The present disclosure encompasses three-dimensional articles comprising flexible-composite materials and methods of manufacturing said three-dimensional articles. More particularly, the present system relates to methods for manufacturing seamless three-dimensional-shaped articles usable for such finished products as airbags/inflatable structures, bags, shoes, and similar three-dimensional products. A preferred manufacturing process combines composite molding methods with specific precursor materials to form fiber-reinforced continuous shaped articles that are flexible and collapsible.

A balloon wrapping apparatus is disclosed by which a balloon can be accurately positioned and inserted in relation to a pleating section. The balloon wrapping apparatus for wrapping a balloon provided at a distal portion of an elongated shaft includes: a pleating section that forms the balloon with wing shapes; a folding section that folds the wing shapes formed in the balloon along a circumferential direction; a support base that supports a portion other than the distal portion of the shaft, and that makes the distal portion of the shaft insertable into the pleating section and the folding section; and a core metal member to be inserted in the shaft. The core metal member is inserted in the shaft from a distal end position of the balloon to at least the proximal side of a proximal end position of the balloon.

A balloon wrapping apparatus is disclosed by which a balloon can be accurately positioned and inserted in relation to a pleating section. The balloon wrapping apparatus for wrapping a balloon provided at a distal portion of an elongated shaft includes: a pleating section that forms the balloon with wing shapes; a folding section that folds the wing shapes formed in the balloon along a circumferential direction; a support base that supports a portion other than the distal portion of the shaft, and that makes the distal portion of the shaft insertable into the pleating section and the folding section; and a core metal member to be inserted in the shaft. The core metal member is inserted in the shaft from a distal end position of the balloon to at least the proximal side of a proximal end position of the balloon.

A manufacturing process for making aircraft engine parts utilizes reusable reconfigurable smart memory polymer mandrel tooling, low temperature metal deposition, and composite part lay-up with resin coated conformable braided carbon fiber sleeves, to fabricate both metal internal engine parts and non-metal external parts for turbine engines.

A manufacturing process for making aircraft engine parts utilizes reusable reconfigurable smart memory polymer mandrel tooling, low temperature metal deposition, and composite part lay-up with resin coated conformable braided carbon fiber sleeves, to fabricate both metal internal engine parts and non-metal external parts for turbine engines.

A composite forming method includes manufacturing either one of a composite structure body and a dry preform having a hollow region, and pulling a core out of the hollow region. In the manufacturing, a rubber-made core having a tubular structure is disposed at a portion that forms the hollow region of either one of the composite structure body and the dry preform. The core has a thickness varied in a direction perpendicular to a longitudinal direction to be foldable inward at a thin portion. In the pulling, the core is folded inward with air being discharged from an inside of the core after either one of the composite structure body and the dry preform is manufactured.

A composite forming method includes manufacturing either one of a composite structure body and a dry preform having a hollow region, and pulling a core out of the hollow region. In the manufacturing, a rubber-made core having a tubular structure is disposed at a portion that forms the hollow region of either one of the composite structure body and the dry preform. The core has a thickness varied in a direction perpendicular to a longitudinal direction to be foldable inward at a thin portion. In the pulling, the core is folded inward with air being discharged from an inside of the core after either one of the composite structure body and the dry preform is manufactured.

Methods and apparatuses are disclosed to mold complex shapes using a cast mold technique. A catalyst-initiated urethane can be used for these complex shapes as there is little thickness restriction on any part dimension. Moreover, urethane, once chemically activated, can be poured into cast molds with various shapes. Due to the exothermic nature of urethane, when the curing chemical reaction takes place, metal molds can be fabricated from aluminum. Cast molds, made from aluminum, utilize elastomeric seals to account for coefficients of thermal expansion.

Forming systems and methods for drape forming a composite charge are disclosed herein. The forming systems include a forming die having a forming surface and a collapsible support having a support surface. The collapsible support is configured to transition from an extended conformation to a collapsed conformation and is configured such that a gap width of a gap between the support surface and the forming surface decreases during the transition. The methods include positioning a composite charge, transitioning the collapsible support from an extended conformation to a collapsed conformation, decreasing the gap width of the gap as the collapsible support transitions from the extended conformation to the collapsed conformation, and deforming the composite charge from an initial conformation to a final conformation.

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.