Abstract: Opaque porcelains for use with metal cores in the manufacture of PFM restorations. The porcelains exhibit a coefficient of thermal expansion (CTE) substantially equal to or slightly above the CTE of the metal to which it is applied. The porcelains exhibit a CTE equal to or up to about 1.5×10−6/° C. higher than the dental alloys to which they are applied as the opaque. The porcelains are fabricated from a mixture of two frit compositions. A high expansion, leucite containing frit is combined with a low melting glass frit to provide a porcelain having an expansion in the range of 16.9 to about 18.5×10−6/° C. in the temperature range of 25°-600° C.

Abstract: A process and apparatus for producing fiber reinforced resin structures using vacuum assisted resin transfer molding technology, wherein the apparatus and process employ a first fluid impervious flexible sheet containing therein a resin port; a fiber containing preform; a primary vacuum line; a resin channeling means; and a secondary vacuum line. The fluid impervious flexible sheet is placed over or around the fiber containing preform to form a chamber to which the primary vacuum line is connected. The resin channeling means is positioned on top of the fluid impervious flexible sheet, exterior to the chamber containing the preform in a fashion so as to form a pocket between or around the resin channeling means and said fluid impervious flexible sheet to which the secondary vacuum is applied. Activation of the secondary vacuum causes formation of channels in the fluid impervious flexible sheet. These channels increase the speed and efficiency of resin impregnation of the fiber containing preform.

Abstract: A method of making a cold cured composite molded article utilizes a mold requiring pressure in only one dimension. The mold is filled with a composite material and closed. The mold is then inserted between two series of rollers, wherein the rollers are positioned at a specified distance from each other such that the proper amount of pressure is applied to the mold. The mold is propelled through the two series of rollers by motorizing at least some of the rollers. The cure time is controlled by controlling the speed at which the mold is propelled through the two series of rollers.

Abstract: The invention relates to a method for the manufacture of well equipment with permanently mounted ladder steps, and wherein the method uses mould parts for forming a mould cavity, which mould parts comprise mould elements that will, following discharge of the cast well equipment, leave a number of mounting apertures in the well equipment, which mounting apertures are located in such a manner that the anchoring parts of the ladder steps can be driven thereinto. The invention also relates to an apparatus for exercising the method, wherein the apparatus comprises a frame with a first arm on which a number of ladder-step grippers are configured, each of which being configured for receiving and securing at least one ladder step.

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 is provided for rapidly forming a cementitious panel. A cementitious mixture is introduced into a mold configured to provide the desired surface appearance and profile of the cementitious panel. The cementitious mixture is then subject to an accelerated curing process by applying microwave energy to the cementitious mixture for a predetermined time period. After a relatively short resting or cooling period, the resulting cementitious panel is ready to be removed from the mold.

Abstract: A method for manufacturing a molded structure in a press that includes the steps of positioning a preform (24) having a thickness in the lower mold (20), placing a quantity of resin adjacent the preform (24) so as to create a resin reservoir, and then selectively actuating one or more of the pressure actuators (28) to apply pressure to the resin reservoir to force at least a portion of the resin reservoir to infuse through the thickness of the preform (24). After the step of positioning, a top cover (32) may be placed upon the preform (24). The step of selectively actuating one or more of the pressure actuators (28) attached to an upper platen (60), may include a computer for controlling the pressure actuators (28).

Abstract: A method of producing an edible product of the sweets industry includes the steps of filling a liquid sugar mass into a mold to only partly fill the mold, the mold at least partly being made of an elastic and resilient material and including a wall, displacing the liquid sugar mass along the wall of the mold by a stamp element, and solidifying the sugar mass between the stamp element and the wall of the mold to attain a solid hollow body. The solid hollow body may then be filled with at least one additional mass to attain an edible product of the sweets industry. Finally, the product is ejected from the mold by at least partly reversing the elastic mold.

Abstract: A hexagonal telescopic column (6) for a lipstick (2) is produced using a mould (30) having opposed mould parts (32,34) including formations (38,40,42,44) which, with formations provided on the core (36), define a number of spaced apart cavities for forming the sections (46,48,50,52) of the telescopic column (6). The mould parts (32,34) are closed around the core (36) and a molten plastics material injected into the mould. The mould parts (32,34) are then opened leaving the column sections (46,48,50,52) exposed on the core (36). While the plastics material is still warm, the core (36) is retracted through a base plate (54) of the mould (30), pulling the column sections (46,48,50,52) towards the base plate (54) to collapse the sections together. The collapsed column is then removed from the mould (30) for assembly into a lipstick.

