Provided are a method and an apparatus for manufacturing a fiber-reinforced resin molding material by which, when the fiber-reinforced resin molding material is manufactured, separated fiber bundles can be supplied to a cutting machine in stable condition while avoiding the influence of meandering of the fiber bundles or slanting or meandering of filaments occurring in the fiber bundles. A method for manufacturing a sheet-shaped fiber-reinforced resin molding material in which spaces between filaments of cut-out fiber bundles (CF) are impregnated with resin includes, so that a condition of the following expression (1) is satisfied, intermittently separating fibers of the continuous fiber bundles (CF) in a longitudinal direction by a rotational blade (18) serving as a fiber separating part and cutting out the fiber bundles with an interval therebetween in a longitudinal direction of a cutting machine (13A) to obtain the cut-out fiber bundles (CF). Expression (1): 1?a/L (where a represents a length of a separated part of the continuous fiber bundles (CF) and L represents an interval when the fiber bundles (CF) are cut out in the longitudinal direction.)

Provided are a method and an apparatus for manufacturing a fiber-reinforced resin molding material by which, when the fiber-reinforced resin molding material is manufactured, separated fiber bundles can be supplied to a cutting machine in stable condition while avoiding the influence of meandering of the fiber bundles or slanting or meandering of filaments occurring in the fiber bundles. A method for manufacturing a sheet-shaped fiber-reinforced resin molding material in which spaces between filaments of cut-out fiber bundles (CF) are impregnated with resin includes, so that a condition of the following expression (1) is satisfied, intermittently separating fibers of the continuous fiber bundles (CF) in a longitudinal direction by a rotational blade (18) serving as a fiber separating part and cutting out the fiber bundles with an interval therebetween in a longitudinal direction of a cutting machine (13A) to obtain the cut-out fiber bundles (CF). Expression (1): 1?a/L (where a represents a length of a separated part of the continuous fiber bundles (CF) and L represents an interval when the fiber bundles (CF) are cut out in the longitudinal direction.)

A parison separation device (30) according to an embodiment includes a cutter (31) with a cutting edge (35), the cutting edge (35) extending in a one direction and facing upward, and a block (33), the cutter being attached to an upper part of the block (33), inclined surfaces (37) being formed on both sides of the block (33) in a thickness direction of the cutting edge (35), each of the inclined surfaces (37) including a component that is inclined increasingly downward as it gets closer to one direction side end, in which the parison separation device (30) is disposed on a discharging direction side of a discharging port of a parison and configured to cut the parison discharged from the discharging port.

A parison separation device (30) according to an embodiment includes a cutter (31) with a cutting edge (35), the cutting edge (35) extending in a one direction and facing upward, and a block (33), the cutter being attached to an upper part of the block (33), inclined surfaces (37) being formed on both sides of the block (33) in a thickness direction of the cutting edge (35), each of the inclined surfaces (37) including a component that is inclined increasingly downward as it gets closer to one direction side end, in which the parison separation device (30) is disposed on a discharging direction side of a discharging port of a parison and configured to cut the parison discharged from the discharging port.

Provided are composite feedstock strips for additive manufacturing and methods of forming such strips. A composite feedstock strip may include continuous unidirectional fibers extending parallel to each other and to the principal axis of the strip. This fiber continuity yields superior mechanical properties, such as the tensile strength along strip's principal axis. Composite feedstock strips may be fabricated by slitting a composite laminate in a direction parallel to the fibers. In some embodiments, the cross-sectional shape of the slit strips may be changed by reattributing material at least on the surface of the strips and/or by coating the slit strips with another material. This cross-sectional shape change may be performed without disturbing the continuous fibers within the strips. The cross-sectional distribution of fibers within the strips may be uneven with higher concentration of fibers near the principal axis of the strips, for example, to assist with additive manufacturing.

Provided are composite feedstock strips for additive manufacturing and methods of forming such strips. A composite feedstock strip may include continuous unidirectional fibers extending parallel to each other and to the principal axis of the strip. This fiber continuity yields superior mechanical properties, such as the tensile strength along strip's principal axis. Composite feedstock strips may be fabricated by slitting a composite laminate in a direction parallel to the fibers. In some embodiments, the cross-sectional shape of the slit strips may be changed by reattributing material at least on the surface of the strips and/or by coating the slit strips with another material. This cross-sectional shape change may be performed without disturbing the continuous fibers within the strips. The cross-sectional distribution of fibers within the strips may be uneven with higher concentration of fibers near the principal axis of the strips, for example, to assist with additive manufacturing.

A bicycle saddle manufacturing method includes the steps of expanding a foamable material to form the foamable material into a semi-finished saddle body, and performing a thermoforming process to form the semi-finished saddle body into a saddle in a forming mold. As a result, the bicycle saddle manufacturing method of the present invention can avoid waste of material and environmental pollution.

A bicycle saddle manufacturing method includes the steps of expanding a foamable material to form the foamable material into a semi-finished saddle body, and performing a thermoforming process to form the semi-finished saddle body into a saddle in a forming mold. As a result, the bicycle saddle manufacturing method of the present invention can avoid waste of material and environmental pollution.

A method of forming a fiber-reinforced molding compound. The method includes establishing a melt stream of a source material including a first polymeric material having a first melt temperature in an extruder and dosing a composite material into the melt stream. The composite material includes pre-impregnated reinforcing fibers comprising reinforcing filaments and a second polymeric material having a second melt temperature greater than the first melt temperature. The composite material has at least 30% of the reinforcing filaments protected by the polymeric material such that the polymeric material surrounds each filament completely forming a barrier between it and an adjacent filament in the at least 30% of the filaments. The temperature of the melt stream at dosing is below the second melt temperature. The method includes forming a molding compound from the source and composite materials. The method includes dispensing the molding compound to produce a part.

A method of forming a fiber-reinforced molding compound. The method includes establishing a melt stream of a source material including a first polymeric material having a first melt temperature in an extruder and dosing a composite material into the melt stream. The composite material includes pre-impregnated reinforcing fibers comprising reinforcing filaments and a second polymeric material having a second melt temperature greater than the first melt temperature. The composite material has at least 30% of the reinforcing filaments protected by the polymeric material such that the polymeric material surrounds each filament completely forming a barrier between it and an adjacent filament in the at least 30% of the filaments. The temperature of the melt stream at dosing is below the second melt temperature. The method includes forming a molding compound from the source and composite materials. The method includes dispensing the molding compound to produce a part.