Abstract: The present invention provides an automobile interior sheet using a bioresin that includes: 5 to 100 parts by weight of a bioresin prepared from a starch extracted from at least one natural plant selected from the group consisting of corn, potato, sweet potato, sugar cane, bamboo, or similarities thereof; 30 to 100 parts by weight of a thermoplastic polyolefin (TPO) resin or a thermoplastic polyurethane (TPU) resin; 5 to 40 parts by weight of a compatibilizer; 0.1 to 1.5 part by weight of a lubricant; and 0.5 to 5 parts by weight of a crosslinking agent. The present invention can prepare an automobile interior sheet using a bioresin that is applicable to vacuum molding and excellent in sewing performance to offer remarkable performances not only in securing the product performance, embossing quality and sensorial quality such as hand feeling as an automobile surface material required to have various mechanical characteristics but also in reducing emission of CO2 and total volatile organic compounds (TVOC).

Abstract: A variable stiffness film, a variable stiffness flexible display, and a manufacturing method thereof may include a lower electrode, a variable fluid, and an upper electrode. A polymer layer may be formed on the lower electrode, and a variable fluid receiving portion is patterned on the polymer layer. A variable stiffness layer is formed by putting a variable fluid in the variable fluid receiving portion. The upper electrode is formed on the variable fluid layer.

Abstract: A method of three-dimensionally shaping articles, such as articles that are difficult to transport, includes the following successive steps: placing at least one flexible cord (1) on a former (10), the cord (1) incorporating a heating electrical resistance surrounded by at least a first set of yarns of thermoplastic polymer material; connecting the flexible cord (1) to an electrical power supply for a given duration to cause the thermoplastic polymer of at least the first set of yarns surrounding the heating resistance to soften, the cord then taking on the shape imposed by the former (10); cooling the cord; and optionally removing the former (10) in order to obtain the three-dimensional object.

Abstract: A method is described in which a composite tape or sheet is processed such that it has an improved drapability when applied to a former having a complex geometrical form. The tape or sheet is selectively perforated across its width as it is dispensed, with a suction force being subsequently applied over the tape's surface to thereby cause stretching of the tape. The degree of stretching varies across the width of the tape in proportion to the degree and local density of the selective perforations.

Abstract: The present invention relates to a transfer printing method and a system using the method for printing images on a workpiece with supercritical fluid. The method includes disposing the workpiece inside the first mold and disposing a transfer film above the workpiece, closing the first mold with a second mold and injecting pressured gas, whose pressure is greater than a critical pressure, into the first mold and the second mold, ensuring a temperature of the pressured gas being greater than a critical temperature so as to convert into supercritical fluid, softening the transfer film with the supercritical fluid, transferring an adhesive layer, a print layer and a hardening layer of the transfer film onto the workpiece, and opening the first mold and the second mold to take out the workpiece.

Abstract: A body may be provided having first and second ends having threaded outer surfaces. A bore may extend between the first and second ends. A tool may be provided having a first outer mold-line surface, a second opposing surface, and a hole extending between the first and second opposing surfaces. The first end may be threadedly attached and sealed, at the second opposing surface, to an inner surface of the hole. A cap may be threadedly attached and sealed to the second end of the body. A composite may be consolidated against the first outer mold-line surface of the tool. The cap may be unthreadedly removed from the second end. A drill bit may be inserted into the bore, through the tool hole, and against the composite to drill a composite hole.

Abstract: Described are methods for processing material, material processing systems, and processable materials. Preferred embodiments relate to a method of and apparatus for producing formable products such as polymer products and thermoplastic materials.

Abstract: Described are: an active-energy-ray-curable composition (38) containing a phosphate ester compound of which an aqueous solution prepared by extracting with 50 mL of water per 1 g of the phosphate ester compound has a pH value of 6.5 to 7.5 at 25° C., wherein the value of (the concentration of phosphoric acid in the aqueous solution, expressed in mass ppm)×(the content of the phosphate ester compound in the active-energy-ray-curable composition, expressed in mass %) is 50 or less; and a process for producing a transparent film (40) which includes the active-energy-ray-curable composition (38) and in which a cured resin layer (44) having a fine uneven structure is formed on the surface of a base film (42).

