Abstract: An umbilical cable, particularly adequate for subsea exploration, contains two or more three-phase power supply circuits, each consisting of three conductors grouped in a trefoil configuration, each conductor including a metal core surrounded by an insulating sheath, each conductor being provided with an individual shielding whose cross-section is less than, equal to or greater than that of the core. Advantageously, each insulating sheath may be surrounded by a layer of semiconductor material. Filler spacers made of an insulating material, preferably polyethylene, may be used to aid in the positioning of the trefoils. The cable provides an economy of material, an increased flexibility, a reduction of the diameter of the finished cable and a substantial decrease of manufacturing time as compared with cables produced in accordance with the known art. A manufacturing method for an umbilical cable is also disclosed.

Abstract: There is provided a method of manufacturing a window having at least one of a radio wave stealth property and an electromagnetic wave shield property comprising: a step for forming a thin-film composed of a conductive material on the surface of a transparent window member having a curved surface, and a step for forming the thin-film into a mesh shape. As a result, it is, possible to manufacture, at lower cost, a window having a radio wave stealth property that scatters radio waves in various directions so as not to be detected by radar, while transparency to visible light is improved, as well as a window having an electromagnetic wave shield property that effectively prevents harmful electromagnetic waves, except for visible radiation, from invasion into an aircraft.

Abstract: A method for producing a formed wooden article by cutting out a primary blank member from a raw wood and forming the same into a final three-dimensional shape having a substantially uniform thickness, comprises: a primary compression step in which the primary blank member is compressed by primary molding dies, and the primary blank member is processed into a primary compressed article having a high compression portion in a vicinity of portions of the primary blank member corresponding to a die surface; a secondary blank processing step in which the primary compressed article is cut and processed into a secondary blank member; and a secondary compression step in which the secondary blank member is compressed by using secondary molding dies and the final three-dimensional shape is transferred onto the secondary blank member.

Abstract: A ribbon used in binding and decorating includes two separate superposed flat films of polyolefin plastic, which are bonded or glued together to form an intimate union, the films differing form each other by their elastic elongaton and/or heat-shrinkage properties such that, on leaving the production equipment, the difference between the films results in a different extent of shortening between the two films, to thereby cause curving of their constituted assembly. The curving is contained within a range of elastic deformation compatible with the curvature of the subsequent winding of the ribbon and such as to create spontaneous curling of the ribbon at the ambient temperatures at which it is used, as soon as it is unwound.

Abstract: A method for producing light-weight twin tank rails of a two-wheeled vehicle including bending a rear portion of each of a pair of tubular rails downward using a roll bending machine to form a pair of primarily bent tubular rails. Each of the primarily bent tubular rails is bent using a press molding machine at its front portion to form a pair of secondarily bent tubular rails. Then, a pressurized liquid is fed into each of the second secondarily bent tubular rails while maintaining the secondarily bent tubular rail in the mold cavity of the press molding machine to plastically deform the peripheral wall thereof into conformity with the mold cavity of the corresponding press molding machine.

Abstract: Disclosed is a method of producing outer covering on a housing of product. A thermosetting adhesive is respectively applied to the inner surface of a flexible covering layer and the outer surface of a housing, and the thermosetting adhesive is dried after being applied thereto. The flexible covering layer and the housing are superimposed and disposed into the lower mold half of a mold, wherein the thermosetting adhesives are softened by a heat and pressure treatment during an assembling process of the lower mold half and a upper mold half, so as to adhere firmly the flexible covering layer to the housing used for consumer electronics.

Abstract: There are provided apparatuses and related methods for forming sheets. The formed sheets can be formed of a thermoplastic material, such as flat sheets of reinforced thermoplastic, which can be lightweight, strong, and perform well in flammability, smoke, and toxicity tests. The apparatus includes a heater for heating the sheet to a processing temperature and a structure for configuring the sheet to a desired shape using one or more rollers, shapers, longitudinal members, and/or support members.

Abstract: A process for molding a plastic object with at least one stationary part and at least one appendage connected to the stationary part via a hinge is provided. The process uses a molding tool having a turnable middle section to mold the object. The turnable middle section rotates, the appendage is moved from an open position to a closed position, and the object is ejected from the molding tool.

