Abstract: The present invention is a composition for making a three-dimensional object. The composition comprises a plasticizer and a base polymer, where the base polymer comprises a carboxylic acid, where the composition is soluble in an alkaline solution.

Abstract: Methods and apparatus are provided for making a rotor blade spar from composite material wherein a multi-component mandrel is used to form the composite spar. The mandrel is made using a number of components, which are assembled to provide a structure that is sufficiently strong to maintain the spar shape during pre-cure lay up, compaction and curing of the composite material. The multiple components used to form the mandrel can be separated from each other and easily removed from the spar either before or after curing of the composite material. The mandrel components can then be re-assembled and re-used to form additional composite spars.

Abstract: A lithography method includes the steps of: A) filling a mold having a patterned surface with a phase change composition at a temperature above the phase change temperature of the phase change composition; B) hardening the phase change composition to form a patterned feature; C) separating the mold and the patterned feature; optionally D) etching the patterned feature; optionally E) cleaning the mold; and optionally F) repeating steps A) to D) reusing the mold. The PCC may include an organofunctional silicone wax.

Abstract: A method of forming hoses is provided. The method includes generating a virtual design for at least one of a solid durable core and a hollow sacrificial core. At least one of the solid durable core and the hollow sacrificial core is formed using rapid prototyping. A mold cavity is formed using the solid durable core. The hose is formed about the hollow sacrificial core with the hollow sacrificial core in the mold cavity.

Abstract: A method of manufacturing a plurality of molded components including (a) providing a carrier to a manufacturing assembly; (b) forming the molded components on the carrier, the molded components having a sacrificial portion secured to the carrier and being movable along the carrier, and a functional portion extending from the sacrificial portion, adjacent sacrificial portions are spaced from one another by a first distance; (c) winding the carrier in a forward direction onto the uptake device; and (d) unwinding the uptake device in a reverse direction such that the carrier and molded components move toward the source device, one of the molded components contacts the latch preventing the molded components from moving in the reverse direction such that adjacent sacrificial portions are moved closer together to a second distance that is less than the first distance.

Abstract: Medical balloons comprising a predetermined pattern of conductive materials and methods of making the same.

Abstract: A beaded preform includes a plurality of adjacently positioned beads for forming a plurality of voids in an engineered material. The beaded preforms may be comprised of a filaments (single strand of beads) and mats (two-dimensional and three dimensional arrays of beads). The filaments and mats may be coated to become tows and laminates, respectively, which may then be assembled into composite materials. The preforms may be produced using novel manufacturing apparatuses and methods, and incorporated into known manufacturing processes to produce porous structures, including stress-steering structures, in any material including metals, plastics, ceramics, textiles, papers, and biological materials, for example. Permanent bead material is preferably made of polyacrylonitrile, carbon fiber, or graphite.

Abstract: The present invention relates to an automated method for manufacturing layer by layer a composite part with rotational symmetry and complex cross-section, comprising the following stages: a) a reel or roll comprising a reinforcement is continuously unwound; b) as an option, the reinforcement is impregnated with a liquid resin by passing through a bath; c) the impregnated reinforcement is wound onto a rotating cylindrical mandrel; d) the impregnated reinforcement is completely or partially polymerised in order to obtain a composite material; e) a support and/or support material is deposited on both sides of the composite material forming the part being manufactured in such a way as to fill the gaps surrounding said part.

Abstract: A system for fabricating a septic tank using an outer mold and an inner removable plug, between which hardenable fluid material is poured. Preferably, the plug and mold are positioned with respect to one another in a manner that permits a septic tank to be fabricated in a single pour.

Abstract: A method is provided that includes providing a mold on a temporary substrate, e.g., a sapphire substrate. Next, a material such as PZT paste is deposited into the mold. Then, the mold is removed to obtain elements formed by the mold. The formed elements will then be sintered. After sintering, electrode deposition is optionally performed. The sintered elements are then bonded to a final target substrate and released from the temporary substrate through laser liftoff. Further, electrodes may also be optionally deposited at this point.

Abstract: The invention relates to a method and a device for producing a structure made up of at least two bodies in a cavity of a mold defining the structure.

Abstract: A method for building a three-dimensional object, the method comprising extruding a build material having a temperature profile between a surface and a central region of the extruded build material in which the surface has a higher temperature than the central region of the build material. The build material comprises a carrier material and nanofibers.

Abstract: An article (10) such as a grid fin that controls the direction of flight of a vehicle, has precisely formed passages (14) with porous locating walls (52A, 52B) and a layer of fibrous material (86) such as graphite cloth lying against one or both opposite sides of the locating wall, and with the locating wall and fibrous material impregnated with resin (84). Locating blocks (30) of foam are molded and the fibrous material (42) is wrapped around each block. The wrapped blocks (44) are each inserted into a passage (54) of a locating grid (50), so the fibrous material is compressed. The locating grid lies in a grid-holding mold (60). With the fiber-wrapped blocks inserted, the grid-holding mold is closed and resin is injected into the mold and allowed to harden. The foam blocks are removed by eroding them, as by sand blasting them, to leave a final article.