Abstract: Used flexographic printing members and unused flexographic printing precursors can be recycled for reuse. This recycling can be achieved by melting a laser-engraveable layer of a flexographic printing precursor or a laser-engraved layer of a flexographic printing member to form a melt, and reforming the melt into a new laser-engravable flexographic printing precursor. The laser-engraveable layer or laser-engraved layer comprises one or more thermoplastic elastomeric nanocrystalline polyolefins that can also be mixed with non-nanocrystalline polymers.

Abstract: The present invention relates to a transfer printing method and a system using the method for printing images on a workpiece with supercritical fluid. The method includes disposing the workpiece inside the first mold and disposing a transfer film above the workpiece, closing the first mold with a second mold and injecting pressured gas, whose pressure is greater than a critical pressure, into the first mold and the second mold, ensuring a temperature of the pressured gas being greater than a critical temperature so as to convert into supercritical fluid, softening the transfer film with the supercritical fluid, transferring an adhesive layer, a print layer and a hardening layer of the transfer film onto the workpiece, and opening the first mold and the second mold to take out the workpiece.

Abstract: A system for forming a composite structure comprises an electromagnetic press including an upper die, a lower die and an electromagnet. The lower die may be mounted in spaced relation to the upper die for receiving a composite layup therebetween. The electromagnet is energizable such that the upper and lower dies apply a compressive force to the composite layup.

Abstract: A game ball, such as a soccer ball, having a cover comprised of one or more cover panel blanks and one or more reinforcement material blanks, is provided. The cover panel blanks and reinforcement material blanks are heat bonded together so that the free edges and interior panel boundaries of the cover panel blanks are aligned with the reinforcement material blanks.

Abstract: The invention relates to a novel gas filter structure, a filtering method and a method of producing the filter structure. The structure according to the invention includes a planar, porous isolation material layer (12) having two opposing surfaces. According to the invention both surfaces of the isolation material layer (12) include comprise a porous conductive layer (14, 16) including a porous filtering matrix treated with a conductive material. The conductive material consists of a material different from the support matrix. By use of the conductive layers it is possible to create in the isolation material an electric field that considerably improves the filtering efficiency of the isolation material, especially for small particles.

Abstract: A method and apparatus may be present for manufacturing. A shell may be formed having a support structure located in a cavity in which the shell and the support structure may be formed using an additive manufacturing system from a design of a tool. The cavity of the shell may be filled with a filler material through an opening in the shell. The shell may be cured with the filler material to form the tool.

Abstract: The present invention describes a process for producing a three-dimensional object, comprising: providing a material to be solidified, the material comprising a filler and a binder; delivering electromagnetic radiation and/or synergistic stimulation in a pattern or an image to a building region for solidifying said material; wherein said delivering of electromagnetic radiation and/or synergistic stimulation is performed selectively to a defined area or volume of said material to be solidified; and wherein an energy density of electromagnetic radiation and/or synergistic stimulation is varied within said pattern or image and/or between patterns or images of different building regions of said material. The present invention may be directed also to a system where different first and second materials are to be solidified.

Abstract: The process of producing a dual damascene structure used for the interconnect architecture of semiconductor chips. More specifically the use of imprint lithography to fabricate dual damascene structures in a dielectric and the fabrication of dual damascene structured molds.

Abstract: The invention relate to a process for forming a cured, partially cured or uncured thermosetting material, comprising: an irradiation step wherein the thermosetting material is exposed to electromagnetic radiation which to a significant extent is within the neat-infrared range in such a way that the temperature of the irradiated thermosetting material is brought to between 40° C. and 400° C., and a forming step wherein the irradiated thermosetting material is brought into a desired shape, whereby the forming step is executed during and/or subsequent to the irradiation step. The invention also relates to an apparatus for carrying out the said process and to a thermosetting material.

Abstract: A compact, optically double-ended sensor probe with at least one 180° bend provided in the optical fiber in close proximity to a fiber Bragg grating temperature sensor suspends the optical fiber within a casing in such a way that the expansion and contract of the probe casing will not materially influence the temperature reading of the fiber Bragg grating by adding time varying or temperature varying stress components.

Abstract: An improved method of imprint lithography involves using fluid-induced pressure from electric or magnetic fields to press a mold onto a substrate having a moldable surface. In essence, the method comprises the steps of providing a substrate having a moldable surface, providing a mold having a molding surface and pressing the molding surface and the moldable surface together by electric or magnetic fields to imprint the molding surface onto the moldable surface. The molding surface advantageously comprises a plurality of projecting features of nanoscale extent or separation, but the molding surface can also be a smooth planar surface, as for planarization. The improved method can be practiced without mechanical presses and without sealing the region between the mold and the substrate.

