Abstract: A method for combining a metal racket frame with a hollow grip includes the following steps: prepare a metal racket frame and a hollow grip in advance, fit two free ends of the metal racket frame in the upper end of the hollow of the hollow grip and then place the fitted portion of the metal racket frame and the hollow grip in a matched mold. After the matched mold is closed and combined together, the matched mold and the metal racket frame with the hollow grip are turned upside down, and liquid resin is injected in the interior of the hollow grip. After the liquid resin is solidified, remove the metal racket frame and the hollow grip from the matched mold, thus finishing the metal racket frame and the hollow grip combined integrally and smoothly.

Abstract: A method of molding a high density composite article which, when completed, has opposed outer skins of fiber-reinforced plastics material and polymer mortar core between the skins. The method is performed by (a) providing an openable mold defining a mold cavity and an injection port through which polymer mortar may be introduced into the cavity; (b) opening the mold and placing within the cavity respective layers of fiber reinforcement to form the opposed outer skins; (c) closing the mold and injecting polymer mortar consisting of a resinous material loaded with high density particulate aggregate through the injection port into the cavity, between the layers of fiber reinforcement placed therein; and (d) applying sufficient pressure to the injected polymer mortar to ensure resin is separated from the polymer mortar and penetrates the said layers.

Abstract: A method for producing a window glass for a vehicle provided with an ornamental braid comprises steps of setting an ornamental braid on a lower mold of an injection molding machine, fixing an ornamental braid connection member on the lower mold, setting a glass plate on the lower mold, closing an upper mold, thereby locking the molds, and injecting molten resin into a cavity formed between the lower mold and the upper mold, thereby integrally molding a resin frame, the ornamental braid and the ornamental braid connection member along a periphery of the glass plate.

Abstract: A concrete floor system used in a building structure and a method of making floor components used with the floor system. The concrete floor system, if installed on grade, provides for expansion and contraction due to expansive soils and eliminates cracks, which heretofore occurred in poured concrete slab floors. The concrete floor system includes a plurality of parallel concrete beams. The beams can be made up of hollow concrete blocks for reduced weight and receiving a tension cable therethrough. Also, the beams can be either solid pre-cast beams, solid pre-cast, pre-tension beams or solid pre-cast, post-tension beams. Opposite ends of the cable are held on end plates inside recessed ends of each hollow beam. The ends of the beams are adapted for mounting next to the inside of the sides of a building foundation wall. The beams can be in a range of 5 to 20 feet and greater in length depending on the dimensions of the concrete floor.

Abstract: There is disclosed a method of forming a fabric 1 on the surface of a mandrel 10, infiltrating the formed fabric with matrix, and leaving portions 12a, 12b of the mandrel as integral with the fabric and removing the mandrel before the fabric adheres to the mandrel by matrix infiltration. Subsequently, a remaining portion of the mandrel is used as a reference surface and machining is performed. Without possibility of adhesion to the mandrel and resulting breakage, machining bases (axial center and reference surface) during machining can accurately be provided, and this can largely enhance machining precision and yield of a final product.

Abstract: A low-cost, efficient method of preparing hierarchically ordered structures by filling a minimold with a microsphere-containing latex suspension, forming an close-packed array of microspheres within the minimold and filling void space in the array with a self-assembling mixture of hydrolyzed inorganic species and amphiphilic block copolymers. A macroporous and mesoporous material can be produced by subsequent thermal removal of the microspheres and copolymers.

Abstract: The present invention involves a process that includes injecting a potting compound such as an epoxy through a hollow portion (2B) of the central mandrel (2) and onto the inner layer(s) of a multi-layered fiber bundle (3) and through the outside of the bundle and onto the outer layer(s) of the bundle. By potting through the central mandrel (2), the potting compound distributes evenly throughout the inner fibers of the bundle (3). The steps may be sequentially or simultaneously. Preferably it is done as a two-step process, with the first step being to apply the potting compound through the central mandrel (2) and onto the inner fibers first. The second step is to pot around the outer layer of the fiber bundle (3) to finish the process. The resultant product is also disclosed.

Abstract: Optical windows for intracorporeal devices, intracorporeal devices comprising a window and a method for forming a window for an intracorporeal device are provided. The method comprises placing within a mold an assembly comprising a mandrel located within a pair of parts separated by a collar of window material, heating the window preform effective to cause the window material to soften, and applying force to urge together the pair of parts to deform the window material so as to form a window. The intracorporeal devices, such as imaging devices, include guidewires, catheters, endoscopes. In addition, the method is suitable for joining plastic parts to other parts, such as metal and ceramic parts.

