Abstract: The present invention provides a process for producing a prepreg of high modulus reinforcing fibers, the process comprising the steps of: a) providing a reinforcing fiber bundle layer wherein such bundle contains a thermoplastic and/or crosslinking resin within the fiber bundle; b) providing a layer of a thermoplastic and/or crosslinking material layer on at least one side of the high modulus fiber layer of step a); c) compressing the layers from step b) under an appropriate amount of heat and pressure, and thereby producing a prepreg of high modulus reinforcing fibers.

Abstract: The present invention generally provides a single use, biodegradable container for storing solids, liquids, and/or gases. The container can be used for toxic, non-toxic, environmentally friendly and/or environmentally unfriendly materials. In a typical embodiment, the container comprises approximately three layers. The first layer is a slurry of paper (e.g., recycled newspapers) that is impregnated (e.g., sprayed) with a non toxic, environmentally friendly, oil and water repellant. The next layer of protection will be a harder (e.g., “coffee cup” like) layer of cardboard, also covered with the same oil and water repellant. The third layer will be a prefabricated container pressed from a mold, made of Biodegradable plastic. This third layer is typically sprayed with the oil and water repellant, made from, for example, Mater-B and PolyActide.

Abstract: A process has been developed for fabricating composite structures using either reaction forming or polymer infiltration and pyrolysis techniques to densify the composite matrix. The matrix and reinforcement materials of choice can include, but are not limited to, silicon carbide (SiC) and zirconium carbide (ZrC). The novel process can be used to fabricate complex, net-shape or near-net shape, high-quality ceramic composites with a crack-free matrix.

Abstract: Composite tooling is fabricated with low cost dry fabrics and a neat resin instead of expensive prepregs. Dry, three-dimensional woven joint preforms are placed on a dry tool substrate and dry, 3D preforms are also placed between pre-cured egg crate-like junctions. The entire tool substrate and substrate-to-support structure joints are then resin-infused simultaneously through the use of rota-molded tooling aids, providing an additional reduction in cost. Tight control of resin content and distribution with vacuum infusion is thereby provided. This process eliminates the primary cause of structural weakness and cooling distortion, which typically occur at the attachment interface when existing methods are used. The preforms provide significantly greater pull-off strengths at interfaces than do hand-laid tie plies. Issues with tool surface durability are addressed through the use of ceramic-filled face coat.

Abstract: A composite wheel and a method of manufacture is provided for a vehicle wherein the composite wheel has a first and second section mounted to an annular mount. At least one of the first wheel section and second wheel section is composed of a resin having at least one braided polymeric fiber. The first and second sections are each formed by folding the braided fiber into a preform and then injecting resin into a mold containing the preform. The first and second sections are then bonded to each other and the annular mount.

Abstract: A cushion body, which can secure both soft touch feeling and durability, a seat having the same, and a manufacturing method thereof are provided. A cushion body 11 is constituted by stacking a sheet-like fibrous structure 4a with a low density in which webs 2 are stacked such that their extending direction conforms with a thickness direction T of the cushion body and a sheet-like fibrous structure 4b with a high density whose flexing degree to load in the thickness direction T is smaller than that of the sheet-like fibrous structure 4a with a low density, where the sheet-like fibrous structure 4a with a low density is disposed nearer a sitting surface 10a than the sheet-like fibrous structure 4b with a high density. Since the sheet-like fibrous structure 4a with a low density on the side of the sitting surface 10a receives load from the outside of the cushion body 11 due to sitting and flexes largely, it provides soft touch feeling to an sitting occupant.

Abstract: A cushion body, which can secure both a soft touch feeling and favorable shape reproduction of a groove portion, a seat having the same, and a manufacturing method thereof are provided. A cushion body 11 is formed by stacking a plurality of sheet-like fibrous structures 4a to 4e, a groove portion 12 is formed in a surface layer, and the sheet-like fibrous structures 4a to 4e have a web 2 stacked so that the web extends in a thickness direction of the fibrous structures. The surface layer sheet-like fibrous structure 4e has a thickness substantially equal to or smaller than a depth of the groove portion 12.

Abstract: A rim and a method for manufacturing a rim in particular for bicycles in which first a rim body is manufactured having a hollow space with a radially outer and a radially inner hollow-space wall. The radially outer hollow-space wall has a diameter matched to the diameter of a tube tire and the radially inner hollow-space wall has a diameter matched to the diameter of a wire tire.