Abstract: A method of forming a socket on a pipe of thermoplastic material is disclosed. In the process, an end section of the pipe is heated in a heating station. Then, the pipe is transferred to a socket-forming station having a socket-forming mandrel. This is followed by the socket-forming mandrel being introduced into the pipe end section, heated to a suitable socket-forming temperature, and the end section being formed into a socket. Prior to the pipe end section being heated in the heating station, a support is introduced into the end section in order to internally support the end section. The support remains in the end section after the socket-forming mandrel is introduced into the pipe and in the process the support is pushed deeper into the pipe.

Abstract: A diaphragm chamber molding apparatus and method including a chamber for containing a mold surface therein; a bottom flexible diaphragm placed over and sealable with respect to the top of the chamber; a top flexible diaphragm placed over and sealable with respect to the bottom diaphragm for containing a lay-up between the top and bottom diaphragms; means for evacuating the area between the top and bottom diaphragms; and means for drawing the top and bottom diaphragms and the lay-up therebetween down over a mold surface located in the chamber to form the lay-up.

Abstract: Apparatus according to a disclosed embodiment are provided for molding a unit of a second material onto an article made of a first material. An inflatable, flexible bladder is fluidly connectable to a source of a pressurized fluid, such as compressed air. The pressurized fluid is used to inflate the bladder such that, when the bladder is at least partially inflated with the fluid, the article may be pushed against the bladder to invert the bladder and cause the exterior surface of the bladder to form a mold around at least a portion of the article.

Abstract: A method of forming a molded article and a molded article itself having a passage therein which has a cross-sectional dimension adjacent an end which is less than at a location which is spaced from the end are disclosed. In the method an elongate, rigid mandrel is covered over a substantial portion of its length with a flexible mandrel. The flexible mandrel, when covering the rigid mandrel, has an exterior surface which has a cross-sectional dimension which is less adjacent an end thereof than at a location which is spaced from that end. The flexible mandrel is then covered with a material which is to form the molded article with the rigid and flexible mandrels defining the mold about which the article is formed by the material. The material is then set to form the molded article about the mandrels with the mandrels defining the passage in the molded article.

Abstract: Improvements are disclosed for an apparatus for continuously molding small fastener elements integral with a base web from a flowable resin. The apparatus comprises a cylindrical mold roll rotatable about an axis and defining small fastener element-shaped mold cavities in the surface thereof, and pressure-applying means to apply operating pressure to force the resin into the cavities at a pressure zone. The pressure-applying means and mold roll define a mold gap therebetween for forming the base web. The advantageous use of relatively long mold rolls, to produce a correspondingly wide web, and the use of higher molding pressures, e.g. to form very small fastener elements, is enabled by various improvements, including means to maintain the mold gap at a desired thickness profile across the length of the molding region of the mold roll under operating pressure. In some cases the pressure-applying means includes a pressure roll, in other cases it includes a resin nozzle assembly or pressure head.

Abstract: A method and apparatus for making and/or decorating bowling balls and the like includes flexible transfer sheets with heat-activated ink applied to at least portions thereof. A form or mold with opposite halves, which shift between open and closed positions, includes a cavity sized to closely receive therein the article to be decorated. At least one transfer sheet is positioned in the mold with the article, such that when the mold is closed, the same are captured in the mold cavity in an overlying relationship. Heat is applied to the mold to a predetermined temperature causing the article to expand through thermal expansion, which expansion is resisted by the mold to uniformly press the transfer sheet against the underlying outer surface of the article, and also causing the heat-activated ink to transfer from the transfer sheet to the outer surface of the article to form the design thereon.

Abstract: A press forming die is fabricated by initially fabricating a die forming panel, by press forming, which provides a die surface for the press forming die. During fabricating the die forming panel, a shaped panel is obtained by initially press forming a first blank material with a die forming prototype and a punch forming prototype. Next, the shaped panel is mounted onto the punch forming prototype again and, thereafter, a die forming panel is obtained by press forming a second blank material. The die forming panel is then mounted on a frame body and a backup material is formed between a space between the frame body and the die forming panel, thereby fabricating the press forming die. Since the die surface of the press forming die can be shaped by press forming, the press forming die can be simply fabricated.

