The present invention relates to manufactured articles consisting of the coupling of at least two polyamide-based parts, one of which consists of a polyamide matrix, preferably loaded with a dispersed filler, and the other consists of a polyamide matrix reinforced with fibres in their turn made of polyamide. The invention also relates to a process for the production of these manufactured articles. The manufactured articles of the invention have high mechanical strength but, unlike similar manufactured articles, they are made of a single polymer.

Process of making a plastic component (1), in particular luggage shell, from self-reinforced thermoplastic material, to a plastic component (1) made of self-reinforced thermoplastic material and an apparatus for making such a plastic component, in particular luggage shell (7). The invention provides a new product and process for manufacturing same on the basis of self-reinforced thermoplastic material by means of the step of tensioning said material (lamina), at least partially tensioning said lamina during all follow-up component shaping and/or molding steps up to a release of a component pre-form shape from the remainder lamina, to form the component. The present invention allow the manufacturing of an ultra-light weight luggage shell (7) on the basis of using self-reinforced thermoplastic material, the manufacturing of same can be further enhanced by permanently tensioning said material during all manufacturing steps up to the final finishing of the product.

Process of making a plastic component (1), in particular luggage shell, from self-reinforced thermoplastic material, to a plastic component (1) made of self-reinforced thermoplastic material and an apparatus for making such a plastic component, in particular luggage shell (7). The invention provides a new product and process for manufacturing same on the basis of self-reinforced thermoplastic material by means of the step of tensioning said material (lamina), at least partially tensioning said lamina during all follow-up component shaping and/or molding steps up to a release of a component pre-form shape from the remainder lamina, to form the component. The present invention allow the manufacturing of an ultra-light weight luggage shell (7) on the basis of using self-reinforced thermoplastic material, the manufacturing of same can be further enhanced by permanently tensioning said material during all manufacturing steps up to the final finishing of the product.

A composite material of particles disposed in a matrix material is provided in which the particles have an asymmetric geometric shape with a longest dimension and a shortest dimension different from the longest dimension. Adjacent volume portions of the composite material are arranged in a mosaic pattern to abut along an interface or surface forming a common boundary between the adjacent volume portions. The particles within the adjacent volume portions are arranged with differing orientations with respect to the interface. The orientations of the particles in the adjacent volume portions are selected so that a crack propagating on a crack propagation path through one or the other of the adjacent volume portions stops at or deflects to propagate along the interface. Methods of making composite materials are also provided.

A composite material of particles disposed in a matrix material is provided in which the particles have an asymmetric geometric shape with a longest dimension and a shortest dimension different from the longest dimension. Adjacent volume portions of the composite material are arranged in a mosaic pattern to abut along an interface or surface forming a common boundary between the adjacent volume portions. The particles within the adjacent volume portions are arranged with differing orientations with respect to the interface. The orientations of the particles in the adjacent volume portions are selected so that a crack propagating on a crack propagation path through one or the other of the adjacent volume portions stops at or deflects to propagate along the interface. Methods of making composite materials are also provided.

A method of forming a headliner for a vehicle includes forming the headliner into a desired shape from one or more materials. The headliner includes a headliner cutout portion corresponding to an opening through the headliner. A reinforcement bracket preform is formed into the headliner cutout portion during the step of forming the headliner. The headliner cutout portion is removed from the headliner. The reinforcement bracket preform is removed from the headliner cutout portion and a shaped reinforcement bracket is formed.

A method of forming a headliner for a vehicle includes forming the headliner into a desired shape from one or more materials. The headliner includes a headliner cutout portion corresponding to an opening through the headliner. A reinforcement bracket preform is formed into the headliner cutout portion during the step of forming the headliner. The headliner cutout portion is removed from the headliner. The reinforcement bracket preform is removed from the headliner cutout portion and a shaped reinforcement bracket is formed.

A network system can optimize 3D models for 3D printing. A smoothing operation can be performed for a 3D model that comprises a plurality of voxels by identifying exterior voxels of the 3D model. For a first exterior voxel of the 3D model, an exterior surface orientation can be determined and a smoothing operation can be performed based on the determined exterior surface orientation. The smoothing operation can include performing a triangulation operation based on the determined exterior surface orientation of the first exterior voxel. Furthermore, in response to determining that a dimension of a set of voxels is below a threshold limit, one or more voxels can be added to the set of voxels to satisfy the threshold limit.

A network system can optimize 3D models for 3D printing. A smoothing operation can be performed for a 3D model that comprises a plurality of voxels by identifying exterior voxels of the 3D model. For a first exterior voxel of the 3D model, an exterior surface orientation can be determined and a smoothing operation can be performed based on the determined exterior surface orientation. The smoothing operation can include performing a triangulation operation based on the determined exterior surface orientation of the first exterior voxel. Furthermore, in response to determining that a dimension of a set of voxels is below a threshold limit, one or more voxels can be added to the set of voxels to satisfy the threshold limit.

A 3D model system is configured to validate and optimize for 3D printing an unprocessed 3D model described by an input data file. The 3D model system is configured to detect printability issues associated with the unprocessed 3D model and automatically address these issues. Such issues can include boundary edges, non-manifold geometries, structural deficiencies, etc. Upon resolving these issues, the 3D model can be optimized for 3D printing. Optimizations can include hollowing to reduce printing cost and exterior surface smoothing. The resulting validated and optimized 3D model can be converted into an output data file which can be an input to a 3D printer or a 3D printing service for printing the object depicted by the 3D model. The 3D model system can operate as a network or cloud-based service. Users are able to interact with the 3D model system using a series of web-based user interfaces.