Abstract: Some embodiments of a compression mold for forming a rib-and-sheet part includes a mold cavity and a mold insert. A sheet is placed in the mold cavity, and the mold insert is placed on the sheet. A preform assemblage is placed in a gap that is formed between the mold insert and the wall of the mold cavity. A mold core is biased above the preform assemblage, prior to molding operations, via a compression spring.

Abstract: A mold in which a fine uneven structure is formed on the surface by anodizing a surface of an aluminum base material having a purity of equal to or more than 99.5% by mass, wherein a 60-degree gloss of the surface on the side where a fine uneven structure is formed is equal to or more than 750%.

Abstract: The present invention features the present invention features a tablet including at least one pharmaceutically active ingredient, wherein the shape of said tablet includes at least one major face wherein: (i) the peak penetration resistance at the perimeter of said major face of the tablet is at least about 10% greater than the peak penetration resistance at the center of said major face; and (ii) the tablet disintegrates in the mouth when placed on the tongue in less than about 30 seconds, and a machine and method for manufacture of such tablet.

Abstract: An expandable molding insert apparatus and corresponding method are provided. The insert apparatus may be expandable between a first uncompressed position with a first diameter and a second compressed position with a second, larger diameter due to axial decompression and compression, respectively, of the insert apparatus. For example, the insert apparatus may include an inner rod, an outer jacket, and a compression member. The compression member may be configured to provide axial compression to the outer jacket, such that the outer jacket may be adjusted between a first uncompressed position with a first outer diameter and a second compressed position with a second, larger outer diameter. The insert apparatus of the present disclosure facilitates withdrawal of the insert apparatus from a molded component, requires a minimal number of mechanical components, and provides for ease of actuation when the insert apparatus is utilized during a molding process.

Abstract: Processes for manufacturing hollow structures such as spars for helicopter rotor blades, fixed wings for aircraft, and other aerostructures can include the provision of a path for gases to exit the material from which the spar is formed as the material is heated and cured, to help eliminate voids within the material caused by the presence of such gases.

Abstract: The present invention relates to methods and devices for forming articles of food. The methods and devices are configured for forming exterior portions and interior portions of a food article so as to form a cavity for placement of similar or different articles of food therein. In one exemplary embodiment, the present invention provides a forming device configured for forming an exterior portion of the food article in a first step, an interior portion of the food article in a second step and an interior and exterior portion in a third step.

Abstract: Tooling aids for applying pressure in laminating, and methods for their use, are described herein. In one embodiment, a caul for applying pressure in laminating includes a base portion positioned between first and second corner portions. The base portion can have a curved shape when it is in a relaxed state, but it moves to a flatter shape when subjected to pressure during lamination. Movement of the base portion to the flatter shape causes the first and second corner portions to move outwardly and away from the base portion. In this manner, the caul can be used to compact laminating materials into corner regions of a corresponding female mold surface.

Abstract: The invention concerns a piston (1) for positioning a food pot decoration in a mold, a positioning device comprising this piston, and an associated positioning method. The piston (1) comprises at least one means (10) for prefolding or folding the decoration over its full height.

Abstract: A collapsible core device for molding articles around the core device in a mold cavity includes an expansion member, a discontinuous first sleeve and a discontinuous second sleeve. When the expansion member is fitted within the first and second sleeves, the expansion member and the first and second sleeves form a substantially continuous, flush top molding surface with the first and second sleeves.

Abstract: An apparatus for manufacturing a display panel includes a pair of pressing jigs respectively having pressing surfaces that overlap each other. A pair of film substrates, each having a display region defined thereon, are molded into a curved shape by holding the pair of film substrates between the respective pressing surfaces of the pair of pressing jigs so that the respective display regions overlap each other with a sealant, which is positioned around the display regions between the pair of film substrates, being interposed therebetween, and at least one pressing jig of the pair of pressing jigs has multiple pressing surfaces, which have different radii of curvature from each other, and are switchable with each other.