Abstract: According to one embodiment of the present invention a method of creating a composite with an object having a central axis is provided which comprises wrapping a first fabric layer around the object in one of a clockwise or a counterclockwise direction around the central axis of the object. A second fabric layer is wrapped over the first fabric layer. The second fabric layer is wrapped around the object in the other of the clockwise or the counterclockwise direction around the central axis. The object is placed in a mold and resin is injected into the mold to form the composite.

Abstract: Ballistic resistant composites and articles formed therefrom for use in airplanes and other vehicles which meets particular structural, impact and ballistic requirements. An aerospace-specification grade honeycomb is positioned between panels comprising non-woven ballistic resistant fibrous layers, and optionally one or more fire resistant layers. The composites and the articles formed therefrom have superior structural, impact, fire resistance and ballistic performance at a light weight.

Abstract: The invention provides a method of fabricating a lug on a structural element of composite material made at least locally out of a stack of primary plies of composite fibers defining at least one extension for forming the lug. The method includes the step of separating the primary plies at least in the extension and of inserting intermediate plies between the primary plies.

Abstract: A composite material assembly (1) comprises a) a surface enhancing layer (5) comprising at least one layer of fibres, having a length to width aspect ratio of more than 5:1 and b) a structural layer (7) comprising at least one reinforcing fibre and at least one polymeric matrix.

Abstract: Catheters such as guide catheters can include a reinforcing braid layer and distal tips in which the reinforcing braid layer does not extend into the distal tip. Such catheters can be formed via a process in which a first polymer segment is secured over a braid layer. The braid layer can be cut through at a cutting position that is proximate a distal end of the first polymer segment and the braid layer extending distally of the cutting position is removed. A second polymer segment that extends over the first polymer segment and that extends distally of the cutting position is secured over the braid layer.

Abstract: An airfoil or vane for a combustive power plant includes an inner core formed from a first composite material having discontinuous fibers. An outer sleeve is formed from a second composite material having continuous fibers. The first composite material is different from the second composite material. The outer sleeve generally surrounds and is bonded or otherwise connected to the inner core. A method of fabrication includes injecting or otherwise introducing thermoplastic fiber composite material including chopped or otherwise discontinuous fibers into a mold to form the core and platforms of an airfoil assembly. The injected thermoplastic fiber composite material is then cured in the mold. The cured thermoplastic fiber composite material is then removed from the mold. A layup including one or more surface plies of a thermoset continuous fiber composite material is then applied to the core material. The surface plies are then compressed and cured in a mold.

Abstract: A method of forming a support beam is provided. One exemplary method of forming a support beam includes supporting a C-shaped charge upon a first forming tool and placing an additional composite charge upon at least a portion of the C-shaped charge and a second forming tool proximate the first forming tool. The method of forming a support beam further includes positioning a fixed forming tool proximate a first portion of the additional charge and bending the additional charge about the forming tool.

Abstract: A method for manufacturing a polymeric article having an integrated reinforcing element. A thermoplastic material is introduced into a mould, after which reinforcing elements are inserted into the mould cavity. A second layer of the thermoplastic material is introduced into the mould, after which the mould is closed, pressing and heating the mould to melt the thermoplastic material and form the article. The thermoplastic layers may be provided in powder, sheet, or pellet form. The reinforcing elements may comprise reinforcing fibres or reinforcing fabrics. A polymeric track for a vehicle may be produced from this method.

Abstract: The invention relates to a method of manufacturing a composite turbomachine blade, the method comprising the following steps: a) making a preform by three-dimensionally weaving yarns including tracer yarns disposed at least at the surface of the preform; b) cutting out said preform so as to leave intact a series of tracer yarns situated along a reference face of the preform; c) pre-deforming said cut-out preform; d) compacting and stiffening said pre-deformed preform; e) providing an injection mold in which said stiffened preform is placed; f) heating said injection mold; g) injecting a binder into said injection mold, the binder comprising a thermosettable resin; and h) extracting from the mold a composite molded part presenting substantially the shape and the dimensions of said blade. The invention is applicable to a making fan blade.

Abstract: Toughened binder compositions are useful with performs that will be infused with a matrix resin in advanced processes, such as resin transfer molding, vacuum assisted transfer molding and resin film infusion, to form composites and their use in such advanced processes form the basis of the present invention.

