Abstract: The present invention relates to a method for preparing a biodegradable piece for medical use including the steps of: a) preparing a mixture including glycerol and sebacic acid, b) pouring said mixture into a one-piece mould made of elastic material, c) placing the mould containing said mixture on a support, d) placing the support into a chamber with controlled temperature and vacuum level until a polymer having the desired consistency is obtained, e) removing the support from the chamber and allowing it to cool down to room temperature, and f) removing the piece thus obtained from the mould.

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: The present invention relates to an apparatus and method for forming molded tapered products, such as masonry blocks, whereby high quality finished products are removed from their mold without the need for complex machinery for demolding. The mold may include one or more mold cavities having one or more movable cavity walls. The movable cavity walls may include an end liner having a planar product forming surface capable of moving from a vertical position to an angled position. Tapered products may be formed by moving the mold towards a pallet so that the pallet engages with the end liner and causes the end liner to move from the vertical position to the angled position. Moldable material may then be introduced into the mold cavity and may be allowed to remain in the mold cavity until it is self-sustaining. The mold may then be moved away from the pallet such that a molded product remains on the pallet, thereby allowing the end liner to move from the angled position to the vertical position.

Abstract: The present invention relates to methods of making microstructures with a flexible mold (100), microstructure precursor compositions and particles.

Abstract: A stepwise contraction and adsorption nanolithography (SCAN) patterning process can shrink complex microstructures (produced by current microfabrication technology) into the nanometer region. The basis of SCAN is to transfer a pre-engineered microstructure onto a extended elastomer. This extended elastomer is then allowed to relax, reducing the microstructure accordingly. The new miniaturized structure is then used as a stamp to transfer the structure onto another stretched elastomer. Through iterations of this procedure, patterns of materials with pre-designed geometry are miniaturized to the desired dimensions, including sub-100 ran. The simplicity and high throughput capability of SCAN make the platform a competitive alternative to other micro- and nanolithography techniques for potential applications in multiplexed sensors, non-binary optical displays, biochips, nanoelectronics devices, and microfluidic devices.

Abstract: A single piece co-cured composite wing is disclosed. The wing has a flying surface and structural members. In one embodiment the structural members may be a plurality of spars. The spars may have various shapes to increase the buckling strength. The spars may be wave shaped, such as a sinusoidal shape. The flying surface and the structural members are co-cured in order to form a single piece, integral wing structure. A process for manufacturing a single piece co-cured wing is also disclosed. The process may include laying out composite sheets for the flying surface of the wing. Then, the composite material of the spars is arranged around a plurality of pressurizable forms. Finally, the composite material is cured in a clamshell frame.

Abstract: Disposable units in current use for performing PCR are limited by their heat block ramping rates and by the thermal diffusion delay time through the plastic wall as well as by the sample itself. This limitation has been overcome by forming a disposable plastic chip using a simple deformation process wherein one or more plastic sheets are caused, through hydrostatic pressure, to conform to the surface of a suitable mold. After a given disposable chip has been filled with liquid samples, it is brought into close contact with an array of heating blocks that seals each sample within its own chamber, allowing each sample to then be heat treated as desired.

Abstract: Manufacturing process for a flexible tube, in which a tubular blank is fitted around a punch so that an end portion of the tubular blank protrudes by a height H from the side wall of the punch; a die is brought up to the punch and the end portion is imprisoned in the cavity thus formed; plastic is injected into the cavity until it comes into contact with the end portion so that it is welded to the skirt, without any additional contribution of heat or matter. The impression of the die used is at a depth greater than the protruding height H of the end portion, and has a ring-shaped boss obstructing the flow of the plastic, the outer edge of the ring-shaped boss and the inner edge of the end portion being distant from each other by a value less than the average thickness e of the transverse wall.

Abstract: An orthopedic implant device and method is disclosed. Specifically, a knee mold system is disclosed, including elastic tibial and femoral molds, each of which may be configured and dimensioned as a unitary mold for in situ placement during a surgical procedure. Each mold may be manufactured from an elastic material that may be disposable. The tibial mold may further comprise a sidewall forming a cavity, markings for relative depth measurement, and depth rings for use as a guide for scoring, cutting, and/or trimming and tearing away an excess portion of the tibial mold. The femoral mold may further comprise a sidewall defining a cavity, two legs extending from a body of the femoral mold for forming the artificial condyles, and an eyelet for aiding in placement and removal of the femoral mold. The resulting prosthetic tibial and femoral components may form an articulation surface that mimics, at least in part, the natural articulation surface of the knee.

