There is provided a polymer fabrication method for forming 3-dimensional shapes from a sheet polymer blank (10) by machining at least one re-entrant, elongate groove forming a reduced thickness portion (25) permitting the blank to be folded and having opposed edges (12) at the surface, folding the blank about the groove to form at least a portion of the 3-dimensional shape, the re-entrant of the groove forming an elongate chamber (21) adjacent the reduced thickness portion and opening through an elongate gap (20) between the opposed edges, hot air welding the opposed edges across the gap with filler rod (22), and heating the reduced thickness portion to a selected thermo-reforming temperature via the chamber.

A method for forming an article includes providing a sheet of material, optionally conditioning the sheet with a surface of a roller, forming the sheet to provide a web, and separating an article from the web to provide the article. An apparatus adapted to form the article from a sheet is provided.

The invention relates to a welding tool and a method for pulse welding films of plastic for medical packs formed as bags. The invention generally provides for the film material that has been plastified during welding, and is consequently free-flowing, to be specifically displaced by increasing the sealing surface area. The displaced film material can for instance compensate for dimensional and form tolerances. At the same time, however, the strength of the welded seam region, which adjoins the interior space of the bag, is not reduced.

It is provided a WPC extrusion profile comprising a WPC material, in which plant fibers are embedded in a plastic matrix, wherein the WPC material has a content of naturally growing plant fibers of between 30 and 75 wt-%, and the WPC extrusion profile includes at least one foam-filled hollow chamber. The at least one hollow chamber of the WPC extrusion profile is completely filled up with a foam, in particular a closed-pore foam. The foam includes or consists of a plastic material of the same type of plastic as the matrix of the WPC material. The foaming is effected by using a physically acting blowing agent, in particular CO.sub.2, wherein the density of the foam is less than 0.4 g/cm.sup.3 and the average cell size of the foam has a mean diameter of less than 0.4 mm.

A method for manufacturing a crosslinked polyolefin separator and the crosslinked polyolefin separator obtained therefrom are provided. The method includes non-grafted polyolefin having a weight average molecular weight of 300,000 or more and silane-grafted polyolefin having a weight average molecular weight of 300,000 or more. The method minimizes gel formation, a side reaction occurring in an extruder during the manufacture of the separator, and provides the separator having a uniform surface.

A three-dimensional object comprises stacked substrate layers infiltrated by a hardened material. Each substrate layer is a sheet-like structure that comprises fibers held together by a sodium silicate binder. The substrate layer material may be non-woven or woven. The substrate layer may be a non-woven fiber veil bound by a sodium silicate binder. The fibers may optionally include carbon fibers, ceramic fibers, polymer fibers, glass fibers, metal fibers, or a combination thereof.

A core-sheath filament having a non-tacky sheath and a hot-melt processable adhesive core, the sheath exhibiting a melt flow index of less than 15 grams per 10 minutes, is provided. Methods of making the core-sheath filament and methods of using the core-sheath filament to print a hot-melt processable adhesive onto a primer-treated substrate surface to provide a structural bond are described.

The invention pertains to the use of sophisticated chemical formulation and spectroscopic design methods to select taggants compatible with the 3D print medium that are easily detected spectroscopically but otherwise compatible with the product, structural integrity and stability, and aesthetics. A spectral pattern employs a different chemical or combination of chemicals to alter the formulation of all or some portion of the printed object so that its authenticity can be monitored later using a spectrometer.

A method for thermoforming an article includes extruding a sheet of material, conditioning the sheet with a roller, thermoforming the sheet to provide a web, and cutting the web to provide the article.

An in-situ melt processing method for forming a fiber thermoplastic resin composite overwrapped workpiece, such as a composite overwrapped pressure vessel. Carbon fiber, or other types of fiber, are combined with a thermoplastic resin system. The selected fiber tow and the resin are prepared for impregnation of the tow by the resin. The resin is melted; and, carbon fiber is impregnated with the melted resin at the filament winding machine delivery head. The molten state of the composite is maintained and is applied, in the molten state, to the heated surface of a workpiece. The portion of the surface being wrapped is heated to the melting point of the thermoplastic resin so that the molten composite more efficiently adheres to the heated surface of the workpiece and so that the uppermost layer of fiber resin composite is molten when overwrapped resulting in better adherence of successive layers to one another.