Abstract: A method for making a metal fluoride trap including: assembling a precipitation tube assembly including a plurality of precipitation tubes supported between a first tube end support and a second tube end support; assembling a precipitation tube, flowsheet and filter media assembly including: wrapping a flowsheet around at least one full circumference of the plurality of precipitation tubes, wherein the flowsheet has a width less than a length of the plurality of precipitation tubes between the first tube end support and the second tube end support; and wrapping a filter media around the wrapped flowsheet, wherein the filter media and the flowsheet are wrapped so as to have a diameter less than an inner diameter of an outer casing of the metal fluoride trap; inserting the precipitation tube, flowsheet and filter media assembly into the outer casing of the metal fluoride trap; allowing the flowsheet to expand; and pressing the filter media between the flowsheet and an inner surface of the outer casing of the me

Abstract: A packaging and applicator device comprising: a body; a block of fluidizable substance that is stationary relative to the body while the substance is in the solid state, said block of substance projecting beyond the body to define at least one surface serving as an applicator surface; and a reshaper member for reshaping the applicator surface, said reshaper member being positionable on the body to co-operate therewith to define at least one cavity into which the substance can flow when fluidized by supplying heat, the substance retaining the shape of the cavity when it returns to the solid state after cooling.

Abstract: A method of producing a composite recycled bottle sheet product, which includes: (a) providing a plurality of empty, cleaned, recycled plastic bottles; (b) stacking the bottles in a molding member having a predetermined width, the stacking having an uncompressed height of at least six inches; (c) compressing and heating the bottles to partially melt and fuse the bottles to create a compressed flat composite recycled bottle sheet so as to visibly display a plurality of deformed identifiable bottles; and, (d) creating a product from the compressed flat composite recycled bottle sheet so as to retain the visible display of the plurality of deformed identifiable bottles.

Abstract: A method of reforming an interlayer film for heat-insulating laminated glass by which an interlayer film for heat-insulating laminated glass capable of exhibiting an excellent optical property may be obtained even if heat-insulating fine particles covered with an inert substance are used, an interlayer film for heat-insulating laminated glass, and laminated glass is provided. The method comprises irradiating an interlayer film for heat-insulating laminated glass comprising a heat-insulating fine particle covered with an inert substance, a matrix resin, and a liquid plasticizer with a high energy ray comprising an electromagnetic wave having energy of 3.0 eV or more to improve transmittance of visible light having a wavelength of 380 to 780 nm, and also to reduce transmittance of a near-infrared radiation having a wavelength of 780 to 2100 nm.

Abstract: A process for continuous consolidation of at least one fold (22, 24), whereby the process includes unwinding a unit that consists of the at least one fold (22, 24) that is placed between two strips (26, 28) continuously along at least one curved path, the at least one fold (22, 24) being placed between guiding elements and a strip (26) to the right of the curved path to heat the at least one fold (22, 24) at least at the curved path and to exert tension on the strip (26) so that the latter compresses the at least one fold (22, 24) at least at the curved path, characterized in that it includes using strips (26, 28) whose width is greater than that of the at least one fold (22, 24) so as to be in contact on both sides of the at least one fold (22, 24).

Abstract: A method for applying microwave techniques to embroidered surgical implants including using microwave technology in the process of acetate removal and using microwave technology in the process of drying implants.

Abstract: A mat for simulating natural terrain for use in an indoors display is the subject of this invention. The mat comprises a sheet of water impervious resinous material, a water base latex emulsion coating applied to the resinous material and a quantity of terrain simulating particles which are adhered to the sheet by the dried coating. The particles are fixed to the sheet by a sealant which is sprayed on the particles after the coating has dried. The particles may comprise flocking, ground foam rubber or rigid solid pieces. The invention also encompasses a method of preparing a simulated natural terrain utilizing the mat as afore described. This method includes outlining desired terrain features, applying water to the outlined area, scraping the substrate to remove particles from the outlined area and then coloring the area.

Abstract: The present invention relates to a composite polymer having two-way shape effect, wherein the composite is made of a shape polymer layer, a resin layer, and an adhesive layer. The composite is suitable for inclusion in films, boards, fabrics, and textiles. Methods of making and using are included herein.