Abstract: A method of fabricating and using a removable, inflatable mandrel of shape memory polymer for use in manufacturing composite parts including the steps of providing a processed pre-form of shape memory polymer, replicating a mold with the shape memory polymer, using the mold as a mandrel in the creation of composite parts, and removing the shape memory mandrel quickly and easily from the part without damage to the finished part.

Abstract: The instant application provides a fluidic array device having an elastomeric body that provides easy fluidic control of the device. The elastomeric body may include plurality of intersecting row and column channels. Reactions may occur at the intersection spots formed by the intersecting channels. Pinching applied at suitable locations along the channels enables the channels to be opened or closed, and thus provides control of fluids pumped through the device. The surfaces of the channels and intersection spots may be engineered to have certain properties. In particular, the intersection spots may be nanoengineered to have surface properties differing from those of the channels, and thus reactions may be selectively controlled to occur only, or highly preferentially, in the intersection spots.

Abstract: An apparatus for applying to the cups of a bra, or to the overall bra, a casing for housing therein a cup supporting element, comprises at least two bobbins, one supporting a resilient element or casing, and the other supporting an adhesive having a protective silicone processed paper, a first hot-applying device for binding the casing to the adhesive material, and a programmable tensioning device, applying to the adhesive processed casing an adjustable pulling force.

Abstract: A method comprises steps of extruding rubber or synthetic resin mixed with short fiber from a mold opening 6 of sectionally annular and molding a cylindrical body of rubber or synthetic resin with short fiber oriented in predetermined direction. And the mold opening 6 is passed through with an expansion portion 9 whose diameter expands in extrusion direction, and a flow passage width Wi of an inlet portion 6i of the mold opening, a flow passage width Wo of an outlet portion 6o, and radiuses Ri and Ro of the inlet portion 6i and the outlet portion 6o respectively that are coaxial with the mold opening satisfy a relation of Wo/Wi<Ro/Ri. And value of Ro/Ri is adjusted within a scope of 2?Ro/Ri?8 by changing the radius Ri of the inlet portion according to mechanical property in circumferential direction of the cylindrical body to be molded, so that orientation of the short fiber is adjusted.

Abstract: Provided are a method and system for imprinting a pattern formed on surfaces of an imprint mask onto a double-sided substrate. A method includes deforming the surfaces of the first and second imprint stamps to produce respective first and second deformed surfaces, each having an arc therein. A Pressure is applied to bring the deformed first and second surfaces into intimate contact with the first and second substrate surfaces, respectively. The applied pressure substantially flattens the deformed surfaces. And to separate the two surfaces, the applied pressure is released.

Abstract: A method of making a fluid cooled microelectronic package in which fluid is circulated through the package in fluid-carrying channels defined at least in part by voids in an encapsulant that surrounds the package components. Preferably, the encapsulant channels are defined in part by heat producing components of the package so that coolant fluid directly contacts such components. The coolant fluid can be electrically conductive or non-conductive depending on the type of components being cooled. The coolant channels are formed by insert-molding a form in the encapsulant, and removing the form following the molding process. Alternately, the encapsulant is formed in two or more pieces that are joined to form the package, and the coolant channels are defined by recesses formed in at least one of the encapsulant pieces.

Abstract: A motor vehicle wheel frame is integrally molded in a split mold including a lower mold portion (12) and a complemental mold portion. Channel-like spoke forming formations (12.1) receive layers (24.1) of molding material wrapped around heat expanding, resilient intensifiers (20) which are inwardly checked by resilient locking inserts (22) partially within a hub cavity and abutting a cylinder (18). During demolding, after curing, the locking inserts (22) and thereafter the intensifiers (20) are removed by longitudinally stretching and cross-sectionally reducing them, leaving the spokes hollow. During curing, the heat expanding intensifiers pressurize the spoke forming layers of molding material against the mold portions.