Abstract: A method of producing a non-crimp fabric and a non-crimp fabric comprising a layup of fabric plies stitched together by a thread, at least part of which is fusible, is provided. The method can include heating the stitched plies to soften or melt the fusible thread. The use of fusible thread can act as an in situ binder within the non-crimp fabric and tension created by the unfused stitching may create channels for matrix resin infusion during manufacture.

Abstract: A pressure container manufacturing method for manufacturing a pressure container by forming an outer shell made of a fiber reinforced composite material on a periphery of a liner, by: preparing a first fiber bundle which has a large diameter fiber bundle unimpregnated with a resin, and a second fiber bundle which has a small diameter fiber bundle and a thermoplastic resin covering the small diameter fiber bundle; forming a body on the periphery of the liner by braiding the first fiber bundle and the second fiber bundle with a braider; impregnating the first fiber bundle with the thermoplastic resin in the second fiber bundle which is heated and melted; and curing the thermoplastic resin to form the outer shell, wherein tension applied to the first fiber bundle is larger than tension applied to the second fiber bundle when forming the body and/or impregnating the thermoplastic resin.

Abstract: A plastic card, including a bottom overlay, a top overlay positioned above a top surface of the bottom overlay and a core layer positioned between the top surface of the bottom overlay and the top overlay. A method for manufacturing a plastic card, including loading a bottom overlay into an injection molding apparatus, loading a top overlay into the injection molding apparatus wherein the top overlay is positioned above a top surface of the bottom overlay and injecting a core layer between the bottom overlay and top overlay, wherein one or more protrusions are formed on the surface of the top overlay. The protrusions may be arranged in such a way as to form designs on the surface of the plastic card.

Abstract: A safety seat comprising a unitary molded shell having a “bucket-seat” shape and a safety restraint system integral to the shell. The molded unitary shell has a bottom portion and a back portion. The shell comprises an inner layer and an outer layer made of a carbon fiber laminate with a core situated between the inner and outer layers. The core comprises aluminum sheeting having a honeycomb-like cross-section. A plurality of attachment plates are selectively located within the shell and disposed between the inner and outer layers. The safety restraint system is fastened to corresponding attachment plates. Support plates located on a non-seating surface of the shell are mated with selected attachment plates. A headrest is selectively attached to the safety seat. The safety seat is secured to structural members within a vehicle by mounting brackets. A method for making the shell and assembling the safety seat are disclosed.

Abstract: The invention relates to a method and a moulding core for producing a fibre composite component (34), in particular in aerospace, comprising the following method steps: introducing a core sleeve (9) into a moulding tool (2) for establishing an outer geometry of a moulding core (27) to be formed; filling the core sleeve (9) that is introduced with a vacuum-fixable filling material (21); applying a vacuum to the core sleeve (9) and consequently vacuum-fixing the filling material (21) for forming the moulding core (27); and at least partly laying at least one semifinished fibre product (33a, 33b) on the moulding core (27) that is formed, for the shaping of the fibre composite component (34) to be produced.

Abstract: The present disclosure pertains to composite articles, and in particular a composite face plate for a golf club-head, and methods for making the same. In certain embodiments, a composite face plate for a club-head is formed with a cross-sectional profile having a varying thickness. The face plate comprises a lay-up of multiple, composite prepreg plies. At least a portion of the plies comprise a plurality of elongated prepreg strips arranged in a predetermined criss-cross pattern in the lay-up. The prepreg strips create one or more areas of increased thickness where the strips overlap each other, thereby creating a desired profile for the plate. Metallic or polymer covers or cover layers can be used to define a striking surface.

Abstract: The present invention relates to a radome which has excellent transmission loss of radio waves and structural strength, which can be easily produced, and which has favorable workability, and a method of producing the same. The radome includes an olefin woven material and a glass cloth, in which the olefin woven material and the glass cloth are impregnated with a matrix resin to be integrated with each other, and the glass cloth is disposed closer to an inner side of the radome than the olefin woven material. As the olefin woven material, a woven material formed of an ultrahigh molecular weight polyethylene fiber can be used. As the matrix resin, an epoxy resin, a vinyl ester resin, an unsaturated polyester resin, or a silicone resin can be used.

Abstract: The present invention is directed to a high-loft nonwoven including a binder or stabilizer including a polyurethaneurea composition that provides flexibility and compression recovery to the nonwoven structure. Included is a polyurethaneurea dispersion as a stabilizer or binder for the short-length fibers which create the high-loft nonwoven structure. The invention is useful as an improved alternative for such things as polyurethane foam in applications such as bra cups.