Abstract: A method of fabricating a damage tolerant shaft is provided in which a plurality of lobes are initially formed and are then positioned relative to one another to define an annular body and a plurality of ribs extending within the annular body. The plurality of lobes are formed of a plurality of reinforcing fibers extending at least partially about a respective lobe. Once the lobes have been positioned relative to one another, interstices between portions of adjacent lobes may be filled. Additionally, the plurality of lobes may be surrounded by an outer layer, also formed of reinforcing fibers extending at least partially about the plurality of lobes. The plurality of lobes may be impregnated with resin and cured, either prior to being positioned relative to one another or thereafter.

Abstract: A process id disclosed for structurally repairing and aesthetically filling, and mutually coupling slabs (1) and layers (2–4) into a block (5), comprising the steps of: heating, drying and impregnating the slabs (1) with resin; penetrating the resin through atmospheric pressure; inserting positive pressures; applying a liquid- or gas-tight sealing coating (6, 7, 8) around the block (5) to allow resin to flow around and inside the block (5), containing hydrostatic resin pressures and checking resin consumptions through a formwork; directly supporting through the block (5) the thrusts generated by pressure differentials; when preparing the block (5), assembling the stone slabs (1) independently from mutual thickness and distance between centers with other stone slabs (1).

Abstract: A first film plate 20 and a second film plate 40, each made of flexible resin film, are attached to a top surface and a bottom surface of a key top 30 made of mold-resin, respectively, so as to cover the key top 30. The first film plate 20 is pressed upward to form a recessed portion 23, the key top 30 is molded within this recessed portion 23. The second film plate 40 is arranged on the bottom surface of the key top 30. All of the first film plate 20, the key top 30, and the second film plate 40 are transparent. Decorative layers 21 and 41 are formed on the first film plate 20 and the second film plate 40, respectively.

Abstract: A thermoplastic elastomer composition produced from a thermoplastic resin and rubber and having a dispersion phase formed of a rubber composition at least part of which is dynamically crosslinked in the continuous phase of the thermoplastic resin, insulating glass using the thermoplastic elastomer composition as a sealing material and spacer, a process for producing the insulating glass using a sealing material made from the thermoplastic elastomer composition, comprising the steps of inserting the leading end of a charging nozzle into a space between the peripheral portions of a plurality of glass sheets, discharging the sealing material from the leading end of the nozzle body at a predetermined rate, and moving the glass sheets or the nozzle body relative to each other to charge the sealing material made from the thermoplastic elastomer composition into the space between the peripheral portions of the glass sheets, and a nozzle used in this process.

Abstract: The invention relates to a method for fabricating a decorative laminate panel, wherein the decorative laminate panel includes a decorative laminate layer and a core. The method is achieved by forming a decorative laminate of a predetermined size, placing the decorative laminate within a die cavity, injection molding the core within the die cavity while the decorative laminate remains within the die cavity to form a decorative laminate panel and releasing the formed decorative laminate panel from the die cavity. The invention further relates to a decorative laminate panel manufactured in accordance with the method defined above and a unitary edge profile member adapted for use in the fabrication of a compound injection molded decorative laminate panel.

Abstract: An intermediate product is formed by combining together plurality of constituent elements. The intermediate product is arranged in a mold an then molten resin is charged in the mold. An opening is formed so as to correspond to a plus terminal, a minus terminal, and a temperature detecting terminal in the intermediate product, and its periphery is covered with the resin. Whereupon, a thin enclosed outer packaging body is realized that is made compact and offers excellent dust-proof, drip-proof structure. Alternatively, the intermediate product is housed in an outer packaging case having an open end that allows insertion of the intermediate product, and resin is charged in the open end, thereby achieving sealing.

Abstract: Gypsum board having inorganic fiber, preferably glass fiber, preferably glass fiber, includes providing face sheets which have been completely impregnated with a gypsum slurry so as to penetrate through said random interstices between the inorganic fibers and to thereby cover the board surfaces with gypsum slurry. The gypsum board product is formed by passing the wet gypsum board through a board forming station having double forming plates, an upper forming plate having at least a portion thereof being set at a predetermined angle relative to a lower forming plate and having a separation between the forming plates defining a predetermined dimension substantially equal to the desired thickness of the manufactured gypsum board product. The method provides a multilayer gypsum board having a polymeric compound added to unset gypsum so as to provide a gypsum board ready for finishing.