Abstract: An aircraft stringer lay-up assembly is provided comprising a contoured curing block and a first mandrel element positioned thereon. The first mandrel assembly includes a first bar assembly having a plurality of rigidity reducing first slots formed along a first mandrel length. The plurality of rigidity reducing first slots protruding partially through a first mandrel depth of the first mandrel element to allow the first bar assembly to conform to the contoured curing block. A composite ply assembly is laid up onto the first mandrel element and cured while conformed to said contoured curing block such that a contoured composite stringer element is generated.

Abstract: The present invention relates to a substrate-supported process for continuous and automated manufacturing of microfibrous fuel cells and other electrochemical cells. Specifically, a removable substrate layer is formed around an inner current collector, followed by sequentially coating multiple structure layers, such as the inner catalyst layer, the membrane separator, and the outer catalyst layer, over such removable substrate layer, and subsequent removing such removable substrate layer, so as to form a lumen around the inner current collector, to allow passage of fluid therethrough. The removable substrate layer preferably comprises a water-soluble polymer, such as polyvinyl pyrrolidone (PVP), polyvinyl alcohol (PVA), or polyethylene glycol (PEG).

Abstract: A method of manufacturing a hybrid structure (100) having a layer of CMC material (28) defining an interior passageway (24) and a layer of ceramic insulating material (18) lining the passageway. The method includes the step of casting the insulating material to a first thickness required for effective casting but in excess of a desired second thickness for use of the hybrid structure. An inner mold (14) defining a net shape desired for the passageway remains in place after the casting step to mechanically support the insulating material during a machining process used to reduce the thickness of the insulating material from the as-cast first thickness to the desired second thickness. The inner mold also provides support as the CMC material is deposited onto the insulating material. The inner mold may include a fugitive material portion (20) to facilitate its removal after the CMC material is formed.

Abstract: A method of producing a molded article includes the steps of positioning an insert within a first mold, and filling the first mold with a low melt allow to form a lost core assembly. The lost core assembly includes an external shape corresponding to the desired cavity formed within the molded article. The inserts are supported within the lost core and form a part of the surface of the cavity of the completed molded article. The lost core assembly is over-molded with a thermoplastic or thermoset material. The alloy material is removed leaving the inserts within the molded article to form specific portions of the cavity.

Abstract: A method of making an inert anode (12?) for use in an electrochemical cell first provides a hollow shaped mold (12) where a metal mandrel (17?) having raised male threads (50) at its top diameter (52) is inserted into the mold (12) and a compressible powder (19, 21) added, then the powder is compressed to form recessed female grooves (70) matching the mandrel threads (50) where the mandrel (17?) is engaged and withdrawn along with the compressed powder inert anode after which the mandrel is rotated to unscrew it from the compressed powder and the compressed powder shape is then placed on a tray (27) and heated to sintering temperature.

Abstract: The invention relates to method for overmolding a painted silicone prosthesis of a human extremity. A silicone prosthesis is first molded from a solid replica of a human extremity and then painted to closely resemble the color of the recipient person. An elasotmeric polymer material having the properties of elasticity, transparency, and non-adhesiveness to cured silicone rubber is applied to the replica to form a transparent glove-like overmold. The glove has an inner surface that is mirrored by the surface of the replica. The distal portion of the glove-like overmold is partially filled with a predetermined amount of viscous uncured silicone liquid and the painted silicone prosthesis is then inserted into the glove which is stretched tightly over the prosthesis. A compressive force is externally applied in a radial compressive and proximate direction to uniformly distribute the liquid silicone over the painted surface of the prosthesis.

Abstract: A method for manufacturing a wax mold of a golf club head includes steps of positioning a male die assembly in a first cavity of a first female die, injecting dissolvable wax into the first cavity to form a dissolvable wax mold, removing the first female die to take out the solidified dissolvable wax mold, positioning the dissolvable wax mold and the male die assembly in a second cavity of a second female die, injecting wax for precision casting into the second cavity to form a head wax mold, removing the second female die to take out the solidified head wax mold, and injecting solvent into the head wax mold to dissolve the dissolvable wax mold.

