Abstract: Described herein are microplates having wells with ultra-thin walls and methods of forming thereof. The microplates can be made by thermoforming processes that use ultrasound, electricity, etc., to heat a thin polymer sheet or film prior to molding. Vacuum can be optionally applied to help form or shape the wells.

Abstract: A system for producing at least one structural thermoplastic part, said structural thermoplastic part being formed from a rough part comprising reinforcing fibres immersed in a thermoplastic matrix, the structural thermoplastic part to be produced comprising an outer face and an inner face, opposite the outer face, the production system comprising at least one inflatable pressure member made of a material having a thermal resistance greater than the heating temperature, the inflatable pressure member being mounted between the first counter-mould and the second mould, the inflatable pressure member being configured to develop between the deflated idle state and an inflated state to flatten the rough part between the imprint of the first mould and the imprint of the first counter-mould so as to consolidate the rough part and to form the structural thermoplastic part.

Abstract: A vehicle interior part includes a structure in which a soft upholstery material covers a front surface of a base material which is located on an interior side of a vehicle. The soft upholstery material is disposed in a stretched state on the front surface of the base material which is located on the interior side of the vehicle.

Abstract: A method of forming a blow molded container in the form of a tub, the method comprising the steps of: providing an injection molded preform composed of a biaxially-orientable thermoplastic material, the preform being substantially planar; heating the preform; and stretch blow molding the heated preform within a mold cavity to form a tub having a bottom wall and an annular sidewall having an upper edge, the tub comprising biaxially oriented thermoplastic material in the annular sidewall and at least an outer portion of the bottom wall, the stretch blow molding step using at least one stretch rod to engage an inner side of the preform and axially to stretch at least a part of the preform prior to blowing a pressurized gas against the inner side which urges the opposite side of the preform radially outwardly against the mold.

Abstract: A method of molding a composite structure having continuous fibers contained therein is disclosed. The method including the steps of compressing a first composite material in a mold; forming a cavity in the first composite material; placing a second composite material having continuous fibers contained therein in the cavity formed in the first composite material to minimize movement and distortion of the continuous fibers; compressing the first composite material such that the compression of the first composite material causes the first composite material to flow to edges of the second composite material; and allowing the first composite material to bond to the second composite material under molding temperature and pressure to form the composite structure.

Abstract: A method and apparatus for curing a composite workpiece to form a part. In one illustrative embodiment, an apparatus may comprise an object, a portable structure, and a heating system. The object may have a shape selected for a part. The portable structure may comprise a retaining structure configured to hold the object. The retaining structure may have a first side and a second side. The heating system may be configured to cover the object at the first side of the retaining structure and the second side of the retaining structure. The heating system may be further configured to generate heat for use in curing a workpiece placed over the object to form the part.

Abstract: A method of molding composite plastic sheet material to form a compression molded, deep-drawn article is provided. The method includes placing a heated blank of moldable, composite plastic sheet material over a female die having an article-defining cavity defined by inner surfaces of the die so that the heated blank has a predetermined position and orientation over the cavity. Then an inner portion of the heated blank is forced into the cavity along a substantially vertical axis and against the inner surfaces of the die to obtain deep-drawn material. Outer peripheral portions of the heated blank adjacent the cavity are controllably held with corresponding predetermined holding forces based on the size and shape of the article to resist movement of the outer peripheral portions towards the cavity during the step of forcing wherein the deep-drawn material controllably stretches during the step of forcing without wrinkling, tearing or ripping.

Abstract: An in-mold grain application system includes a forming machine and an adhesive applicator. The adhesive applicator is configured to apply adhesive to a cover stock sheet prior to the sheet entering the forming machine. A controller is connected to the adhesive applicator and configured to command the adhesive applicator and control the adhesive application to the sheet.

Abstract: A blister packaging for a pharmaceutical cartridge or capsule and methods of forming same are disclosed.

Abstract: Methods to produce thermoforms from P4HB homopolymer and blends thereof have been developed. These thermoforms are produced from films and sheets including P4HB, wherein the intrinsic viscosity of the P4HB is less than 3.5 dl/g, but greater than 0.35 dl/g, and the thermoforms are produced at a temperature equal to or greater than the softening point of P4HB, and more preferably at a temperature higher than the melting point of P4HB. A preferred embodiment includes a P4HB thermoform wherein a film or sheet including a P4HB polymer is thermoformed at a temperature between its melting point and 150° C. In a particularly preferred embodiment the thermoform is a laminate made from a P4HB film and a P4HB mesh.