Abstract: A molding-in-place technique for joint assemblies, such as a ball joint. The technique is particularly well suited for molding “in-place” a linkage structure about a joint structure. The technique uses a molding assembly having a plurality of centering and sealing structures for sealingly centering the linkage structure about the joint structure. A desired mold material is injected between the linkage structure and the joint structure “in-place” to provide a self-toleranced, self-retained, molded-in-place joint assembly.

Abstract: A problem in the manufacture of filters using tubular membrane bundles is keeping potting material from flowing into the openings at the ends of the tubes. A preferred embodiment of a method for manufacturing a tubular membrane filter employs a non-contact heat source such as radiant heating to melt the tips of the tubular membranes. This prevents the migration of potting material into the tubes when the potting material is flowed into the ends of tube bundles during the manufacturing process for a filter.

Abstract: A process for forming a molded polymer resin fiber tube clamp, as well as the tube clamp formed by that process. Continuous top and bottom plies provide increased resistance to delamination/cracking as they sandwich a filler material. The tube clamp is free from exposed fiber ends so than no wear is produced on a tube being clamped.

Abstract: Methods are provided for manufacturing an antiperspirant product that includes an application surface having two portions having different compositions, e.g., a product having two sections having the same composition but separated by a third section (for instance, a central stripe) having a different composition.

Abstract: The invention relates generally to the bonding of one or more sliders in styrene and acrylate polymers. More particularly, the invention relates to planarized slider assemblies formed by using debondable solid encapsulants comprised of styrene and acrylate polymers. The invention also relates to methods that use such encapsulants in conjunction with resists to produce magnetic head sliders having patterned air-bearing surfaces.

Abstract: In a process for manufacturing a plastic pane (1, 1′, 1″) provided with embedded electrical conductors (4), in particular a window pane, in which the conductors are joined to a surface of a plastic sheet (2, 2′, 2″) which subsequently receives another layer of plastic by injection molding via the rear for the purpose of forming a pane body (3), in which the material of the plastic sheet and the injection-molded plastic are joined together directly by mutual adhesion, and in which that surface of the plastic sheet which is located on the opposite side from the conductors forms one of the outer faces of the finished pane, the electrical conductors are, in accordance with the invention, formed by furnishing with at least one metal wire (4) that surface of the plastic sheet (2, 2′, 2″) which is to be exposed to the rear injection molding.

Abstract: A connecting member for structural sandwich plate members comprises a prismatic metal body having one, or preferably two, tapered edges which provide landing surfaces and weld preparations for the face plates of the structural sandwich plate members.

Abstract: A system for manufacturing interstitial radiation seed strand implants is provided. The system includes a seed dispenser, a member for handling an elongated half-shell member; and a controller in communication with the seed dispenser. The controller commands the seed dispenser to place the radioactive seed elements at desired locations in a first elongate half-shell member. The first half-shell member is mated with a second half-shell member to form a seed strand implant. The seed strand implant is axially stiff and longitudinally flexible, and constructed from bioabsorbable material.

Abstract: A method for forming a plurality of composite parts via resin transfer molding in a single molding cycle. The method includes the steps of using a mold having first and second mold members that cooperate to house a plurality of shims and placing a plurality of preform workpiece into the mold cavity such that at least one of the shims is disposed between each of an adjacent pair of the preform workpieces. A liquid resin is then injected into the mold cavity and subsequently cured to thereby form a cured workpiece matrix that is composed of a plurality of semi-finished composite parts and at least one shim separating the plurality of semi-finished composite parts from one another.

Abstract: The invention is a process for the preparation of article comprising placing a film on each inner surface of each part of a two part mold; placing an article in the mold with film located between the surface of the mold and the article such that there is a small space between the article and the surface of the mold; closing the mold about the article; injecting between the film and the article an expandable plastic material under conditions that the article is coated with the expandable material and the expandable material does not expand; removing the plastic article with the expandable material coated thereon with the two films attached to the expandable plastic material. In another embodiment the invention is an article comprising a shaped plastic article; an expandable material coated in the shaped plastic article; and a film covering the material coated shaped plastic article..