Abstract: A linear element, especially a spectacle side, of the type comprising a flexible metal core coated with a flexible elastomer for comfort and/or appearance. Its structure is composed of a plurality of rigid plastic rings placed in fixed positions around predetermined areas of the flexible metal core so that each can serve as a point of intermediate mechanical attachment of the flexible elastomer with respect to the core. The cross section of the rings are inscribed within that of the elastomer surrounding it.

Abstract: A method of correcting the shape of a brittle cast component such as a low pressure turbine blade. The method includes steps of placing the component against a creep mould having a surface defining the desired profile of the component and HIP treating it to creep deform the component to the desired shape whilst consolidating it and removing gas and shrinkage porosity.

Abstract: An ear piece for providing audio (e.g., from an electronic device) to the user is provided. The ear piece may include a compliant element operative to be inserted in the user's ear such that the compliant element deforms to retain the ear piece in the user's ear. The compliant element may include a connector portion coupling the compliant element to the ear piece housing, and an outer portion folded over the ear piece housing. To improve the user's comfort, the compliant element may be manufactured inverted, such that parting lines or other defects due to the manufacturing process are located on the outer surface of the inverted outer portion. Then, when the compliant element is inverted post-manufacturing, the parting lines and other manufacturing defects may be hidden from view and from touch (e.g., the parting lines are then on the inner surface of the outer portion).

Abstract: A one-piece container closure with a collar, leaflets hingedly attached to the collar, and thin flexible foldable webs attached to and extending between the leaflets. The leaflets are flat with the webs folded beneath in closed closure position. The leaflets are pivoted upwardly with webs unfolded therebetween in open position. An integral cap is attached to the collar by a snap-action bow-tie hinge. A central pin on the cap seals with the leaflets when the cap is closed. The closure is integrally molded in open position with raised leaflets and unfolded webs, leaflets then being lowered and the webs folded to closed position while the closure is still warm.

Abstract: To provide an accelerated aging seed testing kit system, a single sheet of plastic or other suitable formable sheet material is pressed into the shape of a compartment base having recesses for mounting a seed holder. A seed holder that includes a seed support and a seed support holder is formed. The seed support holder is formed of a single sheet of plastic having radially extending tabs that fit into the recesses of the container to support the seed support above the bottom of the test kit. A bypass channel for addition of an aqueous solution used in the prescribed test condition is provided in the seed holder. A lid is formed out of one piece of plastic having a bendable tab to serve as a port and the openings and connecting points of the lid and seed holder are positioned so they can only fit together in one orientation having the port above the bypass channel.

Abstract: A tool for imparting a plurality of folds to a balloon comprises a housing, which defines a passage therethrough. The passage has a longitudinal axis and a first opening at a first end of the passage, and a second opening at a second end of the passage. The passage has an inner surface, which defines a plurality of peaks and valleys, wherein the height of each peak is greater at the first end of the passage than at the second end of the passage and the height of each valley is greater at the first end of the passage than at the second end of the passage.

Abstract: As shown in FIGS. 3 through 7, the first step within the manufacturing process is to mold an elongate body 20 having a relatively straight structure when compared to the final manipulated ski structure. The elongate body 20 is preferably comprised of a resilient and flexible material such as but not limited to ultra high molecular weight (UHMW) polyethylene (plastic). It can be appreciated that various other types of resilient and flexible materials may be utilized to construct the elongate body 20. Furthermore, the elongate body 20 may be created utilizing various molding processes such as but not limited to injection molding. Once the elongate body 20 has solidified, the elongate body 20 is removed from the respective mold by various conventional removal means.

Abstract: A method of manufacture of multilayer gypsum board, and a gypsum additive delivery system, including wet gypsum board passing through a board forming station in which additives are delivered to one or more layers of a multi layered gypsum board panels, such as engineered polymers, providing a better and more water resistance surface. Preferably, the gypsum board has a first layer of a mixture of set gypsum having an outer surface and a polymeric compound or wax emulsion additive entrained therein and impregnated in a thin sheet of randomly aligned inorganic fibers to essentially encase the core gypsum within two facing layers.

