Abstract: The invention concerns an electric heating cable intended for pipelines. Sections (11a, 12a and 13a) of three phase conductors (11, 12 are 13) are stripped respectively. These sections are intended to be installed and both secured in place and electrically connected to each other inside a box (14) having, for example, a central cavity (15) having a rectangular cross-section, the depth of which is at least equal to the length of the stripped sections (11a, 12a and 13a) and the length of which is preferably greater than the transverse cross-section of these stripped sections of the phase conductors. They are secured in the central cavity (15) with a conductive binder (16), for example a tin solder, in order to ensure they are secured in place and electrically connected to each other.

Abstract: Described herein is a golf club head having a body and a high density metal piece integrally embedded within the golf club head body, wherein a gap is disposed between the exterior surface of the high density metal piece and the exterior of the golf club head body and a method of manufacturing thereof.

Abstract: A method including the steps of exposing a substrate to focused laser irradiation at a preselected series of locations that trace a subset of the substrate volume that is connected to the surface of the substrate, removing the substrate material from the exposed preselected series of locations to create within the substrate at least one cavity that is connected to the surface of the substrate, immersing the cavity-containing substrate in an appropriate atmosphere such as a selected gas or vacuum and, within this atmosphere, contacting the substrate surface with the molten castable material surface at locations where the cavity or cavities emerges from the substrate, applying pressure to the castable material to cause it to infiltrate the substrate cavities, and solidifying the castable material within the cavities.

Abstract: An apparatus for moulding battery components including a molten metal feed trough, a mould block adjacent to the feed trough, a weir between the feed trough and each cavity and a supply for feeding molten metal to the feed trough. The mould block has at least one mould cavity and a cooling arrangement which cools the mould block, and the mould block is provided with a heating arrangement adjacent to the or each mould cavity. In use, the heating arrangement maintains at least part of the, or each, mould cavity at an elevated temperature relative to the average operational temperature of the mould block.

Abstract: Provided herein are power converter of a drive unit for an electric vehicle. The power converter includes an inverter having a first transistor, a second transistor, and a capacitor, and a laminated bus-bar having a positive bus-bar segment, a negative bus-bar segment and a phase bus-bar segment. The positive bus-bar segment, the negative bus-bar segment, and the phase bus-bar segment can be disposed about the capacitor to form a lead frame coupled with the capacitor. The lead frame can include a first lead coupled with the first transistor. The first lead can include portions of the positive bus-bar segment and the phase bus-bar segment. The lead frame can include a second lead coupled with the second transistor. The second lead can include portions of the negative bus-bar segment and the phase bus-bar segment.

Abstract: Provided herein are power converter of a drive unit for an electric vehicle. The power converter includes an inverter having a first transistor, a second transistor, and a capacitor, and a laminated bus-bar having a positive bus-bar segment, a negative bus-bar segment and a phase bus-bar segment. The positive bus-bar segment, the negative bus-bar segment, and the phase bus-bar segment can be disposed about the capacitor to form a lead frame coupled with the capacitor. The lead frame can include a first lead coupled with the first transistor. The first lead can include portions of the positive bus-bar segment and the phase bus-bar segment. The lead frame can include a second lead coupled with the second transistor. The second lead can include portions of the negative bus-bar segment and the phase bus-bar segment.

Abstract: Provided herein is a power converter component to power a drive unit of an electric vehicle drive system. The power converter component includes an inverter module formed having three half-bridge modules arranged in a triplet configuration for electric vehicle drive systems. Positive inputs, negative inputs, and output terminals of the different half-bridge inverter modules are aligned with each other. The inverter module includes a positive bus-bar coupled with the positive inputs and a negative bus-bar coupled with the negative inputs of the half-bridge inverter modules. The positive bus-bar is positioned adjacent to and parallel with the negative bus-bar. The inverter module can be coupled with a drive train unit of the electric vehicle and provide three phase voltages to the drive train unit. Each of the half bridge modules can generate a single phase voltage and three half-bridge modules arranged in a triplet configuration can provide three phase voltages.

Abstract: An apparatus and method for graphene film synthesis. The apparatus includes a quasi-enclosed substrate holder which includes one open side, a cap disposed over the one open side of the quasi enclosed substrate holder, and a substrate for graphene film synthesis located inside the quasi enclosed substrate holder. The method includes placing a substrate for graphene film synthesis inside of a quasi-enclosed substrate holder and generating a graphene film on the substrate via chemical vapor deposition, wherein the quasi enclosed substrate holder includes one open side and a cap disposed over the open side of the quasi enclosed substrate holder.

