A novel cutting-edge structure and method and apparatus for manufacturing the cutting-edge structure is provided. The cutting-edge structure is comprised of naturally derived or renewable material at greater than 50% by volume fraction. In one embodiment, the naturally derived material is a cellulose nanostructure such as a cellulose nanocrystal. The cellulose nanocrystal is processed using a base or mold structure to provide a cutting edge of any shape such as linear or circular edge structures. The process includes dual cure steps to produce an optimal cutting-edge structure without shrinkage. The formed cutting-edge structure can be utilized as a razor blade as it is formed with very sharp tip and edge suitable for cutting hair. The base structure can form one or more cutting-edge structures simultaneously.

A novel cutting-edge structure and method and apparatus for manufacturing the cutting-edge structure is provided. The cutting-edge structure is comprised of naturally derived or renewable material at greater than 50% by volume fraction. In one embodiment, the naturally derived material is a cellulose nanostructure such as a cellulose nanocrystal. The cellulose nanocrystal is processed using a base or mold structure to provide a cutting edge of any shape such as linear or circular edge structures. The process includes dual cure steps to produce an optimal cutting-edge structure without shrinkage. The formed cutting-edge structure can be utilized as a razor blade as it is formed with very sharp tip and edge suitable for cutting hair. The base structure can form one or more cutting-edge structures simultaneously.

A system and method is provided for manufacturing a composite structure. In an exemplary aspect, the system includes multiple flexible tooling plates that are interlocked to each other to form a tooling surface for forming a composite structure to be manufactured. Moreover, the system includes an actuator array connected to the flexible plates and that can move the flexible plates relative to each other to adjust a contour of the tooling surface to correspond to a design contour of the composite structure to be manufactured.

A system and method is provided for manufacturing a composite structure. In an exemplary aspect, the system includes multiple flexible tooling plates that are interlocked to each other to form a tooling surface for forming a composite structure to be manufactured. Moreover, the system includes an actuator array connected to the flexible plates and that can move the flexible plates relative to each other to adjust a contour of the tooling surface to correspond to a design contour of the composite structure to be manufactured.

Polymer-based molds are described. The polymer-based mold includes a first portion comprising a first material having a glass transition temperature (Tg) lower than about 80 C.; and a second portion comprising a second material having a Tg higher than about 80 C., wherein the second portion at least partially covers the first portion, the second portion is thinner than the first portion and faces a cavity in the polymeric mold.

Polymer-based molds are described. The polymer-based mold includes a first portion comprising a first material having a glass transition temperature (Tg) lower than about 80 C.; and a second portion comprising a second material having a Tg higher than about 80 C., wherein the second portion at least partially covers the first portion, the second portion is thinner than the first portion and faces a cavity in the polymeric mold.

Provided are extrusion tools such as extrusion dies or portions thereof having a surface with at least one coating thereon, and methods of forming the same are disclosed. The at least one coating is formed from a composition that is a metal aluminum nitride or carbonitride with particular characteristics such that the amount of aluminum varies within the coating between a coating outer surface and an intermediate thickness within the coating. The resulting coatings have tailored physical and performance characteristics that result in improved wear and extrusion performance.

According to some aspects, a method is provided of casting an object from a mold, the method comprising obtaining a mold comprising a hollow shell of rigid material, the material comprising a thermoset polymer having a plurality of pores formed therein, providing a metal and/or ceramic slurry into an interior of the mold, exposing at least part of the mold to a low pressure environment so that a net flow of gas is produced from the interior of the mold into the low pressure environment. According to some aspects, a method of forming a porous mold is provided. According to some aspects, a photocurable liquid composition is provided, comprising a liquid photopolymer resin, particles of a solid material, in an amount between 30% and 60% by volume of the composition, and a water-soluble liquid.

A texture structure, an optical film, a mold and a cover plate for an electronic device. The texture structure includes a certain number of small short lines, there existing an included angle between at least one of the small short lines and the horizontal direction, at least one of the small short lines being of a convex structure or a concave structure; wherein intervals are provided between neighboring small short lines. The texture structure can change the directions of the small short lines randomly or according to a wanted effect in a certain direction. The optical film with the texture structure, wherein there exists at least one light pillar in the optical film with such a texture structure under a certain light source. The cover plate for an electronic device adopts the texture structure or the optical film.

A manufacturing method of a mold includes the steps of: providing an aluminum base in the shape of a hollow cylinder which is made of a AlMgSi based aluminum alloy, the aluminum base being mechanically mirror-finished; performing a frosting treatment on a surface of the aluminum base with an aqueous solution which contains a salt of hydrogen fluoride and ammonium; thereafter, forming an inorganic material layer on the surface of the aluminum base and forming an aluminum film on the inorganic material layer, thereby forming a mold base; and alternately repeating anodization and etching on a surface of the aluminum film of the mold base, thereby forming an inverted moth-eye structure which has a plurality of micro recessed portions.