Abstract: A stator structure includes a magnetically conductive element and a winding. The magnetically conductive element is integrally formed as a single unit by at least one magnetic powder. The winding is wound around the magnetically conductive element. The manufacturing method of the motor stator is also disclosed.

Abstract: An apparatus and method for flexing a web is disclosed. The web passes over two co-rotating members, such as rollers or belts, which are separated by a small adjustable gap. The web travels around the first rotating member, is peeled off in the vicinity of the gap, bent back on itself in a small radius and reattached on the second co-rotating member. The location of the small radius is fixed with a closed loop control system sensing the radius location and controlling the relative velocity of the two members. Strain in the web is adjusted with the size of the small radius, which is controlled by the adjustable gap and radius location.

Abstract: A method and apparatus for forming catheters and catheter curves using ferromagnetic materials exposed to an alternating magnetic field. Heat is generated in the exposed ferromagnetic material. The temperature of the ferromagnetic material is allowed to reach a desired temperature, preferably the Curie temperature of the ferromagnetic material containing portion. The heat generated is transferred to a catheter, wherein the catheter can be selectively formed or assembled and bonded at the desired elevated temperature.

Abstract: A method of fabricating an exterior part of a camera is disclosed. The exterior part has an arcuate recess for finger gripping during photography and an arcuately bent portion. The method of fabricating the exterior part includes laminating a plastic protective layer to a surface of a substantially flat stainless steel sheet. An arcuate recess is then formed in the laminated sheet to create a finger grip area. Next, a peripheral flange is formed along a part of the periphery of the sheet, leaving an end portion of the sheet unflanged. The unflanged end portion is manually bent to form an arcuately curved portion with a preliminary curvature. A press die is used to impart a sharper curvature to the curved surface and to perform flanging on the unflanged end portion so as to extend the existing flange along the periphery of the sheet. The extended flange is then ironed to remove any wrinkle.

Abstract: A method for bending a perimeter light and a perimeter light for illuminating curved surfaces. One embodiment of a bending method according to the present invention comprises heating a perimeter light to make it pliable. A radius tool is then provided having a curved surface with a shape and radius for the desired bend in the perimeter light. The heated perimeter light is mounted to the radius tool curved surface. The perimeter light is then cooled and removed from the radius tool.

Abstract: In a continuous molding apparatus equipped with a long core 10 having a curvature disposed on a plane, a release film supplied from a lower release film feeder 20 is sent onto the core 10, and prepreg sheets supplied from a prepreg sheet feeder 30 are laminated thereon and preformed. A release film supplied from a release film feeder 40 is disposed on top of the laminated body, before the body is sent into a hot press 50. A puller 60 moves the laminated body without loading tension thereto. The laminated body enters a postcure device 70 in which thermosetting of the material is completed.

Abstract: A method and apparatus for shaping a section bar (for example, a “T-shaped” or “J-shaped” stringer) made of composite material is provided. The method comprising the steps of placing the stacked reinforced-fiber sheets on a pair of side presses opposing to each other with a predetermined gap; inserting a punch through the gap from above to fold the stacked reinforced-fiber sheets in half, while holding ends of the stacked reinforced-fiber sheets between upper surfaces of the side presses by block members; drawing out the punch upward and then pressing the stacked reinforced-fiber sheets folded by the side presses therebetween. A shaped product shaped thereby is high quality in which a distortion (“fluctuation”) of the stacked reinforced-fiber sheets in the inner side ply or plies of bending does not occur and ends of the stacked reinforced-fiber sheets are aligned between plies.

Abstract: A group of multiple hollow fibers may be shaped to introduce angular divergence among the fibers, or to introduce a selected longitudinal oscillation into the fibers. In one shaping technique, the fibers are held in parallel while upper and lower crimping assemblies of parallel crimping bars are drawn together on opposite sides of the parallel fibers. When bars of the opposing assemblies draw sufficiently close, they sandwich the fibers in between them, causing each fiber to assume a shape that oscillates as the fiber repeatedly goes over and then under successive bars. Since the crimping bars are aligned at oblique angles to the fibers, the peaks and troughs of successive fibers are offset. While in this position, the fibers are heated and then cooled to permanently retain their shapes. A different shaping technique utilizes a lattice of criss-crossing tines defining multiple apertures. In this technique, the lattice and fibers are positioned so that each fiber passes through one of the apertures.