Abstract: The process for the manufacture of a pultruded product characterised by the employment of a phenolic resin that is in a solid state at room temperature and is mixed with an appropriate cross-linking agent, by raising the resin and cross-linking agent to a suitable temperature to maintain said phenolic resin in a liquid state, by impregnating a fibreglass with said liquefied phenolic resin, by forming said fibreglass impregnated with resin, as described above, to make the pre-defined product and by subjecting the product to heat treatment for a preset period to allow polymerisation of said resin.

Abstract: In manufacturing a separator for use in a fuel cell, first, a core (31, 94) is interposed between two preforms (17, 90, 101) and a with-core separator (41, 95, 107) is formed. After this, the core is melted by heating and discharged to form multiple cooling water passages (54). Because consequently there is no need to bring separators together to form the cooling water passages, a seal becomes unnecessary. Also, since there is no need to bring separators together the electrical contact resistance also falls.

Abstract: A problem in the manufacture of filters using tubular membrane bundles is keeping potting material from flowing into the openings at the ends of the tubes. A preferred embodiment of a method for manufacturing a tubular membrane filter employs a non-contact heat source such as radiant heating to melt the tips of the tubular membranes. This prevents the migration of potting material into the tubes when the potting material is flowed into the ends of tube bundles during the manufacturing process for a filter.

Abstract: The invention relates to a method of manufacturing a ski (1) comprising at least one binding-raising zone (5) formed by an extra thickness of the structure of the ski forming a projection in the region of the zone of the runner (2). Such a ski has a groove (12) let in over at least a portion of the length of each of its lateral faces, said groove (12) being located between the upper face (6) of the raising zone (5) and the edge (9) of the ski.

Abstract: A connector and tubing assembly including a multi-lumen molded connector having at least three flexible tubes also molded into the connector. The connector may be “Y” shaped and include three flexible tubes. A process of making the connector and tubing assembly involves forming a first part of the connector with two tubes molded therein and then removing an internal mold member prior to molding the final connector portion and third tube in place.

Abstract: A process for producing a composite molded article is described. The composite molded article includes: (i) at least one base body (1) having a contoured surface; (ii) at least one first thermoplastic part (4, 5, 6); and (iii) at least one second thermoplastic part (2, 3), each of the first and second thermoplastic parts being joined to the base body. The process includes, (a) providing a multicomponent injection molding tool (20) having at least two separate melt flow-way systems and at least two cavities in which each of the first and second thermoplastic parts are separately formed, each of the cavities are in separate communication with each of the separate melt flow-way systems. The base body is placed into the molding tool in a second step (b). The cavities of the mold are separated from each other by a combination of the contoured surface of the base body and sealing edges of the molding tool that abut the contoured surface of the base body.

Abstract: A method and apparatus for removing fouling materials from the surface of a plurality of porous membranes (9) arranged in a membrane module (4) by providing, from within the module, by means (10) other than gas passing through the pores of said membranes, gas bubbles in a uniform distribution relative to the porous membrane array such that the bubbles move past the surfaces of the membranes (9) to dislodge fouling materials therefrom. The membranes (9) are arranged in close proximity to one another and mounted to prevent excessive movement therebetween. The bubbles also produce vibration and rubbing together of the membranes to further assist removal of fouling materials.

Abstract: A method of constructing a frame (10) for a filtering screen from a polymer material is described in which a wire frame reinforcement is wholly encapsulated during the frame moulding process so that two parallel spaced apart wires extend through each of the intersecting orthogonal ribs (14, 16) which define the open area of the frame (10) across which the wirecloths (158, 159) are stretched. The surfaces of the frame (10) in which the wirecloths (158, 159) are embedded are formed with ridges (22, 30, 32) and the crests of the latter extend to different heights. The crests are softened by heating during the manufacturing process and the wirecloths (158, 159) stretched over the frame (10) are forced into the softened crests after which the assembly is allowed to cool and cure. The frame (10) is re-usable by stripping wirecloths (158, 159) from the top of the frame (10) and fitting fresh wirecloths over the plastics material and heating the regions which are to encapsulate the fresh wirecloth.

Abstract: A process for producing cards is provided, which can avoid exposure, on card surface, of unevennesses of components such as IC chips, capacitors and antenna coils mounted or formed on a mount substrate. This process comprises the steps of continuously feeding a mount substrate and simultaneously feeding a pair of sheet members on both surface sides of the mount substrate in such a manner that the mount substrate is interposed between the pair of sheet members; feeding an adhesive in fluid condition between each of the surfaces of the mount substrate and the sheet member opposite thereto; and regulating a distance between the pair of sheet members into a constant spacing and hardening the adhesive.