Abstract: A molding process for a composite article uses a textured film layer to shape the surface of the composite article. The film layer is placed in the mold with the textured film surface exposed and a composite material is placed over the textured film surface. Preferably, the film layer is vacuum-formed onto the mold to take the shape of the mold. As it cures, the composite article takes the shape of the textured film layer to form a textured article surface. After demolding, the film layer adheres to the article as a protective coating, but can be readily removed from the article to expose an underlying textured surface of the article.

Abstract: A simplified lost-core molding system that combines otherwise redundant features such as platens and hydraulic cylinders ordinarily found in separate core molding stations and product molding stations. The preferred system locates the core mold and the product mold between the platens of an injection molding machine and applies a common clamping force to the core mold and to the product mold.

Abstract: A method is shown for manufacturing a polyethylene jacket of the type used in pre-insulated piping systems. A mandrel is first coated with a brittle polymeric coating. A melt profile of polyethylene is then extruded onto the mandrel and spirally wound to produce adjacent windings. The adjacent windings make contact to form a finished jacket which is in engagement with the brittle coating. After the jacket has set, an external compressive force is applied to the tubular member thus formed sufficient to crush the internal brittle coating, thereby freeing the polyethylene jacket from engagement with the mandrel. The jacket can then be removed from the mandrel.

Abstract: A process for manufacturing pre-cured parts of composite material with green-applied stiffeners, comprising the lamination of superimposed pre-impregnated composite material sheets to obtain a base part (1) and a second part (2) intended to be bonded with it; curing the base part (1); hot forming the laminate destined to form the second part (2); removing the second part (2) from the forming tool thereof and deposit it over the base part (1), intercalating a structural adhesive sheet between both of them; closing the assembly of both parts inside a vacuum bag and loading said bag in an autoclave, carrying out a curing cycle of the second part (2) under pressure and temperature, so that it is strongly adhered to the base part (1). The invention is applicable to the field of aeronautics.

Abstract: A cold isopressing method and mold for compacting a granular ceramic material in which the granular ceramic material is introduced into a cylindrical pressure bearing element of an isopressing mold. The cylindrical pressure bearing element is sufficiently rigid so as to maintain its shape during the introducing of the granular ceramic material. Such element is also sufficiently resilient in a radial direction thereof to deform and bear against the granular ceramic material upon the application of the hydrostatic pressure and to substantially return to its original shape upon the relaxation of the hydrostatic pressure, thereby to allow retraction of the cylindrical pressure bearing element from the granular ceramic material after compaction. In a further aspect, an isopressing method and mold is provided in which the cylindrical pressure bearing element thereof is provided with an enlarged end bore to form an enlarged end section in the finished ceramic tube for sealing purposes.

Abstract: A mold has two mold halves (6, 7). One of the mold halves (6) includes a contact section (8) which is adapted to contact a surface (5) of a semiconductor chip (1) mounted in the mold, in use.

Abstract: A method of making a golf club shaft with a bent angular tip using a main shaft body mandrel and a secondary tip mandrel disposed at an angle therewith and a mandrel apparatus for the same.

Abstract: A robot hand member mounted on an arm unit of an industrial robot and a method of producing the same, wherein there are successively executed a step of laminating prepreg sheets each containing a reinforcing fiber on the outer peripheral surface of a core member having a predetermined shape in cross section, a step of heating the laminated prepreg sheets to a predetermined temperature to thermally set, to form a fiber reinforced plastic, and a step of removing the core member from the fiber reinforced plastic to obtain a hollow structure.

Abstract: A method for transferring a three-dimensional structure onto a substrate, which includes filling a plurality of concaves arranged on a sheet-form mold with a paste-like structural material, temporarily fixing the mold to a support member, contact-bonding the structural material in a state in which the structural material has the adhesion property or bonding property to the substrate together with the mold, releasing the temporary fixation of the mold by the support member after the contact-bonding, and removing the mold from the substrate, thereby transferring a three-dimensional structure onto the substrate.

