A process and system are provided for introducing a blend of chopped and dispersed fibers on an automated production line amenable for inclusion in molding compositions as a blended fiber mat for structural applications. The blend of fibers are simultaneously supplied to an automated cutting machine illustratively including a rotary blade chopper disposed above a vortex supporting chamber. The blend of chopped fibers and binder form a chopped mat. The chopped mat has a veil mat placed on either side, and is consolidated with the veil mat using heated rollers maintained at the softening temperature of thermoplastic binder, with consolidated mats being amenable to being stored in rolls or as flat sheets. A charge pattern is made using the consolidated mat, and the charge pattern can be compression molded in a mold maintained at a temperature lower than the melting point of the thermoplastic fibers.

A process and system are provided for introducing a blend of chopped and dispersed fibers on an automated production line amenable for inclusion in molding compositions as a blended fiber mat for structural applications. The blend of fibers are simultaneously supplied to an automated cutting machine illustratively including a rotary blade chopper disposed above a vortex supporting chamber. The blend of chopped fibers and binder form a chopped mat. The chopped mat has a veil mat placed on either side, and is consolidated with the veil mat using heated rollers maintained at the softening temperature of thermoplastic binder, with consolidated mats being amenable to being stored in rolls or as flat sheets. A charge pattern is made using the consolidated mat, and the charge pattern can be compression molded in a mold maintained at a temperature lower than the melting point of the thermoplastic fibers.

A structure includes a reinforcing member made up of reinforcing fibers that are impregnated with a resin. The reinforcing member includes a first region and a second region. The first region is formed by irradiating the reinforcing fibers with plasma. The second region is formed by irradiating the reinforcing fibers with a smaller amount of the plasma than the first region. The reinforcing member is provided such that the first region is positioned in a location where more strength is required than the second region.

A structure includes a reinforcing member made up of reinforcing fibers that are impregnated with a resin. The reinforcing member includes a first region and a second region. The first region is formed by irradiating the reinforcing fibers with plasma. The second region is formed by irradiating the reinforcing fibers with a smaller amount of the plasma than the first region. The reinforcing member is provided such that the first region is positioned in a location where more strength is required than the second region.

Systems, devices, and methods are provided for producing a 3d-printable composite material for large scale printing. A method can include receiving a first component comprising a (meth)acrylic monomer or a (meth)acrylic oligomer, or a combination thereof. The method can include receiving a second component comprising a photoinitiator and a third component comprising a polymerization enhancer. The method can include mixing the first component, second component, and third component with a mixing reactor to form a mixture. The method can include filtering the mixture with a filtration unit and removing a solid residue from the mixture. The method can include curing the filtered mixture with a radiation unit into a gel component and a liquid component. The method can include separating the gel component with a phase separation unit and then milling the gel component. And the method can include mixing the gel component, the photoinitiator, the mineral filler and optionally the recycled previously printed composite material to form the composite material.

Systems, devices, and methods are provided for producing a 3d-printable composite material for large scale printing. A method can include receiving a first component comprising a (meth)acrylic monomer or a (meth)acrylic oligomer, or a combination thereof. The method can include receiving a second component comprising a photoinitiator and a third component comprising a polymerization enhancer. The method can include mixing the first component, second component, and third component with a mixing reactor to form a mixture. The method can include filtering the mixture with a filtration unit and removing a solid residue from the mixture. The method can include curing the filtered mixture with a radiation unit into a gel component and a liquid component. The method can include separating the gel component with a phase separation unit and then milling the gel component. And the method can include mixing the gel component, the photoinitiator, the mineral filler and optionally the recycled previously printed composite material to form the composite material.

Fabrication of ballistic resistant fibrous composites having improved ballistic resistance properties. More particularly, ballistic resistant fibrous composites having high interlaminar lap shear strength between component fiber plies or fiber layers, which correlates to low composite backface signature. The high lap shear strength, low backface signature composites are useful for the production of hard armor articles, including helmet armor.

Fabrication of ballistic resistant fibrous composites having improved ballistic resistance properties. More particularly, ballistic resistant fibrous composites having high interlaminar lap shear strength between component fiber plies or fiber layers, which correlates to low composite backface signature. The high lap shear strength, low backface signature composites are useful for the production of hard armor articles, including helmet armor.

The invention is directed to a blow molded article. The article comprises at least three layers wherein layer A comprises polymer, layer B comprises a foam composition comprising high density polyethylene having a quotient of melt strength and apparent viscosity>2 cN/k.Pa.s and layer C comprises polymer wherein the layer comprising the foam composition is enclosed between two layers A and C and wherein the melt strength is determined as described in ISO 16790:2005 and the apparent viscosity is determined as described in ISO 11443:2014 and wherein the foam composition is produced with a physically blowing agent.

The invention is directed to a blow molded article. The article comprises at least three layers wherein layer A comprises polymer, layer B comprises a foam composition comprising high density polyethylene having a quotient of melt strength and apparent viscosity>2 cN/k.Pa.s and layer C comprises polymer wherein the layer comprising the foam composition is enclosed between two layers A and C and wherein the melt strength is determined as described in ISO 16790:2005 and the apparent viscosity is determined as described in ISO 11443:2014 and wherein the foam composition is produced with a physically blowing agent.