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.

Disclosed herein is a method of forming a mold comprising disposing a film having a textured surface on a support; where the support has a shape of an article to be manufactured; pressing the film onto the support to cover a surface of the support; disposing a backing on the film; separating the support from the backing; and molding a material in the backing. Disclosed herein too is a method comprising contacting a first mandrel with a first mold; where the first mold has a textured surface; texturing a surface of the first mandrel with the first mold; disposing the first mandrel in a die; disposing a first material in the die to contact the first mandrel; imparting a texture from the surface of the first mandrel onto the material to form a second mold; and disposing a texture from the second mold onto a second material; where the second material is different from the first material.

Disclosed herein is a method of forming a mold comprising disposing a film having a textured surface on a support; where the support has a shape of an article to be manufactured; pressing the film onto the support to cover a surface of the support; disposing a backing on the film; separating the support from the backing; and molding a material in the backing. Disclosed herein too is a method comprising contacting a first mandrel with a first mold; where the first mold has a textured surface; texturing a surface of the first mandrel with the first mold; disposing the first mandrel in a die; disposing a first material in the die to contact the first mandrel; imparting a texture from the surface of the first mandrel onto the material to form a second mold; and disposing a texture from the second mold onto a second material; where the second material is different from the first material.

There is provided an ejection material receiving unit capable of increasing the filling amount of ejection material with as little enlargement of the container itself as possible and an ejection material ejecting apparatus including the unit. Therefore, an ejection material receiving unit includes: a first receiving space capable of receiving ejection material; a second receiving space capable of receiving liquid; and a flexible member separating the first receiving space and the second receiving space, and is characterized in that the flexible member has a concave part which takes a concave shape in a state where the first receiving space is not filled with the ejection material and the second receiving space is not filled with the liquid, and the concave shape is a shape dented toward the second receiving space from the first receiving space, and is also a shape conforming to a wall forming the second receiving space.

There is provided an ejection material receiving unit capable of increasing the filling amount of ejection material with as little enlargement of the container itself as possible and an ejection material ejecting apparatus including the unit. Therefore, an ejection material receiving unit includes: a first receiving space capable of receiving ejection material; a second receiving space capable of receiving liquid; and a flexible member separating the first receiving space and the second receiving space, and is characterized in that the flexible member has a concave part which takes a concave shape in a state where the first receiving space is not filled with the ejection material and the second receiving space is not filled with the liquid, and the concave shape is a shape dented toward the second receiving space from the first receiving space, and is also a shape conforming to a wall forming the second receiving space.

[Problem] The objective of the present invention is to provide a sheet expressing a good tactile sensation and a molded product thereof.

[Solution] A sheet expressing a good tactile sensation and a molded product thereof are provided by configuring a thermoplastic resin sheet having a base layer and hairlike bodies arranged regularly on at least one surface thereof, wherein a continuous phase is formed without a structural boundary between the base layer and the hairlike bodies.

Methods, plate elements and heat/enthalpy exchangers. a) perforating an unformed plate element with defined outer dimensions in any desired area and in any desired dimension; b) covering at least one side of the unformed plate element with a thin polymer film with latent energy exchange characteristics and; c) forming the plate element into a desired shape and a pattern of corrugations and/or embossing. The operations b) and c) may be performed in a different order. For instance, when the plate element is made out of plastic, b) may be performed before c) whereas, when the plate element is made out of aluminum (or plastic), c) may be performed before b). Operations a) and/or b) and/or c) may also, in certain embodiments, be combined.

A mold which can improve an appearance of a molded body is provided. A mold includes a cavity, the mold being capable of subjecting a resin sheet under reduced pressure suction via a plurality of reduced pressure suction holes thereby shaping the resin sheet to follow a shape of an inner surface of the cavity; wherein: the inner surface includes a base surface and a plurality of island-like concave portions provided in the base surface; and a concave portion reduced pressure suction hole index defined by an in-concave reduced pressure suction hole ratio divided by a concave portion area ratio is 0.5 or lower.

A mold which can improve an appearance of a molded body is provided. A mold includes a cavity, the mold being capable of subjecting a resin sheet under reduced pressure suction via a plurality of reduced pressure suction holes thereby shaping the resin sheet to follow a shape of an inner surface of the cavity; wherein: the inner surface includes a base surface and a plurality of island-like concave portions provided in the base surface; and a concave portion reduced pressure suction hole index defined by an in-concave reduced pressure suction hole ratio divided by a concave portion area ratio is 0.5 or lower.

A hydro-formed film includes a polymeric web having a first substantially planar surface and a second substantially planar surface opposite the first substantially planar surface, and a plurality of three-dimensional micro-apertures extending from the first substantially planar surface. The plurality of three-dimensional micro-apertures have a mesh count in a range of about 40 to about 75 apertures per linear inch. The hydro-formed film has a Compression Sensor Point (CSP) count of at least about 80.