Systems and methods for forming 3D plastic parts that are cost effective in low volume, have excellent fit and finish, and use many components from 2D construction are disclosed. The systems and methods involve selecting a design and modelling the design. The design comprises 2D and 3D components of plastic parts. A 3D forming buck corresponding to the 3D component is manufactured. At least one of a 2D part and the 3D forming buck may be heated. The 2D part may be loaded onto the 3D forming buck for a predefined period of time. The 3D part formed after the loading may be separated from the 3D forming buck. The 3D part is the 2D part generally having taken the shape of the 3D forming buck. The 3D part may be cooled to obtain an end product.

Object: Provided is a decorative vapor deposition sheet that can reduce or prevent a defect, such as the breaking of a metal vapor deposition layer or the entire sheet, even when applied to a forming method requiring high temperature or the like. The decorative vapor deposition sheet of an embodiment of the present disclosure is a decorative vapor deposition sheet including a cover resin layer and a metal vapor deposition layer, in which the cover resin layer has a thickness of approximately 50 micrometers or greater, the metal vapor deposition layer exhibits a granular structure, a breaking elongation of the decorative vapor deposition sheet at 20° C. is approximately 120% or greater, and a breaking elongation of the decorative vapor deposition sheet at 160° C. is approximately 350% or greater.

A molding tool (1000), in particular a thermoforming tool, for producing a container (10) is provided. The molding tool comprises a mold bottom (200) and a mold insert (100) receiving the mold bottom (200), wherein the mold insert (100) is constructed of at least two mold insert parts (110, 120) that together with the mold bottom (200) define a cavity (300) provided for reshaping a two-dimensional web of material into a container, wherein a first mold insert part (110) is mounted stationary in the molding tool (1000) and a second mold insert part is axially movable in the molding tool (1000).

A molding tool (1000), in particular a thermoforming tool, for producing a container (10) is provided. The molding tool comprises a mold bottom (200) and a mold insert (100) receiving the mold bottom (200), wherein the mold insert (100) is constructed of at least two mold insert parts (110, 120) that together with the mold bottom (200) define a cavity (300) provided for reshaping a two-dimensional web of material into a container, wherein a first mold insert part (110) is mounted stationary in the molding tool (1000) and a second mold insert part is axially movable in the molding tool (1000).

A method of manufacturing cross-corrugated support structures is provided. A mold having a molding surface with a first plurality and a second plurality of corrugations therein is used to introduce corrugations into a flexible, carbonaceous sheet. Cross-corrugations are introduced into the sheet by placing the sheet onto the molding surface, encapsulating the sheet to form a vacuum chamber, and evacuating the vacuum chamber of air. As air is evacuated from the vacuum chamber, the sheet is drawn upon the molding surface causing the sheet to conform to the shape of the molding surface. Thermosetting resin is infused into the sheet and cured causing the sheet to rigidly retain the shape of the molding surface. The sheet is further reinforced by securing at least one support member to the sheet using thermosetting resin.

A frame for a lightweight costume with air permeability, the costume, and a method for manufacturing them. The frame body for the costume includes a main body made of synthetic resin and a plurality of through holes penetrating the main body. The method includes a mold installation step of installing a mold in a predetermined three-dimensional shape on an elevating table, a resin member mounting step of mounting a resin member on a pedestal, a cover mounting step of mounting a cover covering the surface of the resin member on the pedestal, a heating step of heating the resin member and the cover, a vacuum molding step of bringing the mold into contact with the back surface of the resin member and then depressurizing the inside of the chamber, and a mold release step of releasing the frame body and the cover from the mold.

A frame for a lightweight costume with air permeability, the costume, and a method for manufacturing them. The frame body for the costume includes a main body made of synthetic resin and a plurality of through holes penetrating the main body. The method includes a mold installation step of installing a mold in a predetermined three-dimensional shape on an elevating table, a resin member mounting step of mounting a resin member on a pedestal, a cover mounting step of mounting a cover covering the surface of the resin member on the pedestal, a heating step of heating the resin member and the cover, a vacuum molding step of bringing the mold into contact with the back surface of the resin member and then depressurizing the inside of the chamber, and a mold release step of releasing the frame body and the cover from the mold.

This thermoforming machine includes a thermoforming chamber having at least one heated air inlet through which heated air flows into the thermoforming chamber at a controlled pressure. The air inlet cooperates with a heated air flow distribution regulator located in the thermoforming chamber and through which the heated air flows out of the thermoforming chamber at a predetermined temperature. The regulator includes a heated air flow regulating mask receiving heated air flow, having a plurality of flow restricting elements providing different air flow restrictions.

Provided are a film which can be decorated even against a three-dimensional shape, is excellent in moldability during decoration (adhesion) on an adherend, is able to reduce concaves and convexes with a variety of sizes which the adherend surface has, and makes an appearance quality favorable; and a decorative molded product having the film. The film is a film including a layer containing a thermoplastic resin, wherein when a highest temperature of glass transition temperatures of the film is designated as Tg [+ C], a temperature T [° C.] at which an elongation at break is 50% or more exists in a range of Tg to (Tg+50 [° C.]), and when, with respect to concaves and convexes of an abrasive grain surface of a polyester film sheet having, as an abrasive grain, aluminum oxide having a grain size of 12 μm coated thereon, an amplitude relative to a spatial frequency f is designated as A.sub.1(f); with respect to concaves and convexes of a film surface when adhering the film to the abrasive grain surface at any temperature of the range of Tg to (Tg+50 [° C.]) and a pressure of 0.3 MPa, an amplitude relative to the spatial frequency f is designated as A.sub.2(f); and a ratio of A.sub.2(f) to A.sub.1(f) is designated as ϕ(f)=A.sub.2(f)/A.sub.1(f), a minimum value fc of spatial frequencies where ϕ(f) is 0.1 is 2.0 mm.sup.−1 or less.

Provided are a film which can be decorated even against a three-dimensional shape, is excellent in moldability during decoration (adhesion) on an adherend, is able to reduce concaves and convexes with a variety of sizes which the adherend surface has, and makes an appearance quality favorable; and a decorative molded product having the film. The film is a film including a layer containing a thermoplastic resin, wherein when a highest temperature of glass transition temperatures of the film is designated as Tg [+ C], a temperature T [° C.] at which an elongation at break is 50% or more exists in a range of Tg to (Tg+50 [° C.]), and when, with respect to concaves and convexes of an abrasive grain surface of a polyester film sheet having, as an abrasive grain, aluminum oxide having a grain size of 12 μm coated thereon, an amplitude relative to a spatial frequency f is designated as A.sub.1(f); with respect to concaves and convexes of a film surface when adhering the film to the abrasive grain surface at any temperature of the range of Tg to (Tg+50 [° C.]) and a pressure of 0.3 MPa, an amplitude relative to the spatial frequency f is designated as A.sub.2(f); and a ratio of A.sub.2(f) to A.sub.1(f) is designated as ϕ(f)=A.sub.2(f)/A.sub.1(f), a minimum value fc of spatial frequencies where ϕ(f) is 0.1 is 2.0 mm.sup.−1 or less.