Abstract: A fastener member (10) useful for separable engagement with surface fibers of a low-loft, non-woven fabric, or the like, has a base web (12) and a multitude of fastener elements (14) formed with and extending from the base web (12). The fastener elements have a profile that comprises an elongated stem portion (22) adjacent the base web (12) and including at an acute angle to the base. A crook portion (24) is formed on the end of the stem and is directed oppositely to the direction of inclination of the stem, being exposed for engaging a mating fastening member (32). The acute angle of the stem of the elements (14) enables them to flex toward the base. Offset pair of such elements (14) can operatively move in a pincer-type motion to engage fibers (32) and to retain engaged fibers. Other element configurations are disclosed. The fastener member has particular application for fastening of disposable products such as garments and diapers.

Abstract: A method and apparatus for the manufacture of fiber reinforced structures including the tooling and its use in the manufacture of reinforced structures. The apparatus comprises a conformable locating aperture system (CLAS) used for the formation of composite structures. The method includes the use in the formation of a structure and the method of manufacture of a structure.

Abstract: In a process and apparatus for producing long plastic sheets by pressing molten plastic materials between the forming roller and the forming drum unit, the forming drum unit including a thin cylindrical sleeve supported from inside by a drum support unit and pressed against the outer surface of the forming roller to deform elastically in a curve along the outer surface of the forming roller as it rotates, thus maintaining a relatively long contact length.

Abstract: Methods and apparatuses for producing fiber-cement soffit building products. In one embodiment of the invention, an apparatus for producing fiber-cement soffits includes a punch assembly, a support assembly facing at least a portion of the punch assembly, and an actuator operatively coupled to at least one of the punch assembly or the support assembly. The punch assembly can include a punch plate and a plurality of punches coupled to the punch plate. Each punch can have a length and a first cross-sectional dimension generally normal to the length. The support assembly can have a support plate, and at least a portion of the support plate is juxtaposed to at least a portion of the punch plate. The support plate can include a plurality of holes arranged in a pattern so that each hole in the portion of the support plate juxtaposed to the punch plate is aligned with a corresponding punch on the punch plate.

Abstract: Near net shape free standing articles can be produced by chemical vapor deposition techniques when a suitable substrate is suspended in a chemical vapor deposition zone according to the disclosed technique. By suspending such substrates from linear suspension supports such as ropes, cables and wires, multiple near net shape articles can be produced with substantial manufacturing cost savings over previously employed techniques.

Abstract: A method and apparatus for producing a composite component having a variable thickness includes placing a caul member over a plurality of laid-up prepreg plies supported by a mold and curing the lay-up in an autoclave. The mold includes a cavity for receiving the lay-up that is defined by a bottom surface, a plurality of walls extending upwardly from the bottom surface, and an open upper face surrounded by a mold edge. A support flange extends inwardly toward the center of the cavity from each of the walls at a predetermined distance upward from the bottom surface. The predetermined distance varies along the length of the mold and generally conforms to the outer profile of the composite component to be fabricated. The caul is positioned over the lay-up and defines a longitudinal axis extending along the length of the caul and a lateral axis extending along the width of the caul.

Abstract: A method and apparatus for forming a member, such as a column. The invention comprises inner and outer molds that are spaced apart forming a cavity for receiving a viscous material for making the member. A core is inserted within the inner area of inner mold when the viscous material is initially disposed within the mold. Once the material attains a gelled state, an extraction member is inserted within the inner area. A vacuum is applied to the inner area that causes the flexible inner mold to separate from the material and conform to the extraction member allowing for removal.

Abstract: A sheet of uncured polymer, which is preferably reinforced with multiple layers of fiber, is staged or partially cured to a state in which the sheet is rigid at room temperature. Multiple apertures are drilled into, and preferably through, the sheet. The apertures are for acoustic or laminar flow control, and include holes having diameters in the range of 0.025 to 0.120 inch. In the case in which the fabricated panels must conform to a particular shape, the perforated, partially cured panels are heated to a temperature at which the panel softens, and conformed to the desired surface. The partially cured, perforated sheets are then cured. In order to prevent closure of the drilled holes during the cure, the perforated panel is sandwiched between two layers of glass fabric and cured on an elastomeric tool surface which expands with increases in temperature, forcing the glass fabric to seal the holes during cure. Release coatings are used to aid panel/liner separation.