Abstract: The application relates to a process for manufacturing a prosthetic joint with at least one loaded surface which consists at least partially of polyethylene, comprising compressing one or more layers of a woven fabric of drawn gel-spun polyethylene fibres into the desired shape in a hollow mould part using a plug at a pressure of at least 0.05 MPa and at a temperature of between 120 and 165° C. and below the crystalline melting point of the polyethylene at the prevailing temperature and pressure, without a matrix material being present, and at least the woven fabric in a layer situated on a loaded surface comprising at least 90 wt % of fibres with a titre of at most 1000 denier, and to a prosthetic joint with a crease-free surface.

Abstract: The present invention relates to a prepreg laminate, constructed from a first prepreg; a second prepreg; and a thermoplastic layer therebetween. In the inventive laminate, at least one of the first prepreg or the second prepreg is made from a matrix resin comprising a benzoxazine-containing composition.

Abstract: The invention relates to a process for the manufacture of a ballistic-resistant molded article in which a stack of monolayers is formed, each monolayer containing unidirectionally oriented reinforcing fibers and at most 30 mass % of a plastic matrix material, the reinforcing fibers being highly-drawn polyethylene fibers, and with the fiber direction in each monolayer being rotated with respect to the fiber direction in an adjacent monolayer, the stack then being compressed at a pressure of more than 25 MPa and a temperature between 125 and 150° C., and the plastic matrix material having a 100% modulus of at least 3 MPa.

Abstract: The invention relates to a method of producing rectifier parts which are made from a laminate composite material comprising reinforcing fibers that are embedded in a heat-polymerized polyimide resin matrix. The aforementioned parts comprise an inner platform, an outer platform and at least one solid blade which connects said platforms.

Abstract: A composite laminate includes a plurality of sheets of prepreg stacked one over another, and a scrim layer provided on an exterior surface of the sheets of prepreg. Each prepreg sheet is formed of fibers preimpregnated with resin. The scrim layer and the sheets of prepreg form a composite laminate whereby the scrim layer constitutes an outer, exposed surface of the composite laminate. The scrim layer may be a nonwoven carbon or glass fiber scrim that has absorbed resin from the sheets of prepreg. A method of making a composite laminate includes placing into a mold a scrim and a plurality of sheets of prepreg, with the scrim extending between an exterior surface of the sheets of prepreg and an inner surface of the mold; forming a composite laminate whereby the scrim is adhered to the sheets of prepreg; and removing the composite laminate from the mold. An outer layer of the composite laminate includes the scrim.

Abstract: A cushion body, which can secure both soft touch feeling and durability, a seat having the same, and a manufacturing method thereof are provided. A cushion body 11 is formed by stacking a first sheet-like fibrous structure 4a and a second sheet-like fibrous structure 4b where webs 2 are stacked such that their extending direction conforms with a thickness direction T of the cushion body and between the first sheet-like fibrous structure 4a and the second sheet-like fibrous structure 4b, a load receiving member 4e whose flexing degree to load in the thickness direction T is small is disposed. Since the first sheet-like fibrous structure 4a is disposed on a sitting surface 10a, the structure is largely flexed when applied with the load from outside the cushion body 11 due to sitting and gives soft touch feeling to a seat occupant.

Abstract: A method for manufacturing a hollow load-bearing beam structure of fiber-reinforced composite material. The method includes preparing a first lay-up of a first plurality of layers, and a second lay-up of a second plurality of layers. The first and second lay-ups are positioned on different sides of a mandrel and formed to a beam structure by bending the lay-ups against the mandrel, such that the side edges of the respective layers of the first and second lay-ups are arranged as offset butt joints in the circumferential direction of the formed beam structure.

Abstract: The invention provides a method of making a fiber ply for forming a preform of a composite part in the form of a body of revolution having a non-developable surface, the method being characterized in that it comprises the steps consisting in: defining an annular space (23) with first and second canvases (20, 21) respectively defining an inner periphery and an outer periphery thereof; placing fibers between the canvases (20, 21) by placing the fibers in the annular space in at least one direction and by holding said fibers on the canvases by stitching; implementing circular connection stitching in the vicinity of the inner periphery of the annular space (23); and cutting out the fiber ply as made in this way in the annular space (23) in order to extract it from the canvases.