Abstract: Disclosed is a method for producing a three-dimensional composite structure and a method for producing the mold for the three-dimensional composite structure. The mold is formed of at least one rigid die member and a second thermoplastic die member. The second thermoplastic die member is formed by coupling a rubber flexible pattern to a surface of the first die member. Vacuum or pressure is applied to a heated thermoplastic sheet to cause the heated thermoplastic sheet to deform about the flexible pattern, thereby forming the second die. Strips of reinforced polymer thermoset pre-preg material are then positioned within the cavities formed by the flexible pattern and are allowed to cure. Optionally, heat, pressure, and vacuum may be applied to the mold construction to facilitate the curing of the thermoset materials.

Abstract: A two-sided inmold molding method utilizing continuous film passing between a stationary mold and a movable mold, which thereby prevents cut scraps from being mixed into a molded product and prevents striking pock from being formed on the molded product, and which is capable of enhancing the yield of the molded product.

Abstract: A method of forming microstructures on a substrate is disclosed. A microstructured assembly that may be used in the method for forming microstructures on a substrate is also disclosed. The methods and assemblies of the present disclosure can reduce the amount of air entrapped in barrier ribs formed on substrates used in Plasma Display devices.

Abstract: A reef artifact for simulating a coral reef includes a reef-like formation, which forms a base structure for simulating coral. The reef-like formation also has structures on it that simulate reef organisms. The reef-organism structures enhance the varied and diverse coral-like surface of the reef-like formation. The reef artifact is also configured to be mounted on a sea wall or a sea floor. The reef artifact dampens the force of waves and water currents thereby reducing erosion of the sea wall. The reef artifact also provides a suitable marine environment for microorganisms and small marine animals, thereby creating a diverse marine habitat. In yet another use, the reef artifact is suited for use as a sculpture in a garden or on a patio.

Abstract: A method and apparatus is provided for molding a semiconductor device in a mold including two mold halves. One mold half includes a compressible sealing mechanism constructed and configured to exert a sealing pressure between a surface of the mold half and a surface of a semiconductor device located in the mold. A compliant tape is positionable onto the mold half comprising the sealing mechanism between the semiconductor device and the sealing mechanism for molding of the semiconductor device.

Abstract: Precisely configured, especially of geometric shape, flakes of liquid crystal material are made using a mechanically flexible polymer mold with wells having shapes which are precisely configured by making the mold with a photolithographically manufactured or laser printed master. The polymer liquid crystal is poured into the wells in the flexible mold. When the liquid crystal material has solidified, the flexible mold is bent and the flakes are released and collected for use in making an electrooptical cell utilizing the liquid crystal flakes as the active element therein.

Abstract: A mold for manufacturing a corner-shaped simulated stone product has a mold cavity configured to imprint a stone texture on at least a first side face and a front face of the corner-shaped product. The mold also provides a back face with a desirable molded interior angle. The mold cavity can have a flexible edge around a perimeter of the mold cavity to impart a textured surface to a second side face of the corner-shaped product.

Abstract: Molded structures, methods of and apparatus for producing the molded structures are provided. At least a portion of the surface features for the molds are formed from multilayer electrochemically fabricated structures (e.g. fabricated by the EFAB™ formation process), and typically contain features having resolutions within the 1 to 100 ?m range. The layered structure is combined with other mold components, as necessary, and a molding material is injected into the mold and hardened. The layered structure is removed (e.g. by etching) along with any other mold components to yield the molded article. In some embodiments portions of the layered structure remain in the molded article and in other embodiments an additional molding material is added after a partial or complete removal of the layered structure.

Abstract: A method for molding composite structures whereby a material stack including a core having first and second opposing sides is prepared. The preparing of the material stack includes applying a fibrous support layer on at least one of the first side and the second side of the core section, applying an adhesive layer on the support layer, and applying a thermoplastic barrier layer on the adhesive layer. The method also includes preparing a resin and a mold; placing the material stack in the mold; sealing the core; infusing the mold and material stack with resin; curing the structure; and removing the structure from the mold. In one embodiment, the method creates a composite aircraft wing panel.