Abstract: Tools for manufacturing composite parts and methods for using such tools are disclosed herein. A method in accordance with one aspect of the invention includes manufacturing a fiber-reinforced resin part from a plurality of fibers positioned on a tool having a female mold surface. The mold surface can include a first side region, a second side region, an interior region between the first and second side regions, and transition regions between the first and second side regions and the interior region. The method includes positioning a compaction tool over the mold surface. The compaction tool includes a first pressing device and a second pressing device carrying the first pressing device. The method further includes pressing a first portion of the fibers against the transition regions with the first pressing device without generally compacting the portions of the fibers outboard of the transition regions.

Abstract: Tools for manufacturing composite parts and methods for using such tools are disclosed herein. A method in accordance with one aspect of the invention includes manufacturing a fiber-reinforced resin part from a plurality of fibers positioned on a tool having a female mold surface. The mold surface can include a first side region, a second side region, an interior region between the first and second side regions, and transition regions between the first and second side regions and the interior region. The method includes positioning a compaction tool over the mold surface. The compaction tool includes a first pressing device and a second pressing device carrying the first pressing device. The method further includes pressing a first portion of the fibers against the transition regions with the first pressing device without generally compacting the portions of the fibers outboard of the transition regions.

Abstract: A mold assembly including a plurality of mold components configured to form a mold cavity having a desired shape, at least one of the mold components having a notch configured to form a set-back flange in a masonry block formed in the mold cavity, the notch having a depth. The mold assembly further includes a moveable flange plate and a drive assembly configured to extend the moveable flange plate into and retract the moveable flange plate from the notch within a desired range of distances so as to adjust the depth of the notch.

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

Abstract: Methods for making a tubular device that has a rim disposed at one end thereof. In one method, a sleeve having an expandable profiling surface is inserted into an end of the tubular member, and the profiling surface is expanded to form a shoulder projecting outwardly from the tubular member adjacent the end of the tubular member. The profiling surface is collapsed inwardly away from tubular member, and a return margin is formed directed inwardly from the shoulder, distal the tubular member. In another method, return margin of the tubular device adjacent an end is folded inwardly and superposed on an inner surface of the tubular device adjacent the folded margin. A sleeve having an expandable profiling surface is inserted into the end of the tubular device, and the profiling surface is expanded to form the rim comprising a shoulder projecting outwardly from the tubular member and the return margin. As a result, the fold between the shoulder and the return margin defines an edge of the tubular member.

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

Abstract: Making pieces of soap into one solid bar. After being rinsed and soaked in hot water for several minutes, the used pieces of soap are deposited into the center compartment of the soap machine, and depressed with the plunger until all of the water escapes from the solid bar into the other compartments and this water is discarded. Lift the containing walls on the soap machine and slid the spatula under and remove the solid soap bar.

Abstract: The present invention discloses apparatus for molding an elongate annular product such as a pole, the apparatus including two outer mold sections (1) relatively movable to form in a first position a substantially enclosed upright molding cavity and in a second position opening said molding cavity, an upright core member (3) is moveable into and out of said molding cavity and when located in said molding cavity defining an annular molding zone (37) between the core member (3) and the outer mold sections (1), filling means (5) arranged to fill the annular molding zone (37) from below, and end capping means (6) arranged to close an upper end region of the zone (37), the end capping means (6) including a filter membrane adapted to allow fluids to escape through the filter membrane while fine solid particles are retained within the molding zone (37).

Abstract: A compression molding apparatus includes a mold of a first material having a first coefficient of thermal expansion and a plug of a second material having a second coefficient of thermal expansion different from the first coefficient of thermal expansion. The mold has a cavity into which the plug is placed such that the mold and plug are disposed relative to one another providing a gap therebetween having a first volume for holding a body that at least partially fills the gap when the mold and plug are at a first temperature and for molding the body into a molded product when the mold and plug are subjected to a second temperature that causes one of the first and second materials of the mold and plug to change in size more than the other and thereby change the gap to a second volume different from the first volume and compress the body.

Abstract: A process for the production of compacted bodies of powdered medicament is disclosed, the process comprising the steps of:a) positioning expansible means along the longitudinal axis of the mold;b) placing loose powdered medicament in the mold; andc) expanding the expansible means perpendicularly to the longitudinal axis of the mold. An apparatus for use in the process according to the invention and medicament compacts formed by the process are also disclosed.

