An apparatus for molding a part includes a plunger cavity, a plunger, and a mold cavity, wherein the plunger is oriented out-of-plane with respect to a major surface of the mold cavity, and first and second vents couples to respective first and second portions of the mold cavity. In a method, resin and fiber are forced into the mold cavity from a plunger cavity, and at least some of the fibers and resin are preferentially flowed to certain region in the mold cavity via the use of vents.

The invention relates to a method for manufacturing a composite aircraft window frame; the method comprises the steps of: a) positioning in a mold a preform made of pre-impregnated material including dispersed fibers, with a predefined orientation, in a thermosetting resin matrix; b) closing the mold so as to define a gap between at least one surface of said preform and a portion of said mold; c) injecting thermosetting resin into the closed mold through an inlet opening of the mold itself, so as to fill the gap and completely lap said surface of the preform; and d) applying a uniform hydrostatic pressure on the surface by the injection of the resin.

A mold for molding an object having a shape, the mold comprising: a top, middle, and bottom bodies, said bodies having peripheral walls, and defining a central vertical axis and an inside cavity surface having same central vertical axis, when said bodies are in mutual contact; and a center hole disposed centrally in a top surface of the top body, the center hole aligning with the vertical central axis; the middle body comprising separate halves that are identical in shape; wherein the inside cavity surface comprises at least one protrusion disposed horizontally along the inside cavity surface, and at least one channel disposed horizontally along the inside cavity surface, the at least one channel being adjacent to the at least one protrusion; wherein, in the presence of a molding compound, the inside cavity surface defines at least a portion of the shape of the object being molded within the mold.

A method of forming a three-dimensional object, is carried out by (a) providing a carrier and a build plate, the build plate comprising a semipermeable member, the semipermeable member comprising a build surface with the build surface and the carrier defining a build region therebetween, and with the build surface in fluid communication by way of the semipermeable member with a source of polymerization inhibitor; (b) filling the build region with a polymerizable liquid, the polymerizable liquid contacting the build surface, (c) irradiating the build region through the build plate to produce a solid polymerized region in the build region, while forming or maintaining a liquid film release layer comprised of the polymerizable liquid formed between the solid polymerized region and the build surface, wherein the polymerization of which liquid film is inhibited by the polymerization inhibitor; and (d) advancing the carrier with the polymerized region adhered thereto away from the build surface on the build plate to create a subsequent build region between the polymerized region and the build surface while concurrently filling the subsequent build region with polymerizable liquid as in step (b). Apparatus for carrying out the method is also described.

An apparatus for molding a part includes a plunger cavity, a plunger, and a mold cavity, wherein the plunger is oriented out-of-plane with respect to a major surface of the mold cavity, and first and second vents couples to respective first and second portions of the mold cavity. In a method, resin and fiber are forced into the mold cavity from a plunger cavity, and at least some of the fibers and resin are preferentially flowed to certain region in the mold cavity via the use of vents.

A cartridge for storing and transporting fiber-bundle-based preform charges includes a plurality of cells arranged within the housing, wherein each cell is physically adapted to receive a preform charge and prevent it from moving therein as the cartridge is transported. In some embodiments, the cartridge and preform charges it conveys are serialized.

A mold for molding an object having a shape, the mold comprising: a top, middle, and bottom bodies, said bodies having peripheral walls, and defining a central vertical axis and an inside cavity surface having same central vertical axis, when said bodies are in mutual contact; and a center hole disposed centrally in a top surface of the top body, the center hole aligning with the vertical central axis; the middle body comprising separate halves that are identical in shape; wherein the inside cavity surface comprises at least one protrusion disposed horizontally along the inside cavity surface, and at least one channel disposed horizontally along the inside cavity surface, the at least one channel being adjacent to the at least one protrusion; wherein, in the presence of a molding compound, the inside cavity surface defines at least a portion of the shape of the object being molded within the mold.

A mold having an upper, medial, and lower bodies with a composite peripheral wall define an inside cavity which may have a complex shape as for instance, with circular protrusions, circular depressions, and axially aligned cylinders. Pour holes are provided for introducing a molding compound into the mold while allowing air to exit the cavity. The medial body may be made of multiple portions. The upper body may be axially lifted off the medial body and the medial body may be laterally moved away from the molded object which enables removal of the complex molded part.

A tooling assembly for manufacturing a porous composite structure. The tooling assembly includes a first tooling member and a second tooling member. The first tooling member includes a first body that defines a first internal volume and a first inlet. The first inlet is fluidly coupled with the first internal volume. The first tooling member also includes a first tooling surface that defines a plurality of first perforations that are fluidly coupled with the first internal volume. The second tooling member includes a second body that defines a second internal volume and a second inlet. The second inlet is fluidly coupled with the second internal volume. The second tooling member also includes a second tooling surface that defines a plurality of second perforations that are fluidly coupled with the second internal volume.

Particular embodiments of the invention include apparatus and methods for compensating for shrinkage of a polymeric material in a mold during curing operations. Embodiments of the method include providing a mold comprising a molding cavity defining an interior mold volume separated from an exterior environment and introducing a volume of polymeric material into the molding cavity. Such methods further include impeding the development of a void in the volume of polymeric material by, either: isolating the volume of polymeric material within the molding cavity from the exterior environment, or reducing the interior mold volume of the molding cavity to at least substantially consume a volume of polymeric material shrinkage. Such methods further include curing the polymeric material to form a molded polymeric form.