Abstract: Provided is a polypropylene-based resin composition which gives uniform and fine cells and from which a foamed sheet and thermoform excellent in appearance, thermoformability, impact resistance, lightness, stiffness, heat resistance, heat insulating properties, oil resistance and the like can be produced. A polypropylene-based resin composition comprising (X) 5 to 99% by weight of a polypropylene resin having a structure with long chain branches, and (Y) 1 to 95% by weight of a propylene-based block copolymer produced by sequential polymerization, which block copolymer comprises (Y-1) a propylene (co)polymer and (Y-2) a propylene-ethylene copolymer, said resin (X) having properties (X-i) to (X-iv) and said block copolymer (Y) having properties (Y-i) to (Y-v), and the like.

Abstract: Processes for enhancing blown film processability and the blown films formed thereby are described herein. One embodiment of the processes generally includes providing a first propylene based heterophasic copolymer having a first melt flow rate, modifying the first propylene based heterophasic copolymer to form a second heterophasic polymer having a second melt flow rate, wherein the second melt flow rate is greater than the first melt flow rate, contacting the first heterophasic polymer, the second heterophasic copolymer or a combination thereof with a plurality of additives, wherein the plurality of additives include a nucleator, polyethylene and mineral oil to form a modified heterophasic copolymer and blowing the modified heterophasic polymer into a film.

Abstract: A compressed air is ejected from air ejector ports (14) to between a mold surface defining cavity (12) of mold (7) and a surface of a hot melt resin layer after starting to fill or inject the hot melt resin material into cavity (12) and before a temperature of the hot melt resin material becomes equal to or lower than a softening point thereof. Recesses (Q) are formed by positively generating a “sink mark” on a surface of edge protector (6) by ejection of the compressed air, and at the same time, gap (G) is formed between the surface of edge protector (6) and the mold surface. As a result, when bead-shaped edge protector (6) is integrally formed in long-side heat-fused portions (5c) of laminated-film exterior package case (5) by using a thermoplastic hot melt resin material, mold releasability of the molded edge protector from the mold can be enhanced.

Abstract: A gas tank, includes: a liner; and a fiber reinforced plastic layer. A hollow portion is formed within a thickness of the liner along an axial direction of the tank.

Abstract: Techniques and apparatus for providing a flexible shape low volume autoclave are disclosed. In one embodiment, an autoclave includes an elongated pressure vessel that is sealed on both ends and has a circumferential joint between a first portion and a second portion. The autoclave further includes the portions defining an interior configured for accepting an elongated part, the joint being configured to create an angle between the portions and further creating an opening with a seal, the opening facilitating an insertion of the part into the interior, and the seal enabling pressurization of the interior.

Abstract: Methods for making a neutron converter layer are provided. The various embodiment methods enable the formation of a single layer neutron converter material. The single layer neutron converter material formed according to the various embodiments may have a high neutron absorption cross section, tailored resistivity providing a good electric field penetration with submicron particles, and a high secondary electron emission coefficient. In an embodiment method a neutron converter layer may be formed by sequential supercritical fluid metallization of a porous nanostructure aerogel or polyimide film. In another embodiment method a neutron converter layer may be formed by simultaneous supercritical fluid metallization of a porous nanostructure aerogel or polyimide film. In a further embodiment method a neutron converter layer may be formed by in-situ metalized aerogel nanostructure development.

Abstract: A complex-shaped, three-dimensional fiber reinforced composite structure may be formed by using counteracting pressures applied to a structural lay-up of fiber plies. The fiber plies are arranged on a pressurizable member that may become an integral part of the final product, or may be removed before the product is finalized. The pressurizable member may take the form of a hollow blow molded or rotomolded thermoplastic component or a superplastic formed metallic component having an opening such that the pressurizable member may be vented or pressurized and thus expanded against the fiber plies. In addition, a number of the pressurizable members may be joined in fluid communication, where they may each have different configurations, yet be arranged to form a large, complex-shaped lay-up surface for the fiber plies. The arrangement of the fiber plies onto the pressurizable members may produce integral I-Beam stiffeners, ribs, flanges, and other complex shaped structural components.