Abstract: A method for manufacture of a resin block includes setting high-voltage and low-voltage side conductors in dies, assembling the dies, extruding resin so as to form a resin block having the high-voltage side conductor and the low-voltage side conductor embedded therein, cooling the molded resin block, and taking out the molded resin block from the dies.

Abstract: A device for potting a filter is described. The device comprises a housing having a first hole in the first region communicating between the surface and the lumen, and a second hole in the second region communicating between the surface and the lumen. A ridge extends around the first hole and the second hole to define a trough for receipt of a flowable potting material. During the manufacture of the filter assembly, the housing is rotated about an axis that bisects the housing and is perpendicular to an axis of the lumen, a flowable material is placed on the surface of the housing, a portion of the flowable material flows toward the first hole, is retained by the ridge, and passes through the first hole, and a portion of the flowable material flows toward the second hole, is retained by the ridge, and passes through the second hole.

Abstract: A method of forming a composite panel with a facade comprising a planar arrangement of thin discrete facers on a body of structural backing material. The method comprises the steps of providing a horizontal casting bed, providing a plurality of facers each with chamfers at corners between side-rear and end-rear walls, arranging the facers in abutting relationship atop the casting bed and in a selected pattern in a face down planar configuration so that the chamfers on the facers open upwardly and define narrow elongated sealant channels at joints between contiguous facers. Depositing a sealant in the channels and pouring concrete as a structural backing material atop the facers, the rear surfaces of the facers and the concrete adhering to form a composite panel.

Abstract: A planking technique for producing, in a workshop, floors of required length with straight or curved boards having planar or curved shape. The technique restricts the period for which the object is immobilized to the time during which the prefabricated panels are being glued. The technique is particularly adapted for producing the skirts of swimming pools, boat decks, saunas, thalassotherapy installations and, more particularly, floors with complex shapes. A template is produced based on the surface to be covered in a material which will be subsequently eliminated. The boards are glued with their upper surface on the template lower surface with edge bending corresponding to the bending desired for the final production. The sealant between the boards can be produced at this stage of manufacture.

Abstract: The invention discloses a sheet-like structure material and its manufacturing method. The sheet-like structure material has the advantages that impact imposed on its edge ends can be adsorbed to protect its adherends, and that the labor required for installing it and edge ends treatment can be significantly saved. The structure material comprises an outer peripheral structure which has elasticity and is integrally formed at the outer periphery of a sheet-like composite body comprising two glass sheets and an intermediate resin layer disposed between the glass sheets. The outer peripheral structure is formed from a resinous material used for forming the intermediate resin layer, by allowing the material to ooze from between the glass sheets.

Abstract: A method of reinforcing a metal panel or pipe of an existing structure comprising the steps of attaching a reinforcing metal layer to said metal panel or pipe in spaced apart relation to thereby form at least one cavity between inner surfaces of said metal panel and said reinforcing metal layer, injecting an intermediate layer comprised of an uncured plastics material into said at least one cavity, and curing said plastics material so that it adheres to said inner surfaces of said metal panel or pipe and said reinforcing metal layer.

Abstract: A method of fabricating a solid drain cover wherein a plurality of reinforcement layers are inserted into a mold cavity and an unhardened polymer is injected into the mold cavity to surround the reinforcement layers. Each of the reinforcement layers includes a plurality of fiber strands positioned to extend across the mold cavity and are spaced by a predetermined distance. The reinforcement layers are attached to at least one layered spacer which is interposed between adjacent reinforcement layers. The drain cover is produced when the polymer has hardened in the mold cavity with the reinforcement layers and layered spacers embedded therein.

Abstract: A process of making a microcontact printing stamp useful in microcontact printing of microcircuits. In this process an elastomeric microcontact printing stamp is formed by curing an elastomeric monomer or oligomer in a mold in which a photoresist master, defining a microcircuit in negative relief, is predisposed above a flat and rigid backplane laminate. The flat and rigid plane member of the backplane laminate is delaminated from the backplane after the printing stamp is removed from the mold.