Abstract: A method of forming a cannula by forming a cannula mandrel assembly having a nare mandrel, a main body mandrel and mouthpiece mandrel; heating the cannula mandrel assembly, applying a polymeric material to the cannula mandrel assembly to provide a desired material thickness on the mandrel assembly to form the cannula, curing the polymeric material of the formed cannula and extracting the mandrel assembly from the cannula by disassembly and removal of the mandrel assembly parts.

Abstract: A method of forming a cannula by forming a cannula mandrel assembly having a nare mandrel, a main body mandrel and mouthpiece mandrel; heating the cannula mandrel assembly, applying a polymeric material to the cannula mandrel assembly to provide a desired material thickness on the mandrel assembly to form the cannula, curing the polymeric material of the formed cannula and extracting the mandrel assembly from the cannula by disassembly and removal of the mandrel assembly parts.

Abstract: Several methods and machines for continuously forming a fastener product having an array of fastener elements extending from a continuous, sheet-form base, employing a mold belt on which the sheet-form base of the product is formed and from which it is subsequently stripped. The belt defines an array of cavities extending from its outer surface, for molding either the array of fastener elements or an array of preform stems that are subsequently reformed into the fastener elements. In some cases the cavities are blind, such as for forming hook-type fastener elements; in other cases, the cavities extend through the belt, such as for forming mushroom-type fastener elements. Various belt constructions and fastener element shapes are also disclosed.

Abstract: A mold for a microlens includes a substrate at least a portion of which is electrically conductive, such as an electrically-conductive substrate or a substrate with an electrode layer, an insulating mask layer formed on the substrate and including an opening or plural openings, and a plated layer electroplated in the opening and on the mask layer. A first condition that a diameter or width (&phgr;) of the opening has a relation of &phgr;≦0.35R, wherein (R) is a radius of curvature of the plated layer right above the opening, or a second condition that the diameter or width (&phgr;) of the opening is &phgr;≦10 &mgr;m, is met.

Abstract: The present invention relates to methods and apparatus of molding composite parts by liquid resin infusion. The invention involves the creation of temporary resin distribution channels on the surface of a preform to aid in the distribution of resin during infiltration. In general, these methods are improvements over the art because the molds are cheaper to make, the parts produced are of higher quality, minimal waste is produced and the time to infiltrate the preform is reduced.

Abstract: A one piece mold, having a cavity into which fluid material is fed through an input port, to result in a seamless, cast icon. At least the input port portion of the mold is sufficiently elastic so that it can be stretched open: (a) by the hardened icon, when positive pressure is applied into the cavity, remote from the input port; (b) by negative pressure applied around the mold, at least proximate to the input port; or (c) by a combination of such applied positive and negative pressures; to demold through the input port, the then hardened icon. An endless conveyor system carries the molds past several stations, including an icon demolding station, which applies the mold stretching pressure for the icon domolding. The applied pressure(s) does not exceed the elastic capability of the mold, so that it can be reused repeatedly, without deterioration as to form and shape of the icon.

Abstract: A molding process for manufacturing a molded article includes the steps of placing a flexible hollow member in a mold cavity, inserting a supporting member in the hollow member, introducing a molding raw material into the mold cavity around the hollow member to form a molded part that encloses a portion of the hollow member, removing the molded part together with the hollow member and the supporting member from the mold cavity, and withdrawing the hollow member and the supporting member from the molded part to form a channel in the molded part.

Abstract: A sculptor's pressure vessel having a frame, a pressure container and an expandable member for pushing the pressure container against a portion of the frame to seal the container. A pressurized gas supply is connected expandable member to inflate it and to push the pressure container against the top of the frame to seal the pressure container. The pressurized gas supply is also connected to the frame top to pressurize the pressure container when it is in sealed contact with the frame.

Abstract: A device, preferably a micro-device, is molded from a plastic material by injection molding, compression molding or embossing. A microabrader can be molded having microneedles for abrading the stratum corneum of the skin to form an abraded site in the tissue for enhancing drug delivery. The micro-device is molded using a mold assembly having a silicon molding surface. The silicon molding surface can include a recess corresponding to the desired shape and length of the microneedles. The silicon molding surface enables micron and submicron size features to be molded from polymeric materials without the polymeric material adhering to the mold surface. Micro-devices having molded features having micron and submicron dimensions can be rapidly produced without the use of a release agent.