Abstract: Separator for cylindrical cell of the outwardly guided type, wherein a sheet material is wound around a mandrel, and starting from the winding step until the insertion of a separator into the cell, an outward support is used that renders the binding of neighboring turns of the separator winding unnecessary, and the separator sheet has an extended portion, with the extension being at least equal to the radius of the separator cylinder, and with this extended portion being wetted with distilled or de-ionized water until the material softens and the winding and the mandrel are rotated and the bottom part is folded back and heat fused to close the separator cylinder.

Abstract: The composite material formed of a fiber substrate and a matrix is placed in a vacuum bag and then in the molding chamber. Saturated steam of a predetermined temperature needed for the composite material is supplied to the molding chamber, and the temperature and the pressure inside the molding chamber are controlled so that the inside of the molding chamber may be maintained at a predetermined temperature and a predetermined pressure needed for the composite material in order to carry out a curing step.

Abstract: A multi-well plate with wells having ultra-thin walls and yet with sufficient structural rigidity to allow reliable use of the plate in automated instrumentation is formed by first forming a plate blank by injection molding, the blank being of a thickness that provides the desired rigidity, and then subjecting the blank to vacuum forming to stretch designated areas in the blank to form wells or to extend wells already formed, the stretching resulting in a reduction in thickness of the molded resin at the walls of the wells only.

Abstract: A tamper-resistant container with tamper-evident features which includes a cover portion defining a peripheral flange, a base portion defining an upper peripheral edge, and a hinge joining the cover portion with the base portion. The upper peripheral edge includes an upwardly projecting bead extending substantially about the perimeter of the base portion that is configured to render the peripheral flange of the cover portion relatively inaccessible when the container is closed. The hinge includes a frangible portion for facilitating the removal of the cover portion from the base portion to open the container.

Abstract: Manufacturing of a composite component, such as a composite component of an aircraft, is provided with a molding tool that includes, but is not limited to a first mold, a second mold and a pressure generator. Between the first mold and the second mold, a membrane is arranged so that between the first mold and the membrane a first region is formed, and between the second mold and the membrane a second region is formed. In the first region, a fibrous mat is arranged. In the second region with the use of the pressure generator 116 counter-pressure can be produced so that the membrane is pressed in the direction of the fibrous mat.

Abstract: A system for self-repairing matrices such as concrete or cementitous matrices, polymeric matrices, and/or fibrous matrices, including laminates thereof The system includes repair agents retained in and/or on vessels, such as hollow fibers, within the matrix. Upon impact, the vessel rupture, releasing the chemicals. For multi-layer laminates, the systems provides a total dynamic energetic circulation system that functions as an in situ fluidic system in at least one layer or area. The energy from the impact ruptures the vessels to release the chemical(s), and mixes the chemical(s) and pushes the chemical(s) and/or resulting compound through the matrix. The repair agents can withstand high temperatures, such as the heat of processing of many laminates, e.g., 250-350° F.

Abstract: The present invention includes injecting a molten resin into a main cavity, which has on its one end a pressure port provided with a floating core and on its other end a first outlet, and a branch cavity, which communicates with the main cavity and has on its end a second outlet allowed to open and close, injecting a pressurized fluid through the pressure port after the injection of the molten resin, and moving the floating core to the first outlet side, and, at the same time, extruding the molten resin from the first outlet to form a main pipe hollow, and opening the second outlet after the main pipe hollow reaches a portion at which the branch cavity communicates with the main cavity, and extruding the molten resin by the pressurized fluid from the second outlet to form the branch pipe hollow.

Abstract: The apparatus comprises a mold assembly including at least one bore therethrough having a cavity therein defining the shape of the finished microneedle shape to be formed therein. The bore has an inlet opening and an exit opening. The apparatus also comprises means for locating the polymer to be formed at one end of the cavity and means for introducing fluid into the inlet opening of said bore and into the cavity. The apparatus also comprises exhaust means communicating with the exit opening of the bore, so that introducing the fluid through the polymer causes the polymer to assume the shape of the cavity and the fluid forms a hollow channel to define a needle-like structure in the polymer as the fluid is exhausted through the cavity and the bore.

Abstract: A composite part, such as a stiffener is formed in place. A composite charge is placed on a tool spanning a mold cavity, with the centerline of the charge offset from the centerline of the mold cavity. Opposite sides of the charge are held against the tool as the charge is formed into the mold cavity. One side of the charge is held against movement on the tool while the other side of the charge is allowed to slip over the tool toward the mold cavity.

