Abstract: A compression-molding apparatus includes a sleeve plunger and a core pin. The sleeve plunger is movable through a plunger cavity that, in some embodiments, extends through the male portion of the molding apparatus. The sleeve plunger has a bore, and is received by and movable along the core pin, which typically extends upward into the plunger cavity from the female portion of the molding apparatus. In addition to any other functionality, the core pin forms a hole in a molded part. In operation, the fiber-bundle-based-preform feed constituents are placed in the plunger cavity. If any of the preforms are ring-shaped preforms, they are received by the core pin.

Abstract: A multi-material molding apparatus and method includes a single mold having, within a mold cavity, one or more movable partitions that segregate at least first and second molding materials. The first molding material is processed to form a first molded portion of the multi-material part. The second molding material is then flowed, through the movable partition, into contact with the first molded portion. That second molding material is then solidified to form a second molded portion of the multi-material part.

Abstract: In an injection/compression-molding process, an assemblage of fiber-bundle-based preforms are placed in a mold cavity of a mold tool. The mold is then fully closed, but not pressurized. An injection charge, which includes resin and optionally short fibers, is placed in a plunger cavity that is in fluidic communication with the mold cavity. The injection charge is liquefied and injected into the mold cavity, pressurizing it to a pressure suitable for compression molding. If not previously liquefied, the resin in fiber-bundle-based preform is liquefied and, under the applied pressure, the resins and fibers are consolidated and then cooled to form a part.

Abstract: A molding apparatus for injection molding or compression molding includes an “A” portion of a mold, a “B” portion of the mold, and at least one core plunger/ejector. The core plunger/ejector provides dual functionality, wherein it participates in molding operations by consolidating a feed material in the mold cavity, and also is responsible for separating the part from various mold surfaces and ejecting it from the mold.

Abstract: An eyewear frame enables lenses and/or temples to be replaced by a wearer without specialized tools and without the assistance of an eyewear professional. The eyewear frame includes one or more regions having distinct materials composition and/or one or more regions having distinct fiber alignment, in conjunction with one or more lens or temple retaining features.

Abstract: A multi-material molding apparatus and method includes a single mold having, within a mold cavity, one or more movable partitions that segregate at least first and second molding materials. The first molding material is processed to form a first molded portion of the multi-material part. The second molding material is then flowed, through the movable partition, into contact with the first molded portion. That second molding material is then solidified to form a second molded portion of the multi-material part.

Abstract: A cartridge for storing and transporting fiber-bundle-based preform charges includes a plurality of cells arranged within the housing, wherein each cell is physically adapted to receive a preform charge and prevent it from moving therein as the cartridge is transported. In some embodiments, the cartridge and preform charges it conveys are serialized.

Abstract: A compression molding method for creating fine, features having desired fiber-alignment patterns involves creating a pressure gradient in a mold cavity during the soak phase of the compression-molding process. In the illustrative embodiment, the gradient is created by movement of a structure, and results in a flow of nearby fiber and melted resin. This alters local, preexisting, non-random fiber alignments. The process imparts geometries to a part (the bulging features) that are not otherwise present on the mold surface.

Abstract: A cartridge for storing and transporting fiber-bundle-based preform charges includes a plurality of cells arranged within the housing, wherein each cell is physically adapted to receive a preform charge and prevent it from moving therein as the cartridge is transported. In some embodiments, the cartridge and preform charges it conveys are serialized.