A pulp molding production line including as molding machine, pulp molding robot and press, where a transfer device installed on the pulp molding robot includes a wet pulp transfer mold, with the front of the wet pulp transfer mold including a recessed matching chamber configured to fit over the exterior of a wet pulp product, and a moving rack oriented parallel to the wet pulp transfer mold and connected to the back of the wet pulp transfer mold through a guide mechanism, with a driver connected between the back of the wet pulp transfer mold and the moving rack to drive the moving rack to move relative to the wet pulp transfer mold, and several evenly spaced vacuum chucks provided on a side of the moving rack opposite from the wet transfer mold to acquire the molded pulp product from the press.

In one example, a process for manufacture of a pulp-based dispensing capsule is disclosed. The process includes providing one or more mesh tool sets that are each contoured to one or more preform shapes of the dispensing capsule. Note that each preform shape is a partially shaped version of a final form shape of the pulp-based dispensing capsule. The process also includes providing a holding tank containing a suspension that includes water and pulp fibres; and arranging the mesh tool sets to allow immersion into and withdrawal of the mesh tool sets from the suspension. The process also includes applying a vacuum to the mesh tool sets so as to draw pulp fibres from the suspension onto the mesh tool sets while immersed in the suspension to form a preform pulp fibre mat; and in a second toolset, deforming each preform shape in the preform pulp fibre mat towards the final form shape by the application of pressure.

In one example, a process for manufacture of a pulp-based dispensing capsule is disclosed. The process includes providing one or more mesh tool sets that are each contoured to one or more preform shapes of the dispensing capsule. Note that each preform shape is a partially shaped version of a final form shape of the pulp-based dispensing capsule. The process also includes providing a holding tank containing a suspension that includes water and pulp fibres; and arranging the mesh tool sets to allow immersion into and withdrawal of the mesh tool sets from the suspension. The process also includes applying a vacuum to the mesh tool sets so as to draw pulp fibres from the suspension onto the mesh tool sets while immersed in the suspension to form a preform pulp fibre mat; and in a second toolset, deforming each preform shape in the preform pulp fibre mat towards the final form shape by the application of pressure.

In a first step, a molding die is immersed in a raw liquid including cellulosic fibers. Then, the liquid of a raw liquid is sucked through a net material by a liquid suction part, so as to cause the cellulosic fibers to be laminated on the net material. In the second step, the cellulosic fibers laminated on the net material are dried, so as to form a protrusion. In the third step, the dried protrusion and the communication part are removed from the molding die. A passage part of the communication part is formed at a position where a projection portion had been arranged, the passage part being configured to communicate an inside of the protrusion with an outside of the protrusion.

In a first step, a molding die is immersed in a raw liquid including cellulosic fibers. Then, the liquid of a raw liquid is sucked through a net material by a liquid suction part, so as to cause the cellulosic fibers to be laminated on the net material. In the second step, the cellulosic fibers laminated on the net material are dried, so as to form a protrusion. In the third step, the dried protrusion and the communication part are removed from the molding die. A passage part of the communication part is formed at a position where a projection portion had been arranged, the passage part being configured to communicate an inside of the protrusion with an outside of the protrusion.

This disclosure describes systems and methods for creating porous molds using additive manufacturing processes such as three-dimensional (3D) printing. At a high level, it has been found that creating a generally porous mold, or a mold with porous regions or zones, can improve the performance of the mold and the quality of the parts created therefrom. It has further been determined that porous molds can be created using additive manufacturing techniques through manipulation of mold manufacturing parameters such as, but not limited to, layer thickness, number of perimeter layers, fill pattern, and fill density. Through variation of these manufacturing parameters, the porosity of a mold created by an additive manufacturing device, e.g., a 3D printer, can be tailored for use with molded fiber.

A system and method of producing a moulded article, e.g. a one-piece container, comprises delivering a fibre suspension to a porous mould and removing a suspending liquid (e.g. water) via pores of the porous mould. An inflatable bladder is inserted into the mould in a collapsed state and then inflated to apply pressure to internal walls of the article to remove water content. A wet embryonic form of the container is then transferred to a non-porous mould where an inflatable bladder applies internal pressure to compress the walls and remove further water content. The container is further dried by microwave and/or air drying and may be coated with a protective layer.

A system and method of producing a moulded article, e.g. a one-piece container, comprises delivering a fibre suspension to a porous mould and removing a suspending liquid (e.g. water) via pores of the porous mould. An inflatable bladder is inserted into the mould in a collapsed state and then inflated to apply pressure to internal walls of the article to remove water content. A wet embryonic form of the container is then transferred to a non-porous mould where an inflatable bladder applies internal pressure to compress the walls and remove further water content. The container is further dried by microwave and/or air drying and may be coated with a protective layer.

A mould (14) for forming an article from a fibre suspension. The mould includes an insert with a cavity (27) in the negative shape of an article to be formed and two regions of different porosity/permeability (28, 29) about the cavity (27). In use the mould communicates a suspending fluid of the fibre suspension, e.g. by vacuum pump, through the at least two regions of different porosity/permeability about the cavity. A formed shape (22) of fibres is left behind on the cavity.

A mould (14) for forming an article from a fibre suspension. The mould includes an insert with a cavity (27) in the negative shape of an article to be formed and two regions of different porosity/permeability (28, 29) about the cavity (27). In use the mould communicates a suspending fluid of the fibre suspension, e.g. by vacuum pump, through the at least two regions of different porosity/permeability about the cavity. A formed shape (22) of fibres is left behind on the cavity.