Abstract: A hollow body formed of a thermoplastic resin and having uniform inner diameter and thickness and an excellent inner surface smoothness, and, in particular, a pipe-shaped hollow body having a bent portion is manufactured by injection molding. A method of manufacturing a hollow body includes injecting a molten resin 8 into a mold cavity 2 of a mold 1, the mold cavity 2 having on its one end a pressure port 4 provided with a floating core 6 and on its other end an outlet 5, pressure-injecting a pressurized fluid through the pressure port 4 after the injection of the molten resin 8, and moving the floating core 6 toward the outlet 5, and, at the same time, extruding the molten resin 8 from the outlet 5.

Abstract: A process for manufacturing a piece made of composite material that includes fibers that are immersed in a resin matrix, whereby the piece is placed in a first chamber with at least one flexible wall. The process includes a thermal cycle with essentially a first phase (50) at a first temperature during which the resin is liquid or in the “gel” state, and then a second phase (52) at a second temperature that is higher than the first during which solidification of the piece takes place by polymerization of the resin. An external pressure is applied to the outside of the first chamber and an internal pressure is generated inside the first chamber, wherein during the first phase (50), the relative internal pressure is less than 0 during a first period, and then greater than 0 during a second period preceding the beginning of the polymerization for reducing the porosity rate.

Abstract: An apparatus for forming a flange on a component is provided. The apparatus comprises a mold disposed for placement of the component thereon, a forming element configured to hold the component on the mold to facilitate formation of the flange, and a pressure element configured to cooperate with the mold to define a space therebetween. The apparatus further comprises a bladder disposed in the space and configured to impart a forming force to a portion of the component to form the flange on the component when the bladder is inflated. A method for forming a flange on a component is also presented.

Abstract: A pressure debulking system includes a debulking chamber having a debulking chamber interior, a pressure bladder having a bladder interior provided in the debulking chamber interior, a vacuum port disposed in fluid communication with the debulking chamber interior and a pressure port disposed in fluid communication with the debulking chamber interior. A pressure debulking method is also disclosed.

Abstract: An apparatus and method for shaping an airfoil. A prepreg assembly is positioned relative to a part in a plurality of parts for a tool for the airfoil using a positioning section for a frame. The positioning section is configured to move relative to the tool and a base of the frame and move a number of parts in the plurality of parts for the tool relative to each other. A number of sections in the prepreg assembly are heated. A force is applied to the number of sections in the prepreg assembly that have been heated to conform to the tool to cause the number of sections in the prepreg assembly that have been heated to conform to the tool with a shape for a component of the airfoil.

Abstract: A process for manufacturing a composite block of closed geometry, in the form of a continuous ring, based on fibers and on a crosslinkable resin, by continuous winding and superposition of several layers of a tape of reinforcement fibers embedded in a matrix based on a composition comprising a crosslinkable resin. The process comprises from upstream to downstream, the following steps: producing a rectilinear arrangement (12) of reinforcement fibers (11) and conveying this arrangement in a feed direction (F); degassing the arrangement (12) of fibers by the action of a vacuum (13); after degassing, impregnating said arrangement (12) of fibers under vacuum with said resin composition in the liquid state (17); passing the pre-preg thus obtained through a die (20) to make said pre-preg into the form of a tape (21) composed of reinforcement fibers (11) in their liquid resin (17) matrix, the thickness of said tape being less than 0.

Abstract: A method and system is provided for forming a three-dimensional image and, more particularly, for making three-dimensional digital image transfer thermoformed objects on, e.g., generic molds. The method includes manipulating digital images of a subject into a single image; printing the single image onto a media; and thermoforming the media with the single image using a generic mold. The system comprises a computer infrastructure operable to: receive images of a subject; display the images; stitch together the images to form a single image; adjust portions of the images or single image to compensate for deformation during thermoforming of the single image; register the single image with points on a mold; and print the single image.

Abstract: Apparatus and methods of forming selected portions of integral sheets of material are disclosed. Unformed portions of the sheets may remain undistorted during the forming process, allowing them to contain text, art work, or other desired information without material risk of the information being degraded or becoming unintelligible during the forming process. This result may be accomplished, moreover, with less trim than usually occurs in conventional forming processes.