Abstract: Embodiment of a disclosed seam tool comprise a rigid backing configured to be positioned about a seam region defined by at least two adjacent pattern segments. The rigid backing further includes an injection port and, typically, a gas outlet port, fluidly coupled to the seam region. The disclosed device may further include a resilient liner which contacts and forms a seal with surfaces of the pattern segments. Compensating grooves may be formed in the resilient material to allow complete filling of the seam region by weld-forming material. An injection fitting may be operably coupled to an injection port to provide an improved ability to receive weld-forming material to form welds. A method for forming a weld between plural, adjacently positioned pattern segments also is disclosed. The method comprises positioning the disclosed embodiments of the seam tool about a seam region defined between adjacent pattern segments.

Abstract: A method for underfilling and encapsulating flip-chip configured semiconductor devices mounted on a carrier substrate using stereolithography (STL) to form, in situ, at least semisolid dam structures of photopolymeric material about the devices to entrap liquid, unpolymerized resin between the devices and substrate. Prior to the STL process, the carrier substrate and mounted devices are immersed in the liquid polymeric resin, optionally with vibratory energy, to purge contaminants from between the device and substrate, and to fill spaces between the semiconductor devices and carrier substrate with the liquid resin.

Abstract: A system for molding a jointed linkage support system with joints that allow movement and bending in many directions and degrees of freedom. A chain-like linkage system made up of a series of joints is molded in a single step from materials having different melting temperatures in a series of alternating communicating mold cavities. The jointed linkage support system emerges from the mold fully assembled. An electrical switch may be provided within one of the joints between sleeves and rods whereby movement of the rod relative to the sleeve actuates the switch.

Abstract: A method impedes transverse relative displacements of a pipe (2) and at least one cable (3) which extends in this pipe (2), and doing so with a certain transverse play (4). The method has the steps of: selecting at least one portion (8), of a predetermined longitudinal dimension (L8), of pipe (2), and, then, with the cable (3) inserted in the pipe (2), locally constructing between the cable (3) and said pipe (2) at least one wedging element (9) adapted to suppress the transverse play (4) existing between the cable (3) and the pipe (2) in said at least one selected pipe portion (8).

Abstract: The method of manufacturing a sheet stack for electromagnetic assemblies, consisting of ferromagnetic material, includes forming the sheet stack from raw magnetic steel sheets in a shaping tool without the use of spacers, if necessary with the help of positioning aids, and simultaneously introducing a hardenable mixture into the shaping tool in order to totally surround the sheet stack and to form an anti-corrosion layer and hardening or hardening out this casting compound according to the pressure-gelating method to connect the sheets together and to form the finished sheet stack in one single working step.

Abstract: To pot membranes in a header, a dense, viscous liquid, suspension or, preferably, a thixotropic, water soluble gel, is placed in a header pan in space reserved for a permeate channel. A plurality of hollow fibre membranes are collected together and their open ends are inserted into the gel. A fixing liquid, typically a resin, is placed over the gel. The fixing liquid surrounds each membrane and then solidifies, simultaneously sealing the outer surfaces of the membranes and forming a plug in the opening of the header to complete the permeate channel. After the fixing liquid has solidified, the gel is removed by various means. The space initially occupied by the gel becomes part of the permeate channel after the gel is removed. In one embodiment, membranes are grouped by a cushioning adhesive which later surrounds the membranes where they exit the completed header.

Abstract: A manufacturing method for a foldable convertible top assembly in which a window plate is connected to a sheet material by a resin connecting element. The frame member has a predetermined transverse cross-sectional shape formed by hardening a liquid-form synthetic resin at the outer peripheral edge of the window plate. The outer peripheral edge of the window plate is attached to the resin connecting element and the foldable sheet material is also attached to the connecting element.

Abstract: A method of forming a pipeline pig in two or more steps is provided. Selected disks and/or cups, of selected size and hardness, are first formed. These disks and/or cups may include scraper disks, seal disks, flower petal disks, and/or cups in various sizes and hardnesses, in any desired permutation of these characteristics. The preformed pig components are then arranged with a plurality of mold pieces placed between the various disks and/or cups and then a second molding step is performed. The pig components which are formed in the first step preferably include a large central hole through which polyurethane will flow in the second molding step to form the mandrel. The pig components also preferably include a plurality of smaller holes radially spaced around the large central hole. The smaller holes serve to form a mechanically robust coupling between the pre-formed pig components and the polyurethane mandrel.