Abstract: A method for manufacturing a composite structure is disclosed herein. The process uses a frame and selectively pressurizable forms. The forms define the interior members of the composite structure and frames define the exterior surface of the composite structure. Composite material is wrapped around the forms and the forms and composite material are placed in the frame. Selective forms are then pressurized and the composite material is co-cured together. A single piece co-cured fuselage incorporating a plurality of stiffeners is also disclosed in the application. The stiffeners are co-cured to the fuselage and may be in various patterns. The patterns may include an iso-grid pattern, and ortho-grid pattern, and a hoop-grid pattern.

Abstract: For manufacturing a moulded article comprising at least an elastomeric polyurethane skin (9) and optionally a structural backing layer (10) and an intermediate foam layer (12) a mould is used having at least a first mould part (1) comprising at least two mutually movable mould sections (2-4). The skin (9) is moulded with its front against a surface (7) of the first mould part (1) by applying at least one reactive polyurethane mixture to this mould surface. In order to prevent the seam between the mutually movable mould sections (2-4) of the first mould part to leave traces on the front of the moulded skin (9), the first mould part (1) further comprises a removable, flexible liner (6) which is positioned onto these mould sections to cover at least partially the seam therebetween.

Abstract: The invention provides a novel thermoplastic molding process useful in the manufacture of hollow, deformable thermoplastic articles such as hollow doll heads. In the process of the instant invention, a parison is formed at a first injection station and is transferred to a blow mold station. At the blow mold station, the parison is transformed into a hollow, deformable thermoplastic article through application of a vacuum and gas injection. Articles made by the process of the instant invention have a highly realistic appearance and texture.

Abstract: A machine and method for moulding a composite of complex nodal structure includes laying down under CNC a reinforcement (38) of constant cross-section repeatedly into and along channels (26) of a mold (24) and through nodes of the structure, closing the mold, impregnating it with resin and curing the resin.

Abstract: An aircraft barrel lay-up assembly is provided comprising a barrel mandrel assembly having a contiguous outer barrel lay-up surface. A minor barrel outer surface element is movable between a minor barrel engaged position and a minor barrel disengaged position and forms a minority portion of the contiguous outer barrel lay-up surface when in the engaged position. A major barrel outer surface element is movable between a major barrel engaged position and a major barrel disengaged position. The major barrel outer surface has a first major barrel surface end and a second major barrel surface end moving together to reduce an effective major barrel outer surface circumference when in the major barrel disengaged position. A composite ply assembly is formed around the barrel mandrel circumference and cured while coincident to form a composite barrel element.

Abstract: The method of transferring a coating onto articles having skew surfaces comprises the steps of applying a coating on the articles, which coating is carried by a transfer support that has a pyrolysis temperature lower than a melting temperature of the coating, the coating itself having a sealing temperature lower than the pyrolysis temperature of the transfer support, and then of subjecting articles coated in this way to the melting temperature of the coating.

Abstract: A connector element for connecting frame parts at a joint location in a bicycle frame is made of a single part of structural fiber based material, typically carbon fiber material, after reticulation in a mold exploiting the expansion of a core on which windings of fiber fabric material are provided, to obtain the application of a uniform radial pressure on the layers of fiber based material. In one embodiment, the connector element defines a bicycle bottom bracket and tubular extensions extending therefrom for connection to elements of the bicycle frame.

Abstract: A mold assembly for producing a molded object from resin. The assembly includes a cavity configured to be filled with resin to form at least one surface of the molded object into a predetermined shape with at least one transfer surface of the cavity. A molding insertion member is arranged to form another surface of the molded object, and a holding insertion piece is configured to hold the molding insertion member. The holding insertion piece includes a communication path that places a surface of the molding insertion member at a side opposite to the cavity in fluid communication with the exterior of the mold assembly and guides air from the exterior of the mold assembly toward the surface of the molding insertion member.

Abstract: A connector element for connecting frame parts at a joint location in a bicycle frame is made of a single part of structural fiber based material, typically carbon fiber material, after reticulation in a mold exploiting the expansion of a core on which windings of fiber fabric material are provided, to obtain the application of a uniform radial pressure on the layers of fiber based material. In one embodiment, the connector element defines a bicycle bottom bracket and tubular extensions extending therefrom for connection to elements of the bicycle frame.

Abstract: The invention relates to a mold for manufacturing a stick, in particular for cosmetic use. The side wall of said mold has zones of weakness for making the mold easier to deform radially, said zones of weakness being obtained by means of recesses formed in the side wall of the mold and extending longitudinally over substantially the entire height of the mold starting from its bottom end.