Abstract: A sample tube for injection molded with two cores in one base with an intermediate bottom forming a well for receiving the biological material. In a second stage, the bottom edge of the cylindrical wall is heated and turned inwardly to form preferably a rounded bottom of complementary contour to a stamp applied thereagainst in a thermal reforming operation.

Abstract: An elongated composite tube made up of an inner tube 42 and an outer tube 44 (see FIG. 3) with a plurality of elongated helical ribs disposed between the inner tube and the outer tube in a supporting relationship to both. A slinky like toy made from the composite tube is also disclosed, as is a method of making both.

Abstract: Methods for making a tubular device that has a rim disposed at one end thereof. In one method, a sleeve having an expandable profiling surface is inserted into an end of the tubular member, and the profiling surface is expanded to form a shoulder projecting outwardly from the tubular member adjacent the end of the tubular member. The profiling surface is collapsed inwardly away from tubular member, and a return margin is formed directed inwardly from the shoulder, distal the tubular member. In another method, return margin of the tubular device adjacent an end is folded inwardly and superposed on an inner surface of the tubular device adjacent the folded margin. A sleeve having an expandable profiling surface is inserted into the end of the tubular device, and the profiling surface is expanded to form the rim comprising a shoulder projecting outwardly from the tubular member and the return margin. As a result, the fold between the shoulder and the return margin defines an edge of the tubular member.

Abstract: The texturing, patterning and bending of a solid surface material. The end product can be achieved both through casting technologies and heat pressure processes. Controlled surface deformation can be created in a pre-manufactured flat sheet and the sheet can then be heated and bent using conventional thermoforming technology. This contrasts considerably with the conventional norm, whereby an embossed solid surface sheet, when reheated, loses its embossing.

Abstract: A method of making a catheter balloon or other tubular medical device or component, in which a sheet of polymeric material is wrapped on a mandrel and heated to fuse sections of the wrapped sheet together to form a tube. The mandrel has a metallic core and a jacket on an outer surface of the metallic core, and the wrapped sheet of polymeric material is heated without corroding the metallic core of the mandrel. In a presently preferred embodiment, the sheet is formed of a fluoropolymeric material, and the resulting fluoropolymeric tube forms at least a layer of a catheter balloon.

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 presently-preferred process for bending a workpiece includes placing a first portion of the workpiece on a substantially flat surface so that a second portion of the workpiece overhangs an edge of the substantially flat surface, and securing the first portion of the workpiece on the substantially flat surface by clamping the workpiece between the substantially flat surface and a substantially v-shaped end portion of a male die. The presently-preferred process also includes causing the second portion of the workpiece to pivot around a tip of the substantially v-shaped end portion by rotating a bending die around the tip while the bending die contacts the second portion of the workpiece.

Abstract: A method for manufacturing a long molding having an axial bend, includes: forming a long first member; performing an axial bending process for the first member, when the first member passes through a gripping portion; and extruding a heated and molten liquid resin molding material for formation of a second member through a second member molding opening of a second member extrusion die while following a bend of the first member to integrate the second member made of the molding material with the first member. The second member extrusion die has a changeable substantial opening shape of the second member molding opening. The second member having a different cross sectional shape between one part and the other part in the longitudinal direction is extruded in accordance with a change of the opening shape.

Abstract: A method and system (10) having a flowable pressure pad (22) for consolidating an uncured laminate sheet (14) during a cure cycle is provided. The system (10) includes an autoclave machine (12) for utilizing a pinmat (20) for to perforate and consolidate the sheet (14). This pinmat (20) has a mat portion (28) and a plurality of pins (26) extending from the mat portion (28). These pins (26) are intended to penetrate the uncured laminate sheet (14) during a perforation cycle that occurs prior to the cure cycle. During the cure cycle, the autoclave machine (12) applies a predetermined amount of and pressure heat to the pressure pad (22) for a predetermined amount of time so as to cause the pressure pad (22) to flow around the protruding pins (26). This feature allows the pressure pad (22) to transfer a substantial portion of the applied pressure to the uncured laminate sheet (14) so as to improve consolidation of the sheet (14).

