A method for forming a vehicle reinforcing member (26, 28, 30). The method includes conforming a planar body of fibre reinforced material (CFRM) (504), such as a sheet or unidirectional tape, to a shape of a shape defining member (506, 900). In effect, the shape defining member (506, 900) is a core that defines an internal volume of a closed cross-section portion of the vehicle reinforcing member (26, 28, 30). The CFRM material (504) comprises continuous fibres in a synthetic matrix. The method further includes bonding a first edge portion (510) of the CFRM body (504) to a second edge portion (512) of the CFRM body (504) thereby to form the closed cross-section portion of the vehicle reinforcing member (26, 28, 30). An apparatus (800) for implementing the method, and components (e.g. vehicle reinforcing members (26, 28, 30), vehicle seats (10) and so forth) formed using the method are also described.

A plastic faucet body and a die for molding the same are disclosed in present invention. The plastic faucet body comprises a left water inlet pipe (1) and a right water inlet pipe (2), wherein a connecting cross-beam (3) is disposed between the left water inlet pipe (1) and the right water inlet pipe (2), the left water inlet pipe (1) and the right water inlet pipe (2) are embedded with a threaded copper pipe (4), respectively, the copper pipes (4) are formed integrally with the plastic faucet body by means of a single stage process and are in communication with the corresponding left water inlet pipe (1) and the right water inlet pipe (2), respectively.

An asymmetric mold core for forming curved floor openings in pallets is taught. The mold core contains: a base, the base attachable to a frame in a rotomold, a bottom section integral at a distal end to the base, the bottom section comprising a bottom convex curve having a bottom convex curve radius and a bottom convex curve rotational center, a top section integral at a distal end to the base, the top section comprising a top convex curve, the top convex curve having a top convex curve radius and a top convex curve rotational center, the top convex curve radius being different from the bottom convex curve radius and the top convex curve rational center differing from the bottom convex curve rotational center; a first side section, the first side section positioned and integral at a distal end to the base and positioned between and integral with the bottom section and the top section; a second side section the second side section positioned and integral at a distal end to the base and positioned between and integral with the bottom section and the top section, the second side section positioned parallel to the first side section; and a face.

An asymmetric mold core for forming curved floor openings in pallets is taught. The mold core contains: a base, the base attachable to a frame in a rotomold, a bottom section integral at a distal end to the base, the bottom section comprising a bottom convex curve having a bottom convex curve radius and a bottom convex curve rotational center, a top section integral at a distal end to the base, the top section comprising a top convex curve, the top convex curve having a top convex curve radius and a top convex curve rotational center, the top convex curve radius being different from the bottom convex curve radius and the top convex curve rational center differing from the bottom convex curve rotational center; a first side section, the first side section positioned and integral at a distal end to the base and positioned between and integral with the bottom section and the top section; a second side section the second side section positioned and integral at a distal end to the base and positioned between and integral with the bottom section and the top section, the second side section positioned parallel to the first side section; and a face.

A method of making an actuator having a complex internal shape includes providing a core of a shape that defines an internal cavity of an actuator; molding an actuator around the core, wherein the core occupies the internal cavity of the actuator, the cavity having an opening; generating a pressure differential between an exterior surface of the actuator and the internal cavity of the actuator, wherein the external pressure is less than the internal pressure, to expand the actuator cavity; and removing the core through the opening of the expanded actuator cavity.

A method of making an actuator having a complex internal shape includes providing a core of a shape that defines an internal cavity of an actuator; molding an actuator around the core, wherein the core occupies the internal cavity of the actuator, the cavity having an opening; generating a pressure differential between an exterior surface of the actuator and the internal cavity of the actuator, wherein the external pressure is less than the internal pressure, to expand the actuator cavity; and removing the core through the opening of the expanded actuator cavity.

A method that combines injection molding and extrusion is disclosed. First, a molten material is injected into a mold via an injection gate, the mold comprising a first portion and a second portion. Next, additional molten material is injected via the injection gate and pushed through an extrusion die located in the first portion of the mold and the second portion is separated from the first portion. In embodiments, the second portion is separated from the first portion before the additional material is injected. In other embodiments, the second portion is separated from the first portion simultaneously with the additional material being injected. The method may be used to produce longer and thinner parts with detailed features, such as catheters.

A method is provided for preparing a composite product, the method comprising: forming a core structure having a plurality of layers, each layer being build by an additive manufacturing process; wherein the core structure has a shell substantially enclosing an internal chamber of the core structure, wherein the shell is fluid-impermeable, and wherein the outer surface of the shell has a predefined shape; introducing a fluid into the chamber of the core structure; arranging the core structure and reinforcement fibers in a mould, wherein the mould is arranged to accommodate the core structure including the reinforcement fibers, and wherein the reinforcement fibers and the outer surface of the shell are arranged in contact with each other; providing the reinforcement fibers and a resin on the outer surface of the shell of the core structure; and solidifying the resin to form the composite product inside the mould at a moulding pressure P.sub.m, while controlling the fluid pressure P.sub.F of the fluid in the core structure.

Methods for forming rotor blades, rotor blade mold assemblies, and cores for rotor blade mold assemblies are disclosed. A method includes providing a first shell substrate on a first mold, providing a generally hollow core on the first shell substrate, providing a second shell substrate on the generally hollow core, and providing a second mold on the second shell substrate. The method further includes flowing a resin into a mold interior defined between the first mold and the second mold.

Methods for forming rotor blades, rotor blade mold assemblies, and cores for rotor blade mold assemblies are disclosed. A method includes providing a first shell substrate on a first mold, providing a generally hollow core on the first shell substrate, providing a second shell substrate on the generally hollow core, and providing a second mold on the second shell substrate. The method further includes flowing a resin into a mold interior defined between the first mold and the second mold.