Abstract: The present invention relates to a method for casting of cast parts in which molten metal is poured via a feeder, separate runners, or casting channels into a mould cavity defined by a casting mould and modeling the shape of the cast part, whereby the casting mould includes mould parts which determine the shape of the cast part to be cast. Molten metal is conveyed via at least two connections into at least two sections of the mould cavity which correspond to different planes of the part to be cast. At least one of the connections is designed as an additional channel leading through one of the mould parts and independent of the contour of the cast part to be cast. The present invention also relates to a casting mould as described above.

Abstract: Provided herein is a power converter component to power a drive unit of an electric vehicle drive system. The power converter component includes an inverter module formed having three half-bridge modules arranged in a triplet configuration for electric vehicle drive systems. Positive inputs, negative inputs, and output terminals of the different half-bridge inverter modules are aligned with each other. The inverter module includes a positive bus-bar coupled with the positive inputs and a negative bus-bar coupled with the negative inputs of the half-bridge inverter modules. The positive bus-bar is positioned adjacent to and parallel with the negative bus-bar. The inverter module can be coupled with a drive train unit of the electric vehicle and provide three phase voltages to the drive train unit. Each of the half bridge modules can generate a single phase voltage and three half-bridge modules arranged in a triplet configuration can provide three phase voltages.

Abstract: A method for joining materials using additive friction stir techniques is provided. The method joins a material to a substrate, especially where the material to be joined and the substrate are dissimilar metals. One such method comprises (a) providing a substrate with one or more grooves; (b) rotating and translating an additive friction-stir tool relative to the substrate; (c) feeding a filler material through the additive friction-stir tool; and (d) depositing the filler material into the one or more grooves of the substrate. Translation and rotation of the tool causes heating and plastic deformation of the filler material, which flows into the grooves of the substrate resulting in an interlocking bond between the substrate and filler material. In embodiments, the depositing of the filler material causes deformation of the grooves in the substrate and an interlocking configuration between the grooves of the substrate and the filler material results.

Abstract: A gas turbine engine includes a turbine having turbine blades and a shroud having a blade track for positioning radially outside of the blades. At least one of the blades and the blade track are secured in place using a dovetail connection between a dovetail receiver and a dovetail assembly formed to include a contoured root.

Abstract: There is disclosed a method for chemically bonding TiNi materials to Nitinol constructs, comprising placing a Nitinol construct within a mold and packing a powder combination comprising Ti powder and Ni powder, and powder comprised of zero or more of the elements Cu, Hf, Zr, Pt, Pd, Au, Cd, Ag, Nb, Ta, O, N, B, and H, into the mold. The method further includes initiating a process of self-propagating high temperature synthesis of the powder combination within the mold to create a chemical bond between the Nitinol construct and a resulting TiNi foam to thereby create a Nitinol and TiNi assembly.

Abstract: In a method of manufacturing a liquid-cooling cold plate, cast molding is performed after embedding a metal pipe for supplying a cooling liquid inside a casting mold. Fixing brackets to be attached to the metal pipe is provided to maintain a positional relationship between a plurality of portions of the metal pipe embedded in the casting mold. The casting molding is performed by pouring molten metal into the casting mold while the fixing metal parts are attached to the metal pipe.

Abstract: A brake assembly comprising: (a) a caliper including: (i) one or more pistons, (b) one or more rotary to linear actuators that provides an axial force to move the one or more pistons, (c) a motor gear unit in communication with the one or more rotary to linear actuators, the motor gear unit including: (i) a motor, and (ii) an electromagnetic brake that prevents movement of the motor gear unit, the pistons, or both when the motor is turned off so that the brake apply is maintained.

Abstract: A method of producing a steel foam component includes providing a mold defining a cavity. The method also includes positioning an insert within the cavity of the mold. The insert can be configured to form a generally uniform pattern of pores within the steel foam component, and in some cases occupies at least 20% of the cavity. The method can further include pouring molten steel into the cavity, cooling the molten steel into the steel foam component, and removing the steel foam component and the insert from the mold. Steel components having internal shapes corresponding to the insert(s) are also provided.

Abstract: A method includes positioning at least one guide projection on a substrate of a metal part such that the at least one guide projection extends outwardly from an outer surface of the substrate to an exposed length. Hardfacing is then applied to the substrate of the metal part at or near a location of the at least one guide projection. The exposed length of the at least one guide projection is then referenced in determining when to cease application of the hardfacing.