Abstract: It is disclosed a method for producing thermo-insulating cylindrical vacuum panels starting from planar panels, which comprises subjecting the planar panel (1) to a calendering operation, passing it through at least two rollers (2, 3) and a third element (4).

Abstract: A laminated multi-electrode biocompatible implant, comprising a first layer of flexible, biocompatible dielectric material having a first, exposed surface. A second layer of flexible biocompatible dielectric material, is adhered to the first layer. Further, a third layer of flexible biocompatible dielectric material is adhered to the second layer. Additionally, a first conductive trace is interposed between the first layer and the second layer and a second conductive trace interposed between said second layer and said third layer. Finally, a first conductor, which breaches said first layer, conductively connects the first conductive trace to the exposed surface of the first layer, thereby forming a first electrode and a second conductor, which breaches the first layer and the second layer, conductively connects the second conductive trace to the exposed surface of the first layer, thereby forming a second electrode.

Abstract: A method of manufacturing a ski for creating a preload force upon a front portion of a ski combination with a resilient preload member. The method basically including the steps of molding an elongate ski body having a front portion in a position P1, removing the elongate ski body from the mold after solidified, applying a force upon a front portion of the elongate ski body thereby bowing the front portion into position P2, securing a preload member to the front portion and a middle portion of the elongate ski body, and releasing the force applied to the front portion whereby the resiliency of the front portion deforms the preload member until the front portion is into position P3. Position P1 of the elongate ski body is preferably less than 20 degrees with respect to a longitudinal axis of the elongate ski body.

Abstract: This ribbon (3) used in binding and decorating has the feature of comprising preferably two separate superposed flat films of polyolefin plastic which are bonded or glued together to form an intimate union, said union involving basic films differing form each other by their elastic elongaton and/or heat-shrinkage properties such that, on leaving the production equipment, said difference between said films results in a different extent of shortening between the two said films, to hence cause curving of their constituted assembly, said curving being contained within a range of elastic deformation compatible with the curvature connected with subsequent winding of the ribbon formed by said layers onto usual reels (10) by usual methods, and such as to create spontaneous curling of the ribbon (11) at the ambient temperatures at which it is used, as soon as it is unwound from said reel (10).

Abstract: A method for producing an embossed PVA film, which includes embossing the film such that the crystallinity index of the emboss top is 0.50-0.90. The invention provides an embossed PVA film superior in resistance to blocking even when in a rolled state, in appearance to show the high quality of products, and in resistance to pinholes.

Abstract: A method and apparatus for forming catheters and catheter curves using ferromagnetic materials exposed to an alternating magnetic field. Heat is generated in the exposed ferromagnetic material. The temperature of the ferromagnetic material is allowed to reach a desired temperature, preferably the Curie temperature of the ferromagnetic material containing portion. The heat generated is transferred to a catheter, wherein the catheter can be selectively formed or assembled and bonded at the desired elevated temperature.

Abstract: The invention relates to a reinforcing bar for mineral building materials, particularly for cement. The inventive reinforcing bar (10) is made of a bar of plastic material reinforced by fibre, which has a central, elongate core (12) and several ribs (14) which extend along the length of the core, which are disposed at an angular distance from each other, which form a cross or a star in the cross section thereof and which are twisted around the core axis (16) in a helical manner.

Abstract: A method for preparing a hollow tube of shrinkable polymeric material by providing a hollow tube in an expanded state and partially contracting a portion of the length of the hollow tube. A first length in the expanded state is folded over a second length in the partially contracted state. A body such as a length of electrical cable is inserted into the hollow tube, and the first length is unfolded so that it no longer overlies the second length. The first length and the second length are contracted to the fully contracted state over the body.