Abstract: A method and apparatus are provided for forming elongated composite structural members with a desired cross-sectional geometry as taken transverse to the length of the member. An apparatus may include a base with a substantially elongated mandrel mounted thereon. One or more rollers configured to at least partially complementarily engage the mandrel are configured to roll over and press one or more plies of composite material onto the mandrel. The mandrel may be disposed on a rotary table and configured to exhibit a curved elongated geometry to form at least partially curved or arcuate elongated members. The present invention enables the formation of elongated structural members from resin impregnated materials while maintaining the materials in a substantially uncured state. The formed members may then be cocured with a skin or other composite structure.

Abstract: A mat member includes inorganic fibers, a first main surface, a second main surface opposite to the first main surface, an edge surface surrounding the first main surface and the second main surface, and an inorganic fiber scattering reduction unit. The inorganic fiber scattering reduction unit is provided on at least a part of the edge surface of the mat member and configured to reduce scattering of the inorganic fibers.

Abstract: An aircraft wing made of a composite material, and its method of manufacture, require a plurality of kabobs (i.e. substantially rectangular shaped hollow tubes having an open end and a closed end). Of these kabobs, several are aligned end-to-end, to create a section. Several sections are then positioned side-by-side and covered by a layer of composite material to define an aerodynamic surface for the wing. The juxtaposed sections also establish spar webs for the wing, and the closed ends of the juxtaposed sections establish transverse ribs for the wing. Thus, the kabobs form the main load-bearing member of the wing. The sections of composite material are co-cured with the composite material of the aerodynamic surface.

Abstract: Composite structures with internal cavities are constructed with relatively stiff walls that can support additional composite laminate layers, creating a self-tooling structure. The structure is subsequently simulcured, preferably in combination with elevated temperatures or pressures. Preferred structures are long and slender, and are constructed with one or more internal cells. Rotor blades are especially suited to the preferred construction methods. The walls can be advantageously constructed using composite sandwich panels, having an exterior laminate layer. In preferred embodiments, additional composite layers can be added before or after the simulcuring process.

Abstract: An air filter arrangement is (300) disclosed. The air filter arrangement includes strips of media comprising corrugated sheets secured to facing sheets and forming inlet and outlet flutes secured to one another in a stack. Media pack arrangements including such stacked media with a molding arrangement to secure and seal opposite side edges of the media strips, are described. Also described are filter cartridges including such media pack (301) and air cleaners including the filter cartridges. Methods of assembly and use are also provided. Also, systems of use are described.

Abstract: The present invention relates to a process for the manufacture of composite materials having lignocellulosic fibres dispersed in a thermoplastic matrix, while generally maintaining an average fibre length not below 0.2 mm. The process comprises defibrillation of the lignocellulosic fibres using a mixer and at a temperature less than the decomposition temperature of the fibres in order to separate the fibres and generate microfibres, crofÊbres, followed by dispersion of the fibres in the thermoplastic matrix by mechanical mixing to get the moldable thermoplastic composition, followed by injection, compression, extrusion or compression injection molding of said composition. The process produces high performance composite materials having a tensile strength not less than about 55 MPa, a flexural strength not less than about 80 MPa, a stiffness not less than about 2 GPa, notched impact strength not less than about 20 J/m, and un-notched impact strength not less than about 100 J/m.

Abstract: Decorative textured surfaces are formed on articles having curved or contoured surfaces. A reusable, flexible textured blanket is placed in a mold along with a first material charge. A pressurizer is used to both impart the texture of the blanket to the first material charge and consolidate the charge to form a textured shell. The blanket is removed from the mold and a second material charge is introduced into the mold over the shell. The application of heat and pressure consolidates the second material charge and the shell to both form and cure the completed article.

Abstract: A method and an apparatus for manufacturing of a curved elongated structural element of composite material. The curved elongated structural element includes a first elongated portion and a second elongated portion in an angled relation. A substantially flat blank of composite material including a first and second elongated edge is provided. The blank is folded over a first portion forming surface and a second portion forming surface of a forming tool's flexible tool body for forming the first elongated portion and the second elongated portion. The forming tool's tool body is bent such that its bending moment center prevails essentially adjacent the first portion forming surface.