Abstract: A downwardly tapering core forms a guide part for an end portion which can be pushed into the core so as to be flush therewith when the core is introduced into a downwardly tapering cavity in the form member in the production of ice cream cups, cones or the like. Upon an initial baking of the dough to increase the resistance thereof, the core can be pressed further into the dough to compress the latter into final thickness, whereupon baking can occur with the end portion fully pressed into the guide part.

Abstract: The invention provides a device for press forming a sheet blank (5) of the type including a die formed by a pad (2) composed of an elastic material disposed in a retaining box (1), a lower blank holder (3) which rests on the upper part of the box (1) and on which the sheet blank (5) rests, structure for preforming the sheet blank (5) constituted by an outer slide (6) carrying an upper blank holder (6a), structure for forming the sheet blank (5) constituted by a central slide acting on a plunger (7) and, in the region of heating zones of the elastic pad (2), structure (20) for regulating the temperature of the elastic pad (2) in the course of the press forming of the sheet blank (5).

Abstract: A process and apparatus is provided for molding flowable materials. The mold may be provided with deformable or collapsible mold surfaces and a forming member which is positioned in the mold when producing a shell molded article is also deformable or collapsible. After the molded article is formed the forming member and/or the mold surfaces are deformed or collapsed to facilitate removal of the article from the mold and to avoid "backlocking" of the article in the mold.

Abstract: Film-based composite structures meet the requirements of highly weight-efficient SDI space-based systems. These structures are rigid, lightweight, dimensionally stable, and possess a high degree of structural damping. Thin-walled structures (wall thickness less than 50 .mu.) made from self-reinforced ordered-polymer films overcome drawbacks of fiber-reinforced composites, and provide resistance to microcracking, ply delamination and impact. They have high temperature capability (over 300.degree. C.), low temperature (cryogenic) capability and the capability for hardening and survivability. The modulus and dimensional stability of film-based ultralightweight honeycomb sandwich structures is better than currently possible with aluminum or fiber-reinforced composite materials. Other thin-walled structures such as tension web beams and thin facesheets also show similar stiffness-to-weight advantages over current materials.

Abstract: A mold (100) is constructed by forming a shell (125) having a back surface (127) and a mold surface (126) which defines a mold cavity (150), by forming a shell base (124) about the back surface (127) of the shell (125) so as to define an enclosed cavity (134) between the shell base (124) and the shell (125), and by filling the enclosed cavity (134) with substantially incompressible material (135).

Abstract: The invention proposes a method of sealing and/or shaping a food product and apparatus for use in performing the method. Food product is placed on a support surface (10), and a molding surface--comprising a flexible diaphragm (25) is lowered over the food product. Air pressure acting on the diaphragm applies a force to the food product for the purpose of sealing and/or shaping the food product. The arrangement produces a more random appearance to the resulting food product. A plurality of food products are acted on by a respective molding surface which are carried from a common framework. The support surface is preferably a conveyor belt and the framework is mounted for reciprocal movement so that molding pressure can be applied to the food product during an indexing movement of the support surface.

Abstract: In a device for manufacturing composite plastic mouldings, at least two different reaction mixtures are injected simultaneously through different sprues (24,26) into the cavity (28,28',28") of a mould (20,22). During the injection time of at least one of the reaction mixture, the cavity is subdivided into two or more mutually isolated regions. Following the injection of one reaction mixture, the separation between the regions of the cavity is removed and the at least partially liquid reaction mixtures converge in the separation plane. This device makes possible to join at least two materials having different properties in a single operation. It is useful for manufacturing bumper bars, spoilers, coach-work, and internal linings of motor vehicles.

Abstract: A method for temperature conditioning a blank of plastic material in which a conditioning mandrel is placed within the blank and thereafter expanded into reliable abutment against the inner surface of the blank. The mandrel is thereafter returned to its initial position. The outer surface of the mandrel is adjusted to and maintained at a certain temperature, whereby, during the abutment, an energy exchange takes place between the blank and the mandrel for adjusting the temperature of the blank. At high temperatures of the mandrel, the mandrel is displaced out of the blank after such short time that the plastic material in the region of the abutment surface never passes the critical temperature of tackiness of the plastic material and/or thermal crystallization of the plastic material. As a rule, the expansion and contraction of the mandrel is repeated one or more times.