Abstract: A method of manufacturing an improved comb for a disk wound transformer. The method comprises the steps of providing a web of cellulose material; removing a portion of the cellulose material to create a plurality of longitudinal slits along the length of the web, wherein the longitudinal slits have a fixed length and width; and folding the web along a line proximate the midpoint of the length of each of the longitudinal slits such that the cellulose material adjacent the longitudinal slits defines a plurality of tooth members.

Abstract: A pipe section formed of a polymeric material which has a substantially constant thickness throughout, the terminal edge of the female connection having a reinforcement structure which rigidifies the end of the female connection and prevents deformation, the pipe section preferably having a flared end, and the reinforcement structure preferably being a semicircular channel formed at the end of the pipe section by a mandrel after initial extrusion of the pipe section; along with a method and apparatus for forming the pipe section, a pipe assembly including such pipe section, and a method of forming the pipe assembly.

Abstract: An ultrasonic flowmeter of the present invention has a pipe (2) through which a fluid to be measured flows, and measurement portions (3) separated on the pipe by a predetermined distance along the longitudinal direction of the pipe. The measurement portions each comprises a transducer fixing member (4) having an arc shaped indentation (6) into which a part of the pipe can be fitted, and a piezoelectric transducer (5) fixed to the transducer fixing member. The pipe and the arc shaped indentation are closely fixed to each other by an adhesive (7) by fitting and pressing the pipe into the arc shaped indentation via the adhesive.

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: A tamper indicating closure according to the present invention includes a top wall and a skirt depending from the top wall. A tamper indicating band is connected to the skirt along a frangible line. The tamper indicating band includes a ring and at least one tab, the at least one tab having a bi-stable geometric shape. In particular, the tab includes a pair of extending members angled toward one another and connected by a transverse member. The shape of the tab allows it to be molded in a downward orientation and later folded to a stable, upward orientation without reheating or otherwise resetting the tab.

Abstract: An apparatus includes several bending units for forming a singly-bent or doubly-folded edge rim around the perimeter of a molded component, e.g. a laminated contoured interior trim component for a motor vehicle. Each bending unit includes an electrically heatable cutting or impressing tool, and a bending tool. A workpiece holder clamps the component into a forming mold. The heated impressing tool melts and presses one or two grooves forming weakened zones and corresponding bending lines in the edge rim of the component. The bending tool then presses and bends the edge rim flange back along the bending line. Optionally, the bending tool additionally bends the free edge flange portion down along the second bending line to form the doubly-folded rim. The portions of the rim folded against each other are melt-bonded together and then cooled to permanently fix the bonded and folded configuration of the rim.

Abstract: A method of manufacturing a sealing device by preparing a mold for molding both a rubber-like elastic material and a resin material, the resin material having a flat washer shape, inserting an outer diameter portion of the resin material into a mold cavity of the mold, and adhesively baking the rubber-like elastic material to the outer diameter portion of the resin material together with the molding of the rubber-like elastic material. An inner diameter portion of the flat washer shape resin material is pressed by a mold part adjacent to the mold cavity in utilization of a mold clamping pressure, the pressed inner diameter portion of the resin material is bent at an elevated temperature by a mold part to form a resin lip, arranged so as to not interfere with the rubber seal lip, and the sealing device produced is separated from the mold.

Abstract: Methods for bending preformed thermoplastic extrusions having at least one cavity comprise filling at least one of the extrusion cavities with polymer foam and curing the foam within the filled cavity. An extrusion is heated to allow plastic deformation and then smoothly bent over a mandrill to impart a desired curved shape. Following cooling to below the extrusion's plastic deformation temperature on the mandrill, smoothly curved extrusions are removed for cooling to room temperature. Cured polymer foam within an extrusion cavity resists distortion of the cavity during the bending process.

Abstract: The invention is a method of making a foam filled honeycomb core structure comprising the steps of: 1) providing a honeycomb core billet; 2) reinforcing the honeycomb core with foam; 3) placing the foam filled billet in mold having a curved mold surface; 4) creep forming the foam filled billet to the general shape of the structure by applying a load to the foam filled billet; and 5) machining the creep formed billet to the actual shape of the structure.