Abstract: Production methods for producing a fiber-reinforced metal component having a metal matrix which is penetrated by a plurality of reinforcing fibers are provided. One method includes depositing in layers reinforcing fibers in fiber layers, depositing in layers and liquefying a metal modelling material in matrix material layers, and consolidating in layers the metal modelling material in adjacently deposited matrix material layers to form the metal matrix of the fiber-reinforced metal component. Here, the metal component is formed integrally from alternately deposited matrix material layers and fiber layers. An alternative method includes introducing an open three-dimensional fiberwoven fabric consisting of reinforcing fibers into a casting mold, pouring a liquid metal modelling material into the casting mold and consolidating the metal modelling material to form the metal matrix of the fiber-reinforced metal component.

Abstract: A dental model and related systems and methods, including a first component representing a portion of a patient's jaw and a second component that is demountably attachable to the first component, and a second component representing a dental structure of interest, such as the remaining portion of a tooth or a dental implant.

Abstract: Exothermic welding molds, weld-metal containing cartridges for such molds, and methods of use are provided. The mold, cartridges, and methods can provide interaction between the cartridge's disk member with the mold, which allows the housing member to be withdrawn from the mold while leaving the disk member and weld-metal in place. The interaction can be a rotational restraint alone, a vertical restraint alone, or combinations thereof. Alternately, the interaction can be an outward pressure on the housing member and/or disk member, a shear force on the housing member and/or disk member, or combinations thereof. The outward pressure on the housing member and/or disk member can alternately be provided without interaction between the disk member and the mold, but rather by the simple application of an internal pressure to the cartridge. The internal pressure can be applied by squeezing the walls of the cartridge and/or by depressing a pusher member.

Abstract: Method for connecting two portions of a first electrically conducting polymer with a second polymer. The method includes disposing a solution of a second polymer in a solvent to be in contact with the two portions of the first electrically conducting polymer and allowing the solvent to evaporate leaving the second polymer joining the two portions of the first polymer. The second polymer may be doped to improve its conductivity.

Abstract: A method of casting a low alloy steel using a mold is disclosed. The method includes receiving the mold having a foam pattern disposed within a sand casing. The received foam pattern is coated with a permeable refractory coating and is disposed between compacted sand and the sand casing. The method further includes pouring a molten metal comprising a low alloy steel having a carbon content in a range from about 0.1 to about 0.4 percent into the mold so as to vaporize the foam pattern and remove gasification products through the permeable refractory coating, to form a low alloy steel casting. Further, the method includes removing the low alloy steel casting from the mold.

Abstract: A multichip in which a protection IC for detecting at least one of overcharge, over discharge, and overcurrent of a secondary battery and a monitoring IC for monitoring a battery state of the secondary battery are integrated in a package. The protection IC and the monitoring IC are not overlapped in a plan view. A regulator output terminal for the monitoring IC, a ground terminal common to the protection IC and the monitoring IC, a power supply terminal common to the protection IC and the monitoring IC, and a current detection terminal for the protection IC are disposed along a first side of package, and a communication terminal for the monitoring IC, a discharge control terminal for the protection IC, a charge control terminal for the protection IC, and a overcurrent detection terminal for the protection IC are disposed as external connection terminals along the second side of package.

Abstract: A dental model and related systems and methods, including a first component representing a portion of a patient's jaw and a second component that is demountably attachable to the first component, and a second component representing a dental structure of interest, such as the remaining portion of a tooth or a dental implant.

Abstract: A heat dissipating device includes a heat dissipating fin module, a second base, a third base, a heat pipe, a first sleeve and a fourth base. The heat dissipating fin module includes a first base and a plurality of first heat dissipating fins. A recess is formed on the second base. The third base is disposed in the recess. The heat pipe includes a heat dissipating segment, a heat absorbing segment and a connecting segment connecting the heat dissipating segment and the heat absorbing segment. The heat dissipating segment is disposed in the first base. The heat absorbing segment is disposed in the second and third bases and contacts the third base directly. The first sleeve at least covers the connecting segment. The fourth base is formed by a die casting process and covers peripheries of the first and second bases and the first sleeve.

Abstract: Systems and methods are provided for securing ends of tendons in an anchor housing. Tendons having open or expanded sections are inserted through a cylindrical surface of the anchor housing. The tendons are secured in the anchor housing by grout which cooperates with the open or expanded sections and irregularities formed on the interior surface of the anchor housing.