Abstract: A helical tooling process for economical production of high quality, high temperature thermoplastic composite tubes uses a mandrel or external cylinder to resist a force applied from a helical member for consolidation pressure, compaction, and part removal. The helical too long process facilitates the prescription of a desired consolidation pressure and diameter, independent of temperature. The advantages of the disclosed process include improved produced part quality, increased process flexibility, and enhanced economic efficiency. These advantages stem from the device being easily controlled and fabricated and having a low thermal mass.

Abstract: In a process for forming composite laminate parts from reinforcing fibers and resin, a mold is selected which has a mold cavity having a part definition surface therein and a resin passageway leading to the cavity. An expansion member capable of expanding to a larger volume in response to heat is located in the cavity in conjunction reinforcing fibers which will form a part of the composite laminate part. The mold cavity is closed and resin is injected through the resin passageway to saturate the fibers. The expansion member is heated to expand the expansion member an amount sufficient to consolidate the resin and the reinforcing fibers between the expansion member and the part definition surface to shape the fibers and the resin into a component laminate part mimicking the shape of the part definition surface and to expel any excess resin from the cavity to the passageway.

Abstract: A technique is provided for forming an article having a sharp, detailed edge by thermoforming thermoplastic resin prepregs containing randomly arranged reinforcing fibers and ordered, substantially continuous reinforcing fibers. The thermoforming mold used for this technique has a mold cavity with a wedge-shaped interior portion and a mold plug with a wedge-shaped exterior portion wherein the mold plug is capable of applying additional pressure along its edge section. The randomly arranged reinforcing fibers are utilized to form the sharp edge portion of the resulting article while the ordered, substantially continuous reinforcing fibers are utilized to form the remaining wall portions of the resulting article.

Abstract: Shaped products are prepared by molding composite materials based on a fabric consisting of at least two superimposed single-directional layers of continuous fibers stitched together with thread, with the continuous fibers being oriented in different directions from each other. The composite fabric is stamped in a die by means of a stamp while applying at the same time a monitored tension to the fabric as the fabric is forced into the hollow of the die by a stamp. The monitored tension is modulated by interposing relaxation stages having a value slightly greater than zero. The fabric, while maintained under monitored tension, is impregnated with a quantity of resin or binder needed for the formation of the finished part.

Abstract: A composite mold that facilitates the fabrication, in a single curing step, of composite articles having opposing sets of stiffening members disposed in combination with a main structural panel. The composite mold provides for simultaneous co-curing of the opposed stiffening members in combination with the main structural panel. The composite mold includes a rigid mold assembly and a "T" mold assembly, which, in combination, define a rigid lay-up surface for the prepreg laminates forming the main structural panel. The rigid mold assembly includes rigid members that act as reactive surfaces for cure pressures, and removable end and wedge members for assembling/disassembling of the rigid mold assembly, "T" mold assembly combination. The "T" mold assembly is operative during the cure process to generate the pressure required to cure the legs of one set of the stiffening members.

Abstract: A press for making pizza beds includes a mold plug having a plurality of pressure rings fitting telescopically and being guided within one another. Double-acting cylinders sequentially actuate the rings from the innermost one to the outermost one to act on the dough such as to stretch it from its center radially outwardly.

Abstract: A method for resin transfer molding composite articles of complex configuration that have high fiber-to-resin ratios. The molding apparatus includes a compliant mold subassembly having one or more conformable cauls and a complementary, non-permeable membrane that function, in combination, as a semi-rigid molding tool. The compliant mold subassembly is relatively insensitive to bulk variations of layed-up fiber reinforcement material, facilitating fiber reinforcement material lay up and closure of the molding apparatus. The compliant mold subassembly provides uniform pressures during various molding stages, i.e., resin injection, expulsion of excess resin, curing, to enhance the homogeneity and dimensional stability of the finished composite article. The semi-rigid aspect of the compliant mold subassembly facilitates demolding of the finished composite article.