Abstract: A void former or dowel sleeve adapted to be encapsulated in a hardened mass of concrete, which is collapsible upon the application of a tensile force longitudinally thereof to remove the void former from the concrete and provide a void for a load transferring dowel.

Abstract: A method for producing a cast part from metal, a metal alloy or from plastic, with at least one complex internal structure, in particular with at least one hollow space, by at least one casting mold, is disclosed. The method includes the following steps: a) providing at least one core element, wherein the core element peripherally reproduces the complex internal structure and has a metallic layer on its outer periphery; b) forming a first casting mold or negative mold for producing a positive mold reproducing the cast part, with one or more cast-in core elements; c) casting an enclosure around the positive mold to form a second casting mold or negative mold of the cast part and removing the positive mold; d) filling the casting mold or negative mold with casting material and cooling the casting material down; and e) removing the enclosure and removal of the cast part.

Abstract: An open cell or highly porous woven composite truss utilizes fibers of carbon, glass, ceramic, or the like that are woven together in a loom. The warps or tow are woven with the wefts, while the fibers are impregnated with resin. The resin impregnation step may be performed before or after the weaving step. The truss is then cured on the loom and later may be machined as needed. A rigid foam material may be used to stabilize the shape of the truss prior to curing and while machining. The foam may be later chemically dissolved or otherwise disposed of.

Abstract: This invention relates to biodurable, reticulated elastomeric matrices that are resiliently-compressible, their manufacture and uses including uses for implantable devices into or for topical treatment of patients, such as humans and other animals, for therapeutic, nutritional, or other useful purposes.

Abstract: A furnishing element with a conditioning function comprising a base structure having a determinate aesthetic and/or functional conformation for furnishing, and one or more conditioning components, able to carry out a heat exchange with the environment to determine the conditioning thereof. The base structure defines at least a radiant surface and is made by lost mold casting, wherein the mold or core used for casting is destroyed at the end of casting. The conditioning components are constrained to said base structure and are suitably shaped to be disposed at least in proximity to said radiant surface, so that said radiant surface determines a desired radiation, able to condition a room and/or one or more users.

Abstract: A tool assembly including a male tool including an inner shape tool including a bag having a connection connectable to a depressurization source for providing a vacuum in the bag such that beads therein form a body of firm cohesion providing the inner shape tool rigid. The male tool further includes a flexible, hollow curing support arranged around the rigid inner shape tool, the inner shape tool is arranged to be removable from the flexible, hollow curing support by rupturing the vacuum.

Abstract: The present invention is a composition for making a three-dimensional object. The composition comprises a plasticizer and a base polymer, where the base polymer comprises a carboxylic acid, where the composition is soluble in an alkaline solution.

Abstract: Methods and apparatus are provided for making a rotor blade spar from composite material wherein a multi-component mandrel is used to form the composite spar. The mandrel is made using a number of components, which are assembled to provide a structure that is sufficiently strong to maintain the spar shape during pre-cure lay up, compaction and curing of the composite material. The multiple components used to form the mandrel can be separated from each other and easily removed from the spar either before or after curing of the composite material. The mandrel components can then be re-assembled and re-used to form additional composite spars.

Abstract: The invention relates to a hand access laparoscopy device having a gelcap, a retainer, a sleeve and a retention ring. The gelcap includes gel that is bonded to a cap. The cap includes an inner cylindrical wall to which the gel in bonded, thereby providing a sealing area between the device and the wound in a body wall. By securing the gel to the inner cylindrical wall, the thickness of the gel and corresponding cap is minimized along with the overall footprint of the device. With the gel thickness reduced and able to be substantially flush, the “doming” phenomenon produced by insufflation of a patient's abdomen is reduced.

Abstract: An elongate hollow body (1) comprising crystalline cellulose has on an inside wall a plurality of protuberances (3, 4) which extend into a lumen of the hollow body (1). A process for the production of an elongate hollow body (1) comprising crystalline cellulose comprises the steps: preparation of a hollow mould (12); cultivation of cellulose-forming organisms in an interior space formed by the hollow mould (12), in order to allow the hollow body (1) to grow in the interior space; demoulding of the hollow mould (12). In the step of demoulding the hollow mould (12), at least part of the hollow mould (12) is irreversibly deformed.