Abstract: There are provided a semiconductor package and a method of manufacturing the same. The semiconductor package according to an exemplary embodiment of the present disclosure includes: a substrate having a first device mounted thereon; a first lead frame formed on the substrate; a second lead frame formed to be spaced apart from the substrate; a post formed on the substrate and formed between the first lead frame and the second lead frame; and a molding part formed to surround the substrate and formed to protrude portions of the first and second lead frames, wherein the post includes a body part bonded to the substrate and a protruding part protruded to an exterior of the molding part.

Abstract: An induction rotor assembly having an induction cage that is formed using a combination of liquid and solid materials. The first and second end plates of the induction cage may be fabricated before the casting of the conductors of the induction cage. According to certain embodiments, the first and second end plates may be assembled with first and second molds and a rotor core to form a casting assembly. A liquid casting material may be injected into the casting assembly, wherein the liquid casting material may solidify within one or more core passageways of the rotor core, thereby forming the conductors of the induction cage. The first and second end plates may also include flow channels that may be configured to facilitate the flow of the liquid casting material in the casting assembly, and increase the area of contact between the liquid casting material, when solidified, and the end plates.

Abstract: A method for manufacturing a heat-dissipating module includes following steps. A hollow aluminum tube is put on a corresponding heat pipe to form an aluminum-skinned heat pipe. Then, one or more aluminum-skinned heat pipes are disposed in a casting space of a die casting mold. Fins are disposed into the die casting mold. Molten aluminum materials are filled in the casting space of the die casting mold to form a heat-dissipating module. By using a die casting process, molten aluminum materials are used to cover at least one aluminum-skinned heat pipe and connect with the fins, thereby finishing the heat-dissipating module.

Abstract: Construction is achieved that is capable of maintaining overall strength of a cylindrical-shaped steering column, while at the same time making it possible to make the thickness part of the steering column thin. An outer column 10b, which is a column member of a steering column is formed by connecting in the axial direction a main portion 18 made using a light metal alloy with a cylindrical member 19 made of an iron-based alloy. A ring 22 made using a metallic material is fitted and fastened to the inner diameter side of the cylindrical member 19 in the connecting section between the main portion 18 and the cylindrical member 19. The inner diameter of the ring 22 is equal to or greater than the inner diameter of the portion of the main portion 18 that is separated in the axial direction from the connecting section with the cylindrical member 19, and is equal to or less than the inner diameter of the cylindrical member 19.

Abstract: Embodiments of the present disclosure describe techniques and configurations for molded heat spreaders. In some embodiments, a heat spreader includes a first insert having a first face and a first side, the first face positioned to form a bottom surface of a first cavity, and a second insert having a second face and a second side, the second face positioned to form a bottom surface of a second cavity. The second cavity may have a depth that is different from a depth of the first cavity. The heat spreader may further include a molding material disposed between the first and second inserts and coupled with the first side and the second side, the molding material forming at least a portion of a side wall of the first cavity and at least a portion of a side wall of the second cavity. Other embodiments may be described and/or claimed.

Abstract: The centrifugal casting apparatus comprises: a lower half-mould (10) mounted on a support (12) provided with driving means for rotation about a substantially vertical central axis (14), the lower half-mould (10) being a solid of revolution having a first central cavity (36); an upper half-mould (16) facing the lower half-mould (10), the upper half-mould (16) being a solid of revolution having a second central cavity (56); and means for causing the axial movement of the half-moulds (10, 16) towards and away from each other. The lower half-mould (10) and the upper half-mould (16) each have at least one passage (46, 66) which puts the respective central cavity (36, 56) into communication with the outside through an outlet aperture through which the central axis (14) does not pass.

Abstract: Embodiments of the present disclosure describe techniques and configurations for molded heat spreaders. In some embodiments, a heat spreader includes a first insert having a first face and a first side, the first face positioned to form a bottom surface of a first cavity, and a second insert having a second face and a second side, the second face positioned to form a bottom surface of a second cavity. The second cavity may have a depth that is different from a depth of the first cavity. The heat spreader may further include a molding material disposed between the first and second inserts and coupled with the first side and the second side, the molding material forming at least a portion of a side wall of the first cavity and at least a portion of a side wall of the second cavity. Other embodiments may be described and/or claimed.

Abstract: A structural component having an internal support structure extending between outer wall portions of the component with one or more compartments included within the support structure. The support structure has support members including internal walls positioned between and/or defined by the compartments. At least one support member connects between the outer wall portions of the component to enhance the structural integrity of the component. The structural component, including the internal support, are cast from a molten material, and in some cases the support members of the internal support structure are formed with a rectilinear configuration. In some cases the cast structural component is a container and the one or more compartments are configured to store a fluid, such as a gas or a liquid. One or more preforms can be used to form a container and may be retained or eliminated from the container after casting.