Abstract: A method for temperature conditioning a blank of plastic material in which a conditioning mandrel is placed within the blank and thereafter expanded into reliable abutment against the inner surface of the blank. The mandrel is thereafter returned to its initial position. The outer surface of the mandrel is adjusted to and maintained at a certain temperature, whereby, during the abutment, an energy exchange takes place between the blank and the mandrel for adjusting the temperature of the blank. At high temperatures of the mandrel, the mandrel is displaced out of the blank after such short time that the plastic material in the region of the abutment surface never passes the critical temperature of tackiness of the plastic material and/or thermal crystallization of the plastic material. As a rule, the expansion and contraction of the mandrel is repeated one or more times.

Abstract: A reblow former for use in the manufacture of moulded construction products from dry particulate materials is proposed which includes an elongate body part (11) and an inflatable elastomeric sleeve (14) disposed about the body part, the body part having ribs (12) thereon to provide an indented transverse profile and the sleeve (14) having a transverse perimeter length which corresponds to that of the body part (11) and lying in intimate surface contact with the body part (11) in the non-inflated condition thereof. The transvere perimeter length of the sleeve (14) in the unstretched state thereof approximates to the transverse perimeter length of a core void (15) into which the reblow former is inserted such that, on inflation, the sleeve (14) is brought into contact with the core void surface of the core with not material stretching of the material of the sleeve.

Abstract: An isostatic pressurizing bag for consolidating a composite part has an outer flexible elastomer having a fixed resilient outside surface. The outer elastomer surrounds a closed chamber. A thermally expandable inner elastomer is located in the closed chamber. The inner elastomer is selected as an elastomer that can viscously flow or move in response to pressure. The outer elastomer is capable of flexure to relieve expansion of the inner elastomer. The bag is formed by curing plies of uncured silicone rubber around either a silicone gel or a particulated silicone rubber that is capable of phase change to a flowable gel in response to pressure. In use a composite prepreg is overlaid on a surface that defines the shape of a desired part. The isostatic pressurizing bag is located over the prepreg trapping the prepreg between the pressurizing bag and the surface.

Abstract: Apparatus for producing press-molded articles having a plurality of cavities therein includes a mold cavity which can be filled with a particulate molding compound, which mold cavity contains rods sheathed with expandable tubes which can be expanded by means of a fluid under pressure conveyed into the space between the rods and the tubes: this causes compaction of the molding compound to form the pressed article, which can be removed from the mold after reduction of the fluid pressure to allow detumescence of the expandable tubes and withdrawal of these from the mold cavity so that the mold cavity can be opened to remove the shaped pressed article.

Abstract: An apparatus and method are described for the formation of a three dimensional composite article by use of a flexible male mold placeable within a cavity formed within a rigid female mold. Fibers are initially bound to the surface of the flexible male mold and the mold is thereafter placed inside the female mold cavity. The surface of the flexible male mold is thereafter displaced away from the female mold by the injection of hardenable resin between the molds. The flexible surface is thereafter returned to near its original position adjacent the female mold. The flexible mold includes a chamber defined therein capable of pressurization and depressurization during the fabrication process of the composite article.

Abstract: A synchronizer ring has a frictional material and oil grooves extending on the frictional surface of the frictional material in a longitudinal direction and a circumferential direction, and in the oil grooves, the fiber layer of the frictional material is substantially continuous. The oil grooves are formed simultaneously by a shaping apparatus including an arrangement of longitudinal and circumferential groove punches which are simultaneously forced outwardly from a punch holder by a cooperative slide member which reciprocates within the punch holder.

Abstract: Apparatus for producing press-molded articles having a plurality of cavities therein includes a mold cavity which can be filled with a particulate molding compound, which mold cavity contains rods sheathed with expandable tubes which can be expanded by means of a fluid under pressure conveyed into the space between the rods and the tubes: this causes compaction of the molding compound to form the pressed article, which can be removed from the mold after reduction of the fluid pressure to allow detumescence of the expandable tubes and withdrawal of these from the mold cavity so that the mold cavity can be opened to remove the shaped pressed article.