Abstract: A method of manufacturing a large double-sided curved Fresnel lens. The method includes a machining step (A) of performing ultra-precise three-dimensional machining on an upper mold and a lower mold to each have an upper transfer surface and a lower transfer surface engaging an upper surface and a lower surface of a thermoplastic resin plate, respectively. Further, the method includes a hot press molding step (B) of pressing the thermoplastic resin plate between the upper and lower molds by a predetermined pressure with the resin plate being held at a temperature higher than a softening temperature thereof and lower than a melting temperature thereof so that the thermoplastic resin plate is curved, and both lens surfaces for the double-sided Fresnel lens are respectively transferred to an upper surface and a lower surface of the thermoplastic resin plate.

Abstract: The production of pouch-shaped or pot-shaped parts is undertaken in two steps. In the first step, a film located above a die is pressed by a stamp into a cavity that reproduces the part and is subsequently pressed apart in the lower region of the cavity by deformation of the stamp in this region. The device has a rubber-like stamp that expands out on all sides once it has reached the bottom wall of the cavity and causes the film to conform to the shape of the cavity. The stamp is preferably designed in two parts, wherein a stamp insert is guided within a stamp guide and the stamp insert then has at least one deformable region. For removal of the formed film, provision is made that the die can be swung open.

Abstract: A method for manufacturing a molded structure in a press that includes a first mold and a second mold is provided. The second mold has a plurality of pressure actuators, with each pressure actuator capable of independent operation. The method includes the steps of positioning a preform having a thickness in the first mold, placing a quantity of resin adjacent the preform so as to create a resin reservoir, and then selectively actuating one or more of the pressure actuators apply pressure to the resin reservoir to force at least a portion of the resin reservoir to infuse through the thickness of the preform. The method may also include curing the resin-infused preform, and then removing the cured resin-infused preform from the first mold.

Abstract: A unitary polymer substrate having a plurality of microfibers projecting from a surface is provided. The presence of the microfibers greatly increases the surface area and can impart a cloth-like feel to the surface. The projecting microfibers may have a variety of forms, including frayed-end microfibers, tapered microfibers, microfibers having an expanded cross-sectional shape, and microfibers having a very high aspect ratio. A number of methods of producing unitary polymer structures with a plurality of projecting microfibers are also provided.

Abstract: There is provided a method for manufacturing a structural body comprising: a structural body formation step of forming the structural body by combining a plurality of constituent members through a bonding adhesive; a closed space formation step of disposing the structural body into a pressurizing or heating unit, forming a closed space with at least one of the structural body and the pressurizing or heating unit, and charging an elastic body into the closed space; a hardening step of fixing or hardening the bonding adhesive through the elastic body by the pressurizing or heating unit; and a discharge step of discharging the elastic body from the closed space.

Abstract: A method for the layer-by-layer assembly of a free standing thin film includes the steps of preparing a support with a suitable substrate; forming a thin film having a plurality of layers onto the substrate utilizing a layer-by-layer assembly process; removing the substrate and thin film from the support; and separating the substrate from the thin film. Various compounds improving the strength, flexibility, tension and other mechanical properties may be included in the assembly to improve the structural quality of the film. Similar effect may also be achieved by cross-linking the applied layers.

Abstract: Disclosed herein is a press and mould apparatus for moulding cementitious articles comprising a precast mould and a press head having a pressing surface and being moveable between precast mould engaging and disengaging positions, wherein the pressing surface comprises a coating of deformable and resilient material such as urethane. Also disclosed is a process for moulding building blocks. This process comprising filling a precast mould with material, such as concrete, this is to be pressed; and pressing the material with a pressing surface comprising a deformable and resilient coating so as to solidify the material into a green shape ready for cutting.

Abstract: A mold for producing a finished countertop on top of a countertop substrate is provided. The mold is comprised of a shaped inner surface to receive a countertop material pour and form a countertop edge and a tab extending from the shaped inner surface, the tab dimensioned to cover at least part of the substrate edge and extend over at least a part of the substrate top and hold the shaped inner surface adjacent the countertop substrate edge. Also included in the invention is a method of making a countertop using the mold.