Abstract: A seat cushion mold with an elastic member and method provide the manufacture of an improved seat cushion for use in upholstered chairs or the like having a smooth, uniform shape without unsightly underlines. A thick, resilient foam block is positioned on a rigid planer base and is urged into the mold whereby a thin foam cover layer is adhered to the outer edges of the planar base to produce a precisely contoured cushion which can be upholstered and fitted to a chair frame.

Abstract: A process for creating displayable imprints includes the steps of first adding water to a flexible container housing desiccated molding material, and mixing the water and molding material. The molding material is then poured into a mold which is configured to create a window. A predetermined object, such as a child's hands or feet, or a pet's paw, is imprinted in the molding material. The molding material is allowed to set, and a photograph is associated with the window by placing the photograph into a clear plastic insert having opposite faces which capture the photograph, and attaching the insert to the set molding material such that the photograph can be viewed through the window. The finished product can be displayed on an easel.

Abstract: A method for molding composite structural plastic components is disclosed wherein such components are cast from a polymerizable thermoset or thermoplastic composition in a conventional metalcasting mold. In the instant invention, a low viscosity thermoset or thermoplastic composition having reinforcing fibers distributed therein is poured into conventional metalcasting molds, obviating the need for high heats and pressures associated with injection or compression molding of composite materials as taught in the prior art. In the case of a thermoset resin, the object to be fabricated is fully cured by the action of a catalyst at relatively low exothermic resin temperatures. In the case of a thermoplastic resin, curing is generally achieved independently of high added heat and pressure. If using a thermoplastic such as nylon 6 in the present invention, a preferred method of use involves the addition and combination of fiber reinforcements while the nylon 6 resin is being manufactured.

Abstract: A molding process for manufacturing a molded article includes the steps of placing a flexible tube in a mold cavity, introducing a molding raw material into the mold cavity around the tube to form a molded part that encloses a portion of the tube, removing the molded part together with the tube from the mold cavity, and withdrawing the tube from the molded part to form a channel in the molded part.

Abstract: A method of producing a flexible heat-exchange device including a body having a flexible mats and an internal passageway for heat-carrying fluid, an inlet and an outlet, including placing first and second plastic elastic mats in a mould die having supporting surfaces and recesses around the supporting surfaces, separating the first and second plastic elastic mats by a resilient counterdie, bringing the mould dies together with the first and second plastic elastic mats separated by the resilient counterdie into contact wherein the first and second plastic elastic mats are stretched down around abutment surfaces by deformation of the resilient counterdie and around the support surfaces and down into the recesses so as to obtain local plastic deformations as the mould dies are brought together, placing the second plastic elastic mat over the first plastic elastic mat, and mutually joining the first and second plastic elastic mats to form the body.

Abstract: A mechanical fastener. A preferred embodiment of the invention provides a mechanical fastener including engaging stems having heads with demarcation lines. The present invention also provides a method of making a mechanical fastener that includes placing a layer of heated material on stem ends to soften the stem ends and deforming the softened stem ends into convex heads.

Abstract: A device, preferably a micro-device, is molded from a plastic material by injection molding, compression molding or embossing. A microabrader can be molded having microneedles for abrading the stratum corneum of the skin to form an abraded site in the tissue for enhancing drug delivery. The micro-device is molded using a mold assembly having a silicon molding surface. The silicon molding surface can include a recess corresponding to the desired shape and length of the microneedles. The silicon molding surface enables micron and submicron size features to be molded from polymeric materials without the polymeric material adhering to the mold surface. Micro-devices having molded features having micron and submicron dimensions can be rapidly produced without the use of a release agent.

Abstract: A method of forming an ophthalmic lens using a composite ophthalmic lens vacuum mold to quickly and inexpensively produce, on-site, multi-focal, prescription and non-prescription optical quality eyeglasses, with or without photochromic, and photochromic non-prescription (e.g., sunglasses, safety glasses, reading glasses, etc.) optical quality eyeglass via a vacuum remolding. The method further includes a rigid remolding process for forming the composite ophthalmic lens.