Abstract: A method of joining an amorphous alloy material to a heterogeneous material and a composite formed by the same are provided. The method comprises steps of: placing a pre-formed piece made of one of the amorphous alloy material and the heterogeneous material into a mold; heating the other of the amorphous alloy material and the heterogeneous material to a predetermined temperature, and casting the other of the amorphous alloy material and the heterogeneous material into the mold to form a transition connection part joining the amorphous alloy material to the heterogeneous material and having a fusion welded structure, a microstructure reinforcing connection structure and a composite connection structure; and cooling the amorphous alloy material and the heterogeneous material at a rate higher than a critical cooling rate of the amorphous alloy material to obtain a composite formed by joining the amorphous alloy material to the heterogeneous material by the transition connection part.

Abstract: A process for reducing inclusions during manufacturing of a matrix drill bit comprises placing at least a first layer of a first matrix material in a matrix bit body mold. At least a second layer of a second matrix material is placed in the mold. A binder material is placed in the mold with the binder material disposed proximate the second layer of matrix material and a metal a blank. A graphite lid is placed on the mold. The mold and the materials disposed therein are heated to a selected temperature to cause the binder material to melt and to allow the hot, liquid binder material to infiltrate the second matrix material and the first matrix material, with the second matrix material operable to improve infiltration of the first matrix material by the hot, liquid binder material without using a flux material.

Abstract: A three shaft adjustment mechanism including a drive part which can be connected to a drive shaft in a rotationally fixed manner, a driven part which can be connected to a driven shaft, and an actuator which can be connected to an adjustment shaft as a mechanism part. A mechanical stop for defining an adjustment angle between the drive shaft and driven shaft is provided between two of the three shafts. According to the invention, the mechanism part not involved in the stop has a mass distribution or form which is such that a quotient from its mass moment of inertia J and its partial radius r is smaller than 0.4 kg×mm. The invention also relates to a method for producing a shaft generator having this type of mechanism.

Abstract: Seam protected encapsulated arrays of solid ceramic elements are disclosed. Vulnerable seams between solid ceramic elements arranged adjacent to each other in encapsulated arrays of solid ceramic elements are protected by a seam protector arranged in-line with the vulnerable seems and fixed to the encapsulated array. A stiffener may be arranged in-line with the vulnerable seems and fixed to the encapsulated array opposite to the seam protector. The solid ceramic elements may be encapsulated in a barrier material to prevent the base metal from reacting with the ceramic material units during casting, and/or provide crush/compression protection during cooling.

Abstract: A diagonal strut device (1) for reinforcing arrangement on an undercarriage of a motor vehicle. The diagonal strut device (1) has a plurality of struts (2) made from a fibre-reinforced plastic composite material, which extend away from a central joint element (3). Each strut (2) can be connected to the undercarriage via it's end facing away from the central joint element (3). For this, a connecting joint element (4) is arranged on the end of each strut (2) facing away from the central joint element (3). The central joint element (3) and the connecting joint elements (4) are formed from a light metal material. The central joint element (3) and the connecting joint elements (4) are then connected to the struts (2) by an at least firmly bonded cast joint. Further, a method for the production of a diagonal strut device (1), as well as a motor vehicle undercarriage, which uses the diagonal strut device (1) for reinforcement.

Abstract: A universal joint having a hub formed by molding a material around four stub axles which are arranged so that a first and second stub axle are axially aligned and a third and fourth stub axle are axially aligned. Furthermore, the axes of the first and second stub axles are perpendicular to and coplanar with the axes of the third and fourth stub axles. A bearing is positioned around each stub axle. A first yoke is then molded around two aligned stub axle bearings and an end of a first axle while, similarly, a second axle is molded around the bearings on the other pair of stub axles and an end of a second axle.

Abstract: A method for installing a casting double bearing in a casting, and a wheel manufactured according to the method are provided. The double bearing includes at least two bearing units that are essentially similar.

Abstract: One embodiment of the invention includes a method comprising: placing a first insert and a second insert in a casting mold and wherein the first insert and second insert comprising a plurality of connecting post extending inbetween so that the first insert and second insert are in spaced-apart relationship in the mold, each of the first insert and the second insert comprising a first material; casting a molten second material into the casting mold so that the second material flows between the first insert and the second insert and solidifying the second material to provide a product comprising a cast over body portion with the first insert and second insert and so that the second material is mechanically locked or metallurgically bonded to the first material and so that one or both of the first insert and the second insert provides working surface for the product.