Abstract: An apparatus and method for fabricating a three dimensional model from a composite model formed or a plurality of successive layers of model material and sacrificial mold material. Each successive layer is constructed by depositing, drop-by-drop, at least one line of sacrifical mold material delineating at least one boundary of the model material within the layer and thereafter depositing the model material onto all delineated regions of the layer by spray deposition. Each successive layer is completed by a planing process which removes the undesired thickness of both the sacrificial and the model materials. Following completion of the composite model, the sacrificial mold material is removable from the composite model, by a process effecting only the sacrificial mold material, to produce the three dimensional model. A device, for depositing the model material at the rate faster than the rate that the mold material is deposited, is also described.

Abstract: A method and device for making integrally formed one-piece molded parts is provided, where the molded parts are to contain a void within their volume. An exemplary such molded part is an arc tube for a discharge lamp. A wax core is first molded onto a core pin wire in the shape of the desired void, the discharge chamber in the case of an arc tube. Then the part is molded over the wax core to provide an integrally formed one-piece part having the appropriately dimensioned void volume therein defined by the wax core. After the part has been hardened around the wax core, the core is removed by conventional means. The holes through the finished molded part left after the core pin wire is removed can be filled in, or in the case of an arc tube they are useful as passageways to accommodate electrodes therethrough.

Abstract: The present invention relates to apparatus and methods of vibration. In particular, the present invention relates to apparatus and methods of vibration for tooling in a structure, such as, for example, a fuselage. In one implementation, the tooling comprises at least two conductors that create a force to vibrate the media in the tooling, which improves the compaction of the media in the tooling and the extraction of the media from the tooling. Other implementations may be used for compaction and/or extraction of the media in the tooling.

Abstract: A golf club head and a method of making a golf club head are disclosed. The method provides for winding a single continuous filament multiple times about a soluble core. The wound core is located in a mold and pressure coated with a pure or non-continuous fiber filled resin. The resin is allowed to cure to form a filament and resin shell about the core. The soluble core is removed leaving the continuous filament in the shell.

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: The invention disclosed herein relates to hollow fiber reinforced composite material parts having one or more selectively positioned core, structural insert, or veneer pieces integrally associated therewith.

Abstract: The invention provides foams of desired cell sizes formed from metal or ceramic materials that coat the surfaces of carbon foams which are subsequently removed. For example, metal is located over a sol-gel foam monolith. The metal is melted to produce a metal/sol-gel composition. The sol-gel foam monolith is removed, leaving a metal foam.

Abstract: A method of producing an object through solid freeform fabrication includes selectively depositing a boundary structure that defines a surface of the object, and depositing a flowable build material within the boundary structure, wherein the flowable build material forms a portion of the object by flowing to the boundary structure.

Abstract: A method to help control the quality of printed three-dimensional objects is provided. The method may include depositing building materials to print a three-dimensional object with an adjacent support construction such that the object and the support construction are separated by a barrier and the barrier includes vacant pixels, where no building material is deposited.

Abstract: A method of forming a polymer-based microfluidic system platform using network building blocks selected from a set of interconnectable network building blocks, such as wire, pins, blocks, and interconnects. The selected building blocks are interconnectably assembled and fixedly positioned in precise positions in a mold cavity of a mold frame to construct a three-dimensional model construction of a microfluidic flow path network preferably having meso-scale dimensions. A hardenable liquid, such as poly (dimethylsiloxane) is then introduced into the mold cavity and hardened to form a platform structure as well as to mold the microfluidic flow path network having channels, reservoirs and ports. Pre-fabricated elbows, T's and other joints are used to interconnect various building block elements together. After hardening the liquid the building blocks are removed from the platform structure to make available the channels, cavities and ports within the platform structure.

Abstract: A method and device for removing the bulk of the casting investment surrounding a pressed ceramic dental appliance.

Abstract: A three-dimensional model and its support structure are built by fused deposition modeling techniques, wherein a thermoplastic material containing silicone is used to form the support structure and/or the model. The thermoplastic material containing silicone exhibits good thermal stability, and resists build-up in the nozzle of an extrusion head or jetting head of a three-dimensional modeling apparatus. The silicone contained in a support material acts as a release agent to facilitate removal of the support structure from the model after its completion.

Abstract: A void former or dowel sleeve adapted to be encapsulated in a hardened mass of concrete, which is collapsible upon the application of a tensile force longitudinally thereof to remove the void former from the concrete and provide a void for a load transferring dowel.

Abstract: A method for fabricating lens of light emitting diode and device thereof is disclosed, and the method includes providing a lead frame with multiple light emitting diode modules, positioning a mold releasing member on the lead frame, connecting a lens pattern device with the lead frame, injecting a resin into each lens mold, and curing the resin to lenses on the light emitting diodes modules.