Abstract: A molding manufacturing method includes: preparing a molding body including a molding main body made of thermoplastic material and a decorative layer higher than the molding main body in hardness and melt temperature; setting the molding body in a fixed die; heating and softening an end portion of the molding body while maintaining the decorative layer softer than the molding main body, by irradiating an infrared ray onto a back surface of the molding main body corresponding to the end portion; and press forming the end portion of the molding body by applying a movable punch onto the fixed die while the end portion of the molding body is in a softened state to bend the end portion of the molding body to obtain an end cover portion having a predetermined shape.

Abstract: A method of embossing a sheet material includes: heating at least a portion of the sheet directly or indirectly with radiant energy from a radiant energy source; pressing a tool against the heated portion of the sheet, thereby patterning a surface of the sheet; and separating the sheet and the tool. The radiant energy may travel through a solid material that is relatively transparent to radiation, on its way to being absorbed by a relatively-absorptive material. The relatively-transparent material may be an unheated portion of the sheet, and the relatively-absorptive material may be either the tool or the heated portion of the sheet. Alternatively, the relatively-transparent material may be the tool, and the relatively-absorptive material may be all or part of the sheet. The method may be performed as one or more roll-to-roll operations.

Abstract: An apparatus and methods for forming a composite part are provided. A method for forming a composite part may include placing initial composite material on a base tool, placing a tooling mandrel on the composite material, placing additional composite material over the tooling mandrel, covering at least a portion of the composite material that overlays the tooling mandrel with a composite forming tool, heating the composite material to at least partially cure the composite material, and permitting a first portion of the composite forming tool to change size during the heating of the composite material to a greater degree than a second portion of the composite forming tool. In this regard, the second portion of the composite forming tool is closer to the base tool than the first portion of the composite forming tool. A composite forming tool is also provided that permits differential expansion of different portions of the tool.

Abstract: A bodyboard has an improved construction for ease of handling. A variety of different shapes and construction features allows the bodyboard a distinct yet stable performance in the water. A bodyboard has an improved construction for ease of handling. The bodyboard has a bottom finger bulb with a shallow lengthwise bottom depression and shallow rear tail depressions. The process for producing the board requires removal of foam core material, or molding the foam core in a specific shape mold to provide the profile. Rear tail depressions formed at a diagonal angle being no more than 1 cm in depth can extend from a deep portion at the tail of the board and blend into the board at approximately one-quarter of the length of the board.

Abstract: In a method for filling pores between two adjacent layers of a laminate for a component with high demands upon strength and comprising several layers of fibre composite having within each layer substantially parallel fibres embedded in a matrix, a connection path is created, through which a medium may move inside the laminate, between the exterior of the laminate and the pore by exerting the laminate at least in the region of the pore for forces making slots to propagate substantially in the matrix through each laminate layer along the fibre direction of the layer. A flowing, curable material is after that applied at an outer surface of the laminate and this is brought to fill the pore through the connection path. Finally, the material filling the pore is brought to cure.

Abstract: A composite comprising a structural component and a matrix component, the structural component comprising structural fibers and a toughening additive comprising non structural fibers of a first thermoplastic material and the matrix component comprising a second thermoplastic material. The structural component is a fabric formed from the structural fibers and the non structural thermoplastic fibers, the fabric comprising non structural thermoplastic fibers which are in fibre form in the final composite. The first and second thermoplastic materials differ as to their molecular weight or are dissimilar.

Abstract: Process for manufacturing molded articles made of plastics, cellulose, pulp or wood fibers with cavities, in particular composite parts for light weight construction, by means of tool parts, including the following process steps: a) matrix layer is provided at pre-selected locations with inserts containing gas-creating substances or blowing agents and b) these inserts are activated to create gas in tool parts and thus expand the matrix material. Also disclosed are gas-creating insertion elements for use in the process and made of gas-creating blowing substances enclosed in gas-proof sheaths or inserted into the matrix material in order to form locally limited areas. This process allows the production of particularly light and at the same time solid tool parts, in particular composite parts for light-weight construction.

Abstract: A molded sheet has a core which is composed of a number of core layers and, located on both sides of the core, substrate layers, decorative layers, and clear layers. Flame retardants have been added to the various layers of the molding, and specifically in a manner such that the distribution of the flame retardants is non-uniform across the thickness of the molding, and the distribution here may be selected to be symmetrical or asymmetrical with respect to the center of the thickness of the molding.