Abstract: The invention relates to a method of producing a shell member of fibre composite material by means of vacuum infusion, where the fibre material is impregnated with liquid polymer, and applying a mould (18) with a mould cavity. In the mould cavity a lower distribution layer (11) is placed. A fibre insertion (1) including a plurality of fibre layers is placed above the lower distribution layer (11). A first upper distribution layer (9) and a second upper distribution layer (10) are placed at a transverse distance of each other above the fibre insertion, so that at least a part of the first distribution layer overlaps a first zone (2) of the fibre insertion (1), and at least a part of the second distribution layer overlaps a second zone (3) of the fibre insertion (1), the first zone (2) and the second zone (3) being separated by an intermediate zone (6) neither overlapping the first nor the second distribution layer (9, 10).

Abstract: A method for manufacturing SMC components from an appropriately adapted amount of a fibrous reactive synthetic resin which is provided in the form of defined blanks of prepregs. The prepregs are placed in a defined position into a heated mold of a molding press, the heated resin/fiber mass is flow-molded in the closing mold to form the SMC component, said component is thermally cured and subsequently removed from the mold. Two different approaches are taken, one being intended for introducing the resin mass into the mold as multiple layers and the other for introducing the resin mass as a single layer.

Abstract: A forming method for fiber reinforced resin includes the following steps. First, put a stack of pre-pregs into a cavity of a die having a plurality of openings in communication with the cavity and the space outside the die. Then heat the die and exhaust air through the openings from the cavity of the die. Thus, the air bubbles between the pre-pregs as well as surplus resin can be drawn out such that the product has improved mechanical strength.

Abstract: A composite structure comprising a core portion having a pair of generally opposed surfaces. A first fibrous layer is disposed on a first surface of the core portion and has a plurality of fibres disposed substantially parallel to the first surface. A second fibrous layer disposed on a second surface of the core portion and has a plurality of fibres disposed substantially parallel to the second surface. A first polymer layer is disposed over the first fibrous layer and a second polymer layer is disposed over the second fibrous layer. The first fibrous layer is partially embedded in both the core portion and the first polymer layer. The second fibrous layer is partially embedded in the core portion and the second polymer layer. The present composite structure may be used in structural and/or non-resilient components of the vehicle. Such components include exterior body panels (e.g., TONNEAU covers), door panels, beds for pickup trucks and the like.

Abstract: A new and improved cutting instrument is disclosed, having a strong rigid exoskeleton. The exoskeleton is made of a fiber and resin matrix, such as a carbon fiber weave. The carbon fiber exoskeleton can be applied to a scissors handle for increased cutting performance.

Abstract: A composite mandrel includes a filament-wound composite tube, and composite material molded over the filament-wound composite tube. For example, the composite material includes chopped fibers and a matrix of thermoset resin. The chopped fibers are arranged in layers upon the filament-wound composite tube, and the chopped fibers in each of the layers are randomly oriented along first and second orthogonal directions in each of the layers. The composite material includes at least one sheet of the composite material wound over the filament-wound tube, and at least one strip of the composite material wound over the sheet of the composite material and forming a head on the composite mandrel. An internal cavity of the filament-wound composite tube may provide a lumen for the composite mandrel. The internal cavity may be threaded to receive a removable bridge plug.

Abstract: A method for making a windmill blade is provided, whereby problems with glue joints and with exposure of the workers to environmentally hazardous substances are avoided. This is effected by making the windmill blade in a closed mold with a mold core (3) inside mold parts (22, 48) for formation of a mold cavity (51), in which fiber material (45, 47) and core material (46) are placed. After applying vacuum to the mold cavity (51), matrix material (57) is injected via a filling pipe (29), which is placed at a downwardly oriented side edge of the blade during the filling. Hereby is established a flow front (61) which is used for indicating complete filling when this reaches the trailing edge of the blade and penetrates out through overflow apertures.

Abstract: A method of making an aircraft component is provided, wherein the method comprises the steps of: providing a mould (1) for the receipt of a material (3) from which the aircraft component is to be made providing the mould with said material providing an intensification tool (14) in spaced relationship to the mould and heating the material, tool and mould so that the tool expands and applies pressure to the material and so as to form the component and wherein the linear coefficient of thermal expansion of the tool in a first direction is matched to the coefficient of thermal expansion of the component in the first direction, and the coefficient of thermal expansion of the tool in a second direction is greater than the coefficient of thermal expansion of the component in the second direction, the tool being provided with at least one contacting surface for contacting the material and through which pressure is applied to the material, the expansion of the tool in the second direction causing the at least one c