Abstract: An inner mold construction and an outer mold construction are provided to define a mold cavity or shape into which wet or uncured concrete is introduced. The method includes the sequential steps of compressing the concrete by movement of the inner mold relatively toward the outer mold to remove surplus liquid from the inner surface of the concrete so that the concrete is at least partially cured. The compression applied on the inner surface of the concrete by the inner mold is maintained while inward pressure is applied over the outer surface of the concrete by the outer mold to remove surplus surface liquid from the outer surface of the concrete. The inner and outer surface pressures on the concrete are released to release the molded article from the mold so that it may be separated therefrom.

Abstract: The invention is an apparatus for molding an article made of layed up materials having opposed principle surfaces, such as one that is hollow tubular shaped. In detail, the invention includes a first mold part for forming one surface of the article on which the layup is placed and a second mold part for forming the opposite surface. Additionally included are rubber layers placed on both surfaces of the layup which expand when heated compacting the layup. A containment structure is mounted about the first and second mold parts and is in moveable relationship to the first and second mold parts. First and second inflatable bags are mounted between the containment structure and the first and second mold parts for balancing the loads on the mold parts while the silicon rubber layers compact the layup.

Abstract: This invention is generally accomplished by providing continuous self-adhesive strands of elastic to a substrate having retractable supports extending therefrom. The retractable supports in a convex pattern are contracted with the self-adhering elastic and the substrate bearing the elastic and supports is brought into contact with the web to which the elastic is to be transferred. The series of supports around which the elastic contacts are forced to retract as the self-adhering elastic is pressed against the web causing the elastic to transfer to the substrate thereby creating an elastic band on the substrate. In a preferred form the substrate is fed two strips of self-adhering elastic that are applied on each side of a series of a convex pattern of pins and then pressed together around opposing sides of the convex pattern of pins to seal the elastic to itself and sever the elastic, creating a contoured closed loop around the pins.

Abstract: A method and apparatus are disclosed for the reduction of mold cycle time. A deflatable member is positioned flush with the surface of a mold in an opening defined downwardly therein. Prior to flow of a resin or other hardenable liquid within the mold, the deflatable member is deflated so as to define a resin flow channel across selected portions of the mold surface. Prior to hardening of the hardenable liquid within the mold, the deflatable member is inflated so as to become flush with the surface of the mold so as to yield an article of manufacture having a relatively planar surface.

Abstract: A device for producing annular-shaped articles comprises a hub (4) and a cylinder-shaped body (1) made up of sectors (2 and 3), of which the sectors (2) are rigidly coupled to the hub (4), while the other sectors (3) are traversable with respect to the hub, a pusher (6) being axially arranged in the hub (4) and adapted to interact, while axially moving, through its ends extending towards the other sectors (3), with stops (8) secured on the other sectors (3) for traversing the latter with respect to the hub (4). The stops (8) are held to the other sectors (3) at angles (.alpha.) less than 90 degrees with the direction of movement performed by the pusher (6) when the other sectors (3) are being brought together.

Abstract: Apparatus, for molding a seal in an annular metal casing, including core and surrounding mold insert members for engaging and holding the casing against deflection during molding.In re embodiment the casing is tapered and the apparatus is configured to accommodate the casing is tapered and the apparatus is configured to accommode the casing shape.In a second embodiment concentric resilient members are provided to bias the core away from a bold base member.

Abstract: A method for manufacturing a plastic foam, wherein a plastic compound with chemical foaming agent is charged in molding cavity which is defined by a pair of upper and lower die cavities and wherein the plastic compound is subject to a dielectric heating, so that the chemical foaming agent decomposes. One of the cavity surfaces is movable to vary the volume of the molding cavity in accordance with the expansion of the plastic compound, so that the movable cavity surface is kept in contact with the plastic compound which expands during heating.

Abstract: A method for the manufacture of cored construction products from dry particulate materials including feeding the materials into a vibrating mould so as to bring the same into pre-compacted condition, and subjecting the materials when in such condition to a transverse pressure so as to effect final compaction thereof. After compaction, a free standing surface of the material is impregnated with a setting liquid. The vibration is of such frequency and amplitude as to bring the individual particles into substantially uniform closely spaced disposition, the subsequent application of pressure bringing the material into a compacted state without any substantial re-arrangement or crushing of the particles.