Abstract: There are disclosed a resin composition which is excellent in rubber elasticity, oil maintainability and adhesivity to a metal, and comprises a thermoplastic elastomer composition comprising a (a1) hydrogenated block copolymer which is obtained by hydrogenating a block copolymer consisting essentially of a polymer block composed principally of a vinyl aromatic compound and a polymer block composed principally of a conjugated diene compound, which has a weight average molecular weight of at least 200,000, in which the polymer block composed principally of a vinyl aromatic compound is polystyrene, and in which the content by weight of the polystyrene moiety contained in the hydrogenated block copolymer is 20 to 40%; a (b1) non-aromatic rubber-softening agent having a kinematic viscosity at 40° C.

Abstract: An embossed, cast polyolefin film or an embossed, oriented polyolefin film includes: (a) a core layer including a propylene polymer; (b) an embossed outer layer on one side of the core layer, the embossed outer layer including an olefin polymer capable of being embossed; and (c) an additional outer layer on a side of the core layer opposite to the embossed outer layer, the additional outer layer including an olefin polymer. The embossed film can then be metallized to produce a shiny, metallic film having a prismatic or holographic appearance.

Abstract: A pultrusion apparatus for manufacturing a fiber-reinforced plastic article having a non-linear shape includes a mold configured to receive a partially cured fiber-reinforced plastic article and to form the partially-cured fiber-reinforced plastic article into a spirally wound shape. A drive mechanism is coupled to the mold and configured to rotate the mold such that the fiber-reinforced plastic article is taken up on the mold. An energy source is operatively associated with the mold and positioned so that the partially cured fiber-reinforced plastic article is cured in a spirally wound shape as the article is taken up on the longitudinally extending mold. The pultrusion apparatus allows for continuously shaping a non-linear fiber-reinforced plastic article, obviating the need for any of the work to be done by hand, which may be labor intensive, not as highly reproducible, and potentially contaminating.

Abstract: A thermally conductive molded article is produced by molding a conductive composition into a predetermined shape. The composition includes a polymer matrix and carbon powders. The carbon powders are obtained by graphitizing a polymeric material that has an aromatic ring on its main chain by heating. The carbon powders are aligned in a certain direction in the polymer matrix. Thus, the molded article can be produced easily and effectively that has excellent thermal conductivity in a given direction and that is suitable for use as a heat radiator, heat transfer member, or a component thereof in electronic hardware.

Abstract: The present invention is directed towards contact planarization methods that can be used to planarize substrate surfaces having a wide range of topographic feature densities for lithography applications. These processes use thermally curable, photo-curable, or thermoplastic materials to provide globally planarized surfaces over topographic substrate surfaces for lithography applications. Additional coating(s) with global planarity and uniform thickness can be obtained on the planarized surfaces. These inventive methods can be utilized with single-layer, bilayer, or multi-layer processing involving bottom anti-reflective coatings, photoresists, hardmasks, and other organic and inorganic polymers in an appropriate coating sequence as required by the particular application. More specifically, this invention produces globally planar surfaces for use in dual damascene and bilayer processes with greatly improved photolithography process latitude.

Abstract: A pultrusion apparatus for manufacturing a fiber-reinforced plastic article having a non-linear shape includes a mold configured to receive a partially cured fiber-reinforced plastic article and to form the partially cured fiber-reinforced plastic article into a spirally wound shape. A drive mechanism is coupled to the mold and configured to rotate the mold such that the fiber-reinforced plastic article is taken up on the mold. An energy source is operatively associated with the mold and positioned so that the partially cured fiber-reinforced plastic article is cured in a spirally wound shape as the article is taken up on the longitudinally extending mold. The pultrusion apparatus allows for continuously shaping a non-linear fiber-reinforced plastic article, obviating the need for any of the work to be done by hand, which may be labor intensive, not as highly reproducible, and potentially contaminating.

