mixture of a fungal inoculum and the liquid aggregate is formed. Nanoparticles are homogenously distributed throughout the mixture. The mixture is inserted into a mold cavity. Live mycelium is grown to fill the mold cavity. The live mycelium is heated to terminate further growth and develop a formed part.

Abstract: A method of making a molded part, including forming a liquid aggregate from a mixture of finely ground aggregate and a fluid. A mixture of a fungal inoculum and the liquid aggregate is formed. Nanoparticles are homogenously distributed throughout the mixture. The mixture is inserted into a mold cavity. Live mycelium is grown to fill the mold cavity. The live mycelium is heated to terminate further growth and develop a formed part.

Abstract: A method of making a molded part, including forming a liquid aggregate. A fungal inoculum and the liquid aggregate are inserted into a mold cavity. A portion of an object is inserted into the mold cavity. The fungal inoculum is grown into live mycelium that operably couples with the object. The mycelium is heated to terminate further growth and develop a composite part made of mycelium and the object.

Abstract: A method of making a plasticized mycelium structure, including dissolving a soluble polymer in a liquid thereby forming a polymer solution of polymer particles. The polymer solution is combined with a fungal inoculum capable of growing hyphae in the presence of an aggregate. The resulting mixture is allowed to grow into a mycelium network. The mycelium network is made up of hyphae which bond with the polymer particles found in the polymer solution forming a structure substantially made up of mycelium that has a plasticizer homogenously distributed throughout the structure. The structure is cured to terminate mycelium growth.

Abstract: An active knee bolster for an automotive vehicle has a base which is attached to a supporting structure, such as a glove box. The base has an outer periphery and an inner field containing a number of frangible attachment tabs. A combination inflatable bladder and cover is attached to the frangible attachment tabs such that the tabs tear partially free, and effectively become hinged from, the base when the bladder is inflated.

Abstract: A method of making a vehicle part, including growing a live mycelium mat from interwoven hyphae. The mycelium mat is cured to terminate mycelium growth. The mycelium is cut into a single structural component without further processing for use in a vehicle.

Abstract: An active knee bolster for an automotive vehicle has a base which is attached to a supporting structure, such as a glove box. The base has an outer periphery and an inner field containing a number of frangible attachment tabs. A combination inflatable bladder and cover is attached to the frangible attachment tabs such that the tabs tear partially free, and effectively become hinged from, the base when the bladder is inflated.

Abstract: A method of preparing a mycelium component, including growing live mycelium from a fungal inoculum and a liquid aggregate. The live mycelium is cured to terminate further mycelium growth and form a mycelium structure. Moisture is applied to the mycelium structure such that the mycelium structure is nearly fully saturated. The mycelium structure is dried to form a hardened mycelium structure.

Abstract: A method of making a vehicle part, including growing a live mycelium mat from interwoven hyphae. The mycelium mat is cured to terminate mycelium growth. The mycelium is cut into a single structural component without further processing for use in a vehicle.

Abstract: A method of making a molded part, including forming a liquid aggregate from a mixture of finely ground aggregate and a fluid. A mixture of a fungal inoculum and the liquid aggregate is formed. Nanoparticles are homogenously distributed throughout the mixture. The mixture is inserted into a mold cavity. Live mycelium is grown to fill the mold cavity. The live mycelium is heated to terminate further growth and develop a formed part.

Abstract: A method of making a molded part, including forming a liquid aggregate from a mixture of ground aggregate and a fluid. A fungal inoculum and the liquid aggregate are injected into a first mold cavity. The first mold cavity is sealed against a second mold cavity. Live mycelium is grown from the fungal inoculum to fill the first and second mold cavities. The live mycelium is cured to terminate further growth and develop a formed substrate.