Methods of manufacturing an extrusion die (100) having a plurality of pins (600a-c) and a plurality of slots (601) defined by the plurality of pins, each pin having a base, the method including applying a coating material (604) over side walls of the bases of the pins of the extrusion die and removing a portion of the coating material coated over the side walls of the bases of the plurality of pins with a cutting tool (650). In some embodiments, the cutting tool has a cutting width (652) equal to a target slot width (640) of the slots. In some embodiments, applying the coating material over the side walls of the bases of the pins includes overcoating a coating material to a thickness that is greater than a thickness needed to define a target slot width of the slots.

Forging dies are formed from a plurality of layers stacked together to form an assembly, or laminate. Each respective layer may be cut to form a portion of a die cavity, and the layers may be stacked together such that the cut portions are aligned to form the die cavity. The layers are fastened together to form a first die half and/or a second die half of disclosed forging dies. Each layer may be selectively removable from the die half for maintenance and/or replacement. Disclosed forging dies may be formed of lower grade materials as compared to conventional forging dies, and the number and thickness of layers may be varied to accommodate the specific part geometry of the part being forged. Related methods of making said forging dies and using said forging dies to make parts are also disclosed.

A system for additive manufacturing of a three-dimensional object, comprising: a controller for identifying a set of planar cross-sectional shapes of the three-dimensional object, the set extending in a sequence from a first end of the three-dimensional object to a second end of the three-dimensional object; a three-dimensional scanner, associated with the controller, configured to scan a prototype of the three-dimensional object to generate a computer-aided design model; at least one cutting station for cutting at least one barbed metal sheet into a plurality of individual planar barbed metal pieces corresponding to the cross-sectional shapes; and for cutting at least one substrate sheet into a plurality of individual planar substrate pieces corresponding to the cross-sectional shapes, wherein the at least one substrate is penetrable by the barbs; and a binding station for receiving and pressing the individual barbed metal pieces and the individual substrate pieces together.

A mold which can improve an appearance of a molded body is provided. A mold includes a cavity, the mold being capable of subjecting a resin sheet under reduced pressure suction via a plurality of reduced pressure suction holes thereby shaping the resin sheet to follow a shape of an inner surface of the cavity; wherein: the inner surface includes a base surface and a plurality of island-like concave portions provided in the base surface; and a concave portion reduced pressure suction hole index defined by an in-concave reduced pressure suction hole ratio divided by a concave portion area ratio is 0.5 or lower.

A mouthpiece (10) for extruding a molding compound into a formed body which has internal channels, comprises: a mouthpiece frame (14) with a frame opening (16); a first core retaining plate (22) which is fastened in the area of an upstream end of the frame opening (16) when viewed in the flow direction (15) of the molding compound; and a plurality of longitudinal cores (28) which are axially and laterally held by an upstream end section (26) on the first core retaining plate (22). It is proposed that, furthermore, it comprises a second core retaining plate (36) which is loosely arranged downstream of the first core retaining plate (22) relative to the mouthpiece frame (14) in the flow direction (15), and in which the areas (32) of the cores (28) farther from the upstream end section (26) are arranged to be radially fixed but axially loose.

A system for forming a metal strip into a die having a predetermined shape through a series of forming operations is described herein. The system includes a base configured to support the metal strip as the metal strip undergoes the series of forming operations; a feeding device configured to advance the metal strip between each forming operation of the series of forming operations and grip the metal strip during each forming operation; a bending device configured to bend a portion of the metal strip extending from the feeding device as one of the series of forming operations; a forming head configured to house a pair of forming tools and provide features to the portion of the metal strip extending from the feeding device as one of the series of forming operations using the one or more forming tools; a robotic arm configured to selectively provide the one or more forming tools to the forming head; and a computing unit in communication with the robotic arm and configured to transmit a control signal to cause the robotic arm to retrieve the pair of forming tools and provide the pair of forming tools to the forming head.

A system for forming a metal strip into a die having a predetermined shape through a series of forming operations is described herein. The system includes a base configured to support the metal strip as the metal strip undergoes the series of forming operations; a feeding device configured to advance the metal strip between each forming operation of the series of forming operations and grip the metal strip during each forming operation; a bending device configured to bend a portion of the metal strip extending from the feeding device as one of the series of forming operations; a forming head configured to house a pair of forming tools and provide features to the portion of the metal strip extending from the feeding device as one of the series of forming operations using the one or more forming tools; a robotic arm configured to selectively provide the one or more forming tools to the forming head; and a computing unit in communication with the robotic arm and configured to transmit a control signal to cause the robotic arm to retrieve the pair of forming tools and provide the pair of forming tools to the forming head.

A honeycomb extrusion die (120) includes a die body (302) including an inlet face (306) and an exit face. The die body (302) has slot inlets (309) and a plurality of pins (320, 500) disposed between the slot inlets (309) and the exit face. The plurality of pins (320, 500) include side surfaces (322, 500B) configured to define a matrix of intersecting slots (324), wherein the matrix of intersecting slots (324) has slot exit (509) widths at the exit face. Divots (526) extend into a plurality of the side surfaces (322, 500B) between the slot inlets (309) and the exit face. Each individual divot (526) has a divot san depth (D55) extending into a side surface (500A, 500B, 502A, 502B) of the side surfaces (322, 500B). A ratio between a slot exit width (W53) W53 of an individual slot (324) and the divot depth (D55) of an individual divot (526) extending into a side surface (500A, 500B, 502A, 502B) of the individual slot (324) is greater than 1.2. Methods of forming honeycomb bodies with honeycomb structures are provided, as are other aspects.

A honeycomb extrusion die (100), a method of making the same, and an apparatus for forming the same. The die (100) includes: a feed hole plate (202) comprising an input surface (202A), an opposing output surface (202B), and feed holes (108) configured to guide a batch material from the input surface (202A) to the output surface (202B); and a pin assembly (204) comprising pins (300) disposed on the feed hole plate (202). At least one of the pins includes: a tail (304); a head (302) connected to the tail (304) and comprising alignment surfaces (314) configured to align the pins (300), flow surfaces (316) disposed between the alignment surfaces (314), and a tapered portion (310) comprising a contact surface (308) adhered to the output surface (202B) of the feed hole plate (202); and a first groove (306) disposed between the head (302) and the tail (304). In the pin assembly (204), the alignment surfaces (314) contact adjacent pins (300) to align the pins (300), such that discharge slots are at least partially defined by the tails (304) of the pins (300).

The present invention provides a bi-metal assembling method. The method provides a machine-shaped aluminum piece and places the machine-shaped aluminum piece into a die-cast mold. The machine-shaped aluminum piece is encapsulated with a magnesium metal liquid and die cast is performed. The assembled bi-metal structure is coated for protection and CNC high-gross treatment and anodizing treatment is performed in the machine-shaped aluminum piece. The magnesium alloy piece is hooked with the machine-shaped aluminum piece for assembling. The bi-metal structure has smooth surface to reduce the time for polishing, surface shrinkage and generation of blowholes. The present invention also provides a bi-metal assembled structure.