Abstract: An apparatus and method for bonding polymeric materials is disclosed. The apparatus and method both utilize ferromagnetic materials in association with the polymeric materials to be bonded together. The polymeric materials, and the ferromagnetic material, are placed within a magnetic field, which causes hysterisis losses in the ferromagnetic field, and thus elevation in the temperature of both the ferromagnetic material and the polymeric materials to the point where the polymeric materials melt and fuse together. The ferromagnetic materials only rise in temperature to their Curie temperatures, at which point the hysterisis losses cease, and the polymeric material stops being heated. Removing the electromagnetic field allows for cooling and fusing.

Abstract: A mat of polymeric fibers is treated to alter a filtration surface by the application of heat and pressure. The filtration surface is heated to a temperature sufficient to soften the fibers and pressure is applied to compact the softened fibers in order to reduce the average pore size on or at the filtration surface.

Abstract: A method for manufacturing balloon catheters, and the catheters manufactured thereby. In accordance with the method, a workpiece comprising a tube-within-a-tube is placed within a mold, and a first region of the outer tube is distended into contact with the mold to form a seamless balloon of a desired configuration. The distension of the first region of the outer tube may be facilitated by electron beam irradiation, heating and/or longitudinal drawing of the workpiece concurrently with the introduction of a pressurized fluid into the space between the inner surface of the outer tube and the outer surface of the inner tube so as to exert the required outwardly distending pressure against the first region of the outer tube.

Abstract: The invention relates to a multi-layered biaxially-oriented film, mainly made of a crystallizeable thermoplastic polyester and economically produceable with a high surface quality, i.e. without pinning bubbles and without electric arcing and film breaks, at production speeds of 340 m/min or higher. According to the invention the multi-layered polyester film has an average specific electrical melt resistance over its total thickness which lies within a range from 1.5×107 to 30×107 &OHgr;×cm. The invention also relates to a method of production of the film.

Abstract: An ink jet printhead has a number of nozzles each ejecting drops of ink toward a surface. Each nozzle has a nozzle chamber at least partially defined by an apertured roof portion operatively connected to an actuator such that the actuator moves the roof portion away from the surface to be printed to eject the ink. The ink jet printhead also has a projection within each nozzle for effectively dislodging any dried ink clogging the nozzle rim, hence preventing blocking of the nozzle.

Abstract: A method for molding an end of a long resin molded article that is obtained by extrusion molding and has a design surface and an attachment surface extended in a longitudinal direction of the long resin molded article, and the attachment surface is attached to other parts. An end portion of the long resin molded article is heated so as to soften the end portion of the long resin molded article. The design surface of the heated end portion is pressed so as to stretch resin on a side of the design surface thereby forming an inclined surface on the end portion, whereby the end portion is inclined from the design surface at the end portion to said attachment surface at the end portion along said inclined surface. The attachment surface of the heated end portion is pressed so as to form a cavity on the attachment surface and stretch resin on a side of the attachment surface.

Abstract: A process forms lightweight molded articles by positioning inserts having gas creating substances at set positions on a matrix layer positioned between mold halves. The matrix layer with inserts is pressed into the mold cavity and sandwiched between molding material. The gas forming substances are activated to produce gas and the mold halves partially opened to allow the gas to form gas cavities at the position of the inserts. The matrix may be a film or net with gas creating substances in attached packets. Alternatively, the matrix may be developed with inserts of gas producing substances encapsulated within molding material by co-extrusion or co-injection nozzles.

Abstract: An embossed, cast polyolefin film or an embossed, oriented polyolefin film comprises: (a) a core layer comprising a propylene polymer; (b) an embossed outer layer on one side of the core layer, the embossed outer layer comprising an olefin polymer capable of being embossed; and (c) an additional outer layer on a side of the core layer opposite to the embossed outer layer, the additional outer layer comprising an olefin polymer. The embossed film can then be metallized to produce a shiny, metallic film having a prismatic or holographic appearance.

Abstract: A method and apparatus for making insignias with a raised design is capable of providing more aesthetic appearance to the insignias thus made. A base material consisting of a base sheet and a surface sheet overlaying the base sheet is prepared for making into an insignia. The base material is coating with a surface coating of decorative material. A bottom mold and an upper mold are used to press the base material to form raised design of patterns. The bottom and upper molds are coupled to a composite heating device including high-frequency induction and electric heating means for applying both high-frequency induction heat and electric heat to the base material while the upper molding is being pressed against the bottom mold. The upper mold is formed with a plurality of edge-defining blades for cutting an edge for the insignia, a plurality of pattern-defining blades for forming a pre-designed pattern on the insignia.