Abstract: A method and apparatus are provided for forming a sheet of polymeric material, such as polycarbonate. A forming mold is provided having halves that engage for forming a heated sheet therebetween. Each of the halves defines an interior cavity having a peripheral edge. The sheet is retained between the peripheral edges of the halves and a vacuum is generated within one of the cavities for drawing the sheet therein, whereby a sensing mechanism detects a draw depth for initiating a cooling mechanism to cool the sheet to a temperature below a glass transition temperature of the material. A series of retention mechanisms are provided about the peripheral edge of one of the halves, for biasing the sheet into engagement with the peripheral edge of the opposing half. A trimming mechanism is further provided for trimming the perimeter of the sheet to a desired form.

Abstract: A biaxially oriented polyester film is provided, in particular, a biaxially oriented polyester film for molded part capable of being used suitably as a metallic molded part processed after metal deposition on a film surface and a surface protection film in forming a decorative sheet. Provided is a biaxially oriented polyester film for molded part, which is a polyester film that at least two layers of A layer composed of polyester A and B layer composed of polyester B are laminated, wherein interlayer adhesion between A layer and B layer is 5 (N/15 mm) or more, and stress at 100% elongation (F100 value, unit: MPa) at 200° C. and 150° C. in the longitudinal direction and transverse direction of a film is 1 to 50.

Abstract: A curved composite aircraft frame comprises a multi-ply composite laminate having a generally Z-shaped cross section. At least certain of the laminate plies include unidirectional reinforcing fibers that are substantially tangent at substantially all points along the curvature of the frame.

Abstract: In a method for manufacturing a socket for connecting a fluid conduit to a container made from thermoplastic synthetic material, wherein the socket has a first socket-shaped material arrangement of at least one layer and a second socket-shaped material arrangement of at least one layer, wherein the first material arrangement is thinner than the second material arrangement and the first and second material arrangements are both made of thermoplastic material at least predominantly and fuse with one another to form a fused joint, the first material arrangement is molded by extrusion or injection molding to a plane film or plate or to a hose. The film or plate is deepdrawn or the hose is blowmolded to a first preform with a socket contour. The second material arrangement is applied onto one side of the first preform in a socket contour by injection molding, coinjection or a monosandwich process.

Abstract: A tool for the infusion of a resin into a preform made of fiber material includes a mould which can be closed around the preform and in the body of which at least one inlet duct is formed to allow resin to be injected into the mould so that the resin can be infused into the preform. At least one reservoir which can contain the resin, is also formed in the body of the mould and is connected to the at least one inlet duct. The mould can be inserted in an autoclave and the reservoir is configured to permit the transfer of the resin from the reservoir to the inlet duct under the effect of the temperature and of the pressure that are produced in the autoclave, thus allowing the resin to be injected into the mould.

Abstract: A method for making a polymeric web exhibiting a soft and silky tactile impression on at least one side thereof. The method comprises the steps of providing a forming structure being moveable upon a forming drum and comprising a plurality of protrusions extending from the forming structure, the protrusions being generally columnar forms having an average aspect ratio of at least about 1. The forming structure is disposed adjacent a vacuum chamber and vacuum is applied at a sufficient level to induce a sufficient partial pressure to conform a precursor web to the forming structure, thereby forming the polymeric web. The precursor web can be cast directly onto the forming structure, or it can be re-heated by re-heat means to elevate its temperature sufficiently to permit vacuum formation.

Abstract: A transparent plastic container which is transparent, allows good design and can be used for an anticounterfeit system that determines authenticity by visual check with the use of polarization property. A transparent plastic sheet of a polystyrene-based resin having a total light transmission of 85% or higher and a haze of 7% or less is subjected to vacuum, pneumatic or vacuum/pneumatic forming at a sheet temperature ranging from a glass transition temperature plus 50 degrees C. to a glass transition temperature plus 130 degrees C., thereby obtaining a transparent plastic container having a planar portion with a strain amount of 150 nm or less.

Abstract: A method of debulking a fiber preform includes debulking a three-dimensional fiber preform from a first size to a second, smaller size. A solvent may be infiltrated into the preform to distribute a tackifier material therein. The solvent is then removed and the dried preform is compressed to the smaller size such that, upon removal of the pressure, the tackifier material causes the preform to substantially remain at the smaller size.