Abstract: A degradable sipe blade for forming sipes in a tire tread, where the degradable material may be removed by exposure to water. A tire curing apparatus is also provided having a plurality of degradable sipe blades affixed to the mold surface within the tread pattern. In addition, a cured tire is provided having the degradable sipe blades embedded in the tread elements of the tire tread after removal of the cured tire from a curing mold. Further provided is a method for forming sipes in a tire tread using degradable blading.

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: 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: The present invention provides a silicone-based ocular prosthesis. In one aspect, the prosthesis includes a posterior sclera portion fabricated from a white-tinted silicone material. The sclera portion is formed from a molding process. The prosthesis also includes an anterior iris portion placed on the sclera portion. The prosthesis further includes a transparent layer over the sclera portion and the iris portion to provide a protective coating, and depth to the eye. Finally, a clear coat finish may optionally be applied to the prosthesis to create a realistic, wet look. A method for making the silicone-based ocular prosthesis using a molding process is also provided herein.

Abstract: Methods are provided for producing a shrunken replica or a shrunken inverse replica of a multicontinuous structure. In one embodiment, the method comprises (1) infiltrating a first multicontinuous structure with a first fluid material which can be immobilized and shrunken, wherein the first multicontinuous structure comprises at least a first phase and a second phase which is immiscible with the first phase, and the infiltration displaces the second phase in the first multicontinuous structure to form a second multicontinuous structure which comprises at least the first phase and a third phase which consists of the first fluid material; (2) immobilizing the infiltrated first fluid material in the second multicontinuous structure; (3) removing the first phase from the second multicontinuous structure; and (4) shrinking (e.g., by a pyrolysis process) the third phase of the second multicontinuous structure, to produce an isotropically shrunken inverse replica of the first multicontinuous structure.

Abstract: The present invention includes methods and appartus for forming a biomedical device, such as an ophthalmic lens, wherein the biomedical device is formed with a mold part which is water soluble.

Abstract: A method for removing supports from a three-dimensional objected formed by selective deposition modeling. The three-dimensional object is formed from a curable phase change material and the supports are formed from a non-curable phase change material. The curable phase change material contains between about 5% to about 25% of a non-reactive wax in order to achieve the desired phase change characteristics of the material. When removing the supports with heat, discoloration undesirably occurs in the three-dimensional object as the non-reactive wax migrates within the object. The method prevents wax migration by cooling the object slowly past the freezing point of the build material such that a temperature differential no greater than about 5° C. is present within the object. With the preferred build material having a freezing point of about 49.5° C., this is achieved by lowering the temperature between about 62° C. to about 52° C.

Abstract: The present invention is directed to a brace apparatus having a core member configured to absorb energy generated by seismic or other forces by undergoing plastic deformation. A buckling restraining assembly is included for maintaining the structural integrity of the brace after the core member has undergone plastic deformation. The buckling restraining assembly includes one or more bearings is located proximal the core member. The bearings are adapted to minimize friction between the core member and the buckling restraining apparatus. An air gap is positioned between the core member and the one or more bearings of the buckling restraining apparatus are adapted to prevent bonding of the core member and buckling restraining assembly. Projections are included in the core member of the brace apparatus to minimize movement of the middle portion of the core member relative to the buckling restraining assembly.

Abstract: A method of manufacturing a polishing pad is described. A mold having a mold cavity therein is provided. At least a strip is buried in the mold. A polymer foam material is injected into the mold cavity of the mold. The polymer foam material is cured to mold the polymer foam material into a molding polymer article. A mold release process is performed to obtain the molding polymer article. The strip on the molding article is removed to form a polishing pad having at least one groove thereon.

Abstract: A method of forming optically transparent and electrically conductive SWNT films includes the steps of providing a porous membrane and dispersing a plurality of SWNTs into a solution, the solution including at least one surface stabilizing agent for preventing the SWNTs from flocculating out of suspension. The solution is then applied to the membrane. The solution is then removed, wherein the SWNTs are forced onto the surface of the porous membrane to form a SWNT film on the membrane. The method can include the step of separating the SWNT film from the porous membrane, such as by dissolving the membrane. An electrically conducting and optically transparent single wall carbon nanotube (SWNT) film provides a sheet resistance of less than 200 ohm/sq and at least 30% transmission at a wavelength of 3 ?m.

Abstract: A thin walled microtube is formed by providing a continuous elongated member having an outer surface. The member is at least partially formed of a water soluble material. A coating material is provided. The coating material may be a silicone compound that is curable such that the coating material cures into a substantial non-porous silicone. The outer surface of the elongated member is coated with a coating material so as to form a substantially uniform and continuous layer of coating material on the outer surface. The layer of coating material is cured so as to form a substantial uniform and continuous layer of substantially non-porous silicone on the outer surface. The elongated member is at least partially dissolved using water and purged from the silicone layer, such that an elongated tube of substantially non-porous silicone is formed.