Composite structures and methods of forming composite structures are provided. The composite structures can include one or more composite structure components. Each composite structure component is formed from a composite panel that includes one or more sheets of material. The sheets of material include a thermoplastic material and a plurality of reinforcing fibers. A composite panel can be formed in three dimensions to form a composite structure component. Multiple composite structure components can be fused to one another to form a composite structure. In addition, each composite structure component and the composite structure formed therefrom can include an aperture. An interior volume can be formed between adjacent composite structure components. Methods for forming a composite structure can include a step of simultaneously molding and fusing composite structure components.

Provided is a method for producing a packing sheet with improved insulation and storage properties, which can greatly reduce logistics costs by minimizing a volume during storage and transportation and also greatly increase insulation.

Provided is a method for producing a packing sheet with improved insulation and storage properties, which can greatly reduce logistics costs by minimizing a volume during storage and transportation and also greatly increase insulation.

The device intended to be thermoformed comprises a substrate capable of being thermoformed and an electrically conductive member integral with the said substrate. The electrically conductive member comprises: electrically conductive particles, an electrically conductive material, electrically conductive elements of elongated shape. The electrically conductive material has a melting point which is strictly less than the melting point of the electrically conductive particles and than the melting point of the elements of elongated shape.

The device intended to be thermoformed comprises a substrate capable of being thermoformed and an electrically conductive member integral with the said substrate. The electrically conductive member comprises: electrically conductive particles, an electrically conductive material, electrically conductive elements of elongated shape. The electrically conductive material has a melting point which is strictly less than the melting point of the electrically conductive particles and than the melting point of the elements of elongated shape.

Methods for fabricating three-dimensional microstructures are provided. The method includes disposing a reflow material on a mold, heating the reflow material, and creating a pressure gradient across the reflow material to reflow the material towards a bottom surface of the mold. The mold includes a molding region, a boundary region, and a thermal-isolating region disposed therebetween. The molding region includes a cavity and a projection projecting upwards from a bottom surface of the cavity. The thermal-isolating region includes at least one pocket formed adjacent to and along a perimeter of the cavity of the molding region. During heating, the temperature of the molding region is higher than that of the boundary region and the thermal-isolating region controls the thermal conductivity and mass therebetween. The material reflows towards the bottom surface of the cavity and the protrusion helps shapes the reflow material to form a substantially symmetrical three-dimensional microstructure.

A fixture plate includes a base having a contact face configured to support a dental model having a material formed thereon. The material includes an aligner material portion and an excess material portion. The fixture plate includes one or more channels formed in the contact face. The fixture plate includes a bore extending through the base from a bottom opening to the contact face. A portion of the bore located along the bottom opening is configured to couple with a hose of a vacuum system configured to generate a suction force at the contact face via the one or more channels. The suction force is applied to the dental model and at least part of the excess material portion to retain the dental model and the material formed thereon against the contact face.

A method of creating a selectively plated three-dimensional thermoplastic part. The method includes the steps of: a) providing a film of uncured polycarbonate film having a hardcoated layer on a first surface thereof; b) selectively catalyzing the polycarbonate film by depositing a catalyst in a desired pattern on the first surface of the polycarbonate film; c) thermoforming the polycarbonate film to form a three-dimensional polycarbonate film; d) UV-curing the hardcoated polycarbonate film by irradiating the film with UV rays; e) molding the hardcoated polycarbonate film to produce a three-dimensional molded part comprising the hardcoated polycarbonate film; f) activating the selectively catalyzed hardcoated polycarbonate film; and g) plating a metal layer on the catalyzed portions of the hardcoated polycarbonate film, wherein the plated metal only deposits on the catalyzed portions of the hardcoated polycarbonate film.

A molded pool step, a method of fabricating the pool step and a method of matching a decorative pattern on the pool step to the decorative pattern on a pool liner is disclosed. The pool step is fabricated by applying a decorative pattern to one surface of a transparent sheet of moldable material; positioning the sheet of material on a pool step mold such that the sheet contacts a molding surface of the pool step mold; molding the sheet of material on the pool step mold such that the decorative pattern is located a distance inwardly from an outer surface of the pool step and is thereby prevented being contacted by pool water or people using the pool. When the pool step is molded and installed the decorative pattern on the three-dimension pool step is substantially continuous with the decorative pattern on the liner adjacent the pool step.

A molded pool step, a method of fabricating the pool step and a method of matching a decorative pattern on the pool step to the decorative pattern on a pool liner is disclosed. The pool step is fabricated by applying a decorative pattern to one surface of a transparent sheet of moldable material; positioning the sheet of material on a pool step mold such that the sheet contacts a molding surface of the pool step mold; molding the sheet of material on the pool step mold such that the decorative pattern is located a distance inwardly from an outer surface of the pool step and is thereby prevented being contacted by pool water or people using the pool. When the pool step is molded and installed the decorative pattern on the three-dimension pool step is substantially continuous with the decorative pattern on the liner adjacent the pool step.