Abstract: There is provided a method of manufacturing a hollow structural member suitable for precisely manufacturing a hollow structural member whose pitch space of the hollows is below 30 ?m. The method of manufacturing a hollow structural member of this invention is to encapsulate, by using a gas-permeable material in part of a material that constitutes the substrate (5) for manufacturing the hollow structural member, a high-pressure gas by injection in advance, under high-pressure conditions, into the gas-permeable material; to form a plastic deformation film (10) on a surface under reduced-pressure conditions; and to expand and draw the plastic deformation film (10), while preventing the plastic deformation material from entering the recesses (5b), by discharging the high-pressure gas that is encapsulated in the gas-permeable material into each of the recesses (5b), whereby the hollow structural member is manufactured.

Abstract: In one aspect, the invention is directed to an efficient and economical process for dispersing fiber in water and clay. In another aspect, the process for dispersing fiber in water and clay is used in methods of making fiber reinforced composite products. In another aspect, the dispersed fiber/clay material is formulated to make products which include, but which are not limited to, fiber reinforced thermoplastic composites, paperboard products, kitty litter, and/or lightweight building materials comprising fiber.

Abstract: Disclosed are poly(hydroxyalkanoic acid) resin compositions comprising poly(hydroxyalkanoic acid), such as polylactic acid, and a polyoxymethylene. Also disclosed are articles such as films, sheets and thermoformed containers comprising the compositions.

Abstract: The present invention generally relates to a mold assembly (32, 34) and a method of using the mold for the manufacture of composite parts which, more particularly, are generated from a strengthener in a generally solid phase and a matrix in a generally liquid phase. Various types of molds and processes may be used in order to impregnate a strengthener with a matrix such that a composite part may be manufactured, but the efficiency rate and the duration of the manufacturing process significantly varies depending on the chosen type of mold and process. The present invention relates to a mold assembly and to the manufacture of composites by using the mold assembly which includes the injection of the matrix in the mold assembly containing the strengthener and a deformable member (36) which favors the impregnation of the matrix toward the strengthener.

Abstract: Process for the production of an at least partly printed, metallized and/or otherwise coated thermoformed film part with at least the following process steps: a flat film piece which is at least partly printed, metallized and/or otherwise coated on one or on both surface(s) and is made of at least one thermoplastic, and which includes at least one film section which corresponds to the thermoformed part to be produced with respect to size and printing, metallizing and/or coating is provided; this film piece is mounted in a defined arrangement on a frame, only the edge sections of the film piece lying on the frame; the film piece lying on the frame in this way is introduced into a heating zone, and at least the film section is heated there to a given temperature; and the film piece heated in this way is introduced rapidly into a forming zone and is charged there immediately and directly with a fluid pressure means under a pressure means pressure of greater than 20 bar and is formed isostatically to give the

Abstract: This invention relates to a method of making a heat-resistant transparent container which involves the steps of: a primary stretching and heat-setting process wherein an amorphous polyethylene terephthalate sheet is heated, primarily stretched and then primarily heat-set and a secondary stretching and heat-setting process wherein the sheet treated in the primary stretching and heat-setting process is molded with heating in a mold of a thermoforming machine while secondary stretching is performed, followed by secondary heat-setting in the same mold.

Abstract: A method for glass-blowing on a microscopic level includes the steps of defining a plurality of microholes in a wafer, disposing a sheet of thermally formable material onto the wafer covering the microholes, heating the sheet of thermally formable material until a predetermined degree of plasticity is achieved, applying self-induced fluidic pressure by expansion of the heated trapped gas in the microholes to the sheet of thermally formable material, while the sheet is still plastic, and simultaneously forming a plurality of blown micro-objects in the sheet on the wafer by means of continued application of pressure for a predetermined time.

Abstract: A forming tool and method for its use with flat pre-preg composite laminate assemblies which incorporates a mandrel segmented into multiple forming blocks, the forming blocks sized to receive a draped composite laminate assembly with all portions of the composite laminate assembly spaced from a shaping surface on each block. A spline plate engages the shaping surface of the forming blocks to provide a neutral axis for maintaining the entire composite laminate assembly in tension during forming. In the exemplary embodiments, the draped composite laminate assembly is formed to the forming blocks from the flat composite laminate assembly and maintained in contact with the forming blocks using a vacuum bag. The mandrel forming blocks are then displaced to a desired curvature on the spline plate.