Abstract: A composite ballistic armor or other composite component may be formed by placing one or more ceramic cores in a mold and introducing molten base metal into the mold, such that the molten base metal encapsulates the one or more ceramic cores to form the composite component. The ceramic cores may comprise, for example, porous packed-particle ceramic cores or pre-cast porous ceramic cores. The base metal may comprise, for example, a steel alloy, such as FeMnAl.

Abstract: A method for assembling a heat-dissipating module includes a step of mechanically pressing one time or multiple times a heat pipe into a trough of a metallic base, whereby at least one end of the heat pipe can be pressed into the trough of the metallic base and thus firmly combined with the metallic base. In this way, the time and the cost for assembly are reduced, and the yield is increased.

Abstract: A Method of Producing a hybrid tile metal matrix composite armor is disclosed. First, dense ceramic plates are placed within the mold cavity and may rest on spacer(s) that separate the bottom surface of the ceramic plates from the base of the mold cavity to create a space therebetween. The plates are further positioned within the mold cavity to create a controlled space between any adjacent plates. A second set of spacers may be placed on the plates top surface to create a space between the mold cavity cover and the ceramic plates top surface. A plurality of ceramic plates and spacers may also be stacked into multiple layers according to the shape of the mold cavity and desired ballistic resistance. The mold cavity is next infiltrated with liquid metal under pressure forming a hybrid metal matrix composite structure with an encapsulating aluminum rich skin.

Abstract: Multi-component vane segment and method for forming the same. Assembly includes: positioning a pre-formed airfoil component (12) and a preformed shroud heat resistant material (18) in a mold, wherein the airfoil component (12) and the shroud heat resistant material (18) each comprises an interlocking feature (24); preheating the mold; introducing molten structural material (46) into the mold; and solidifying the molten structural material such that it interlocks the pre-formed airfoil component (12) with respect to the preformed shroud heat resistant material (18) and is effective to provide structural support for the shroud heat resistant material (18). Surfaces between the airfoil component (12) and the structural material (46), between the airfoil component (12) and the shroud heat resistant material (18), and between the shroud heat resistant material (18) and the structural material (46) are free of metallurgical bonds.

Abstract: The invention relates to a method for producing a piston for a combustion engine comprising a combustion recess, during which an annular fiber preform for reinforcing the edge of the combustion recess is firstly fastened inside the casting mold. Afterwards, a low-silicon aluminum/copper melt is introduced into the casting mold by which the fiber preform is infiltrated and molded into the recess edge within the scope of the casting process. The piston blank produced in this manner is then subsequently compacted by a high-temperature isostatic pressing before the piston is completed by means of a machining completion process. The flanks and the base areas of the second and third annular groove are coated by means of anodic oxidation, and the hub boreholes are smoothed and hardened by roller-burnishing. This results in a very high-quality and heavy-duty piston.

Abstract: A method of forming a brake rotor includes forming a plurality of metal insert portions. Each insert portion includes an inner side and an outer side with a plurality of attachment members coupled to the inner side. The method also includes positioning the plurality of insert portions into a mold such that the inner side of one of the plurality of insert portions faces the inner side of another one of the insert portions. The method also includes introducing a molten aluminum into the mold such that the molten aluminum contacts the inner side of each insert portion. The method further includes forming a mechanical bond between the aluminum and at least a portion of at least one of the inserts.

Abstract: A method of forming a molded porous product is provided. The method comprises injecting a material into a mold to form a molded product, and removing the molded product from the mold. The mold comprising multiple layers of shaping elements extending through a cavity, each layer of shaping elements including multiple shaping elements. The molded product produced after removal from the mold has a porous structure formed by at least some of the shaping elements of the layers of shaping elements. The mold used to make the molded porous product may include a relatively large number of shaping elements within a small area.

Abstract: A method of forming a brake rotor includes forming a plurality of metal insert portions. Each insert portion includes an inner side and an outer side with a plurality of attachment members coupled to the inner side. The method also includes positioning the plurality of insert portions into a mold such that the inner side of one of the plurality of insert portions faces the inner side of another one of the insert portions. The method also includes introducing a molten aluminum into the mold such that the molten aluminum contacts the inner side of each insert portion. The method further includes forming a mechanical bond between the aluminum and at least a portion of at least one of the inserts.