A system includes a forming funnel, a cutting element, and a fusing device. The forming funnel has divergent surfaces arranged to receive a mailer in an insertion direction between the divergent surfaces. The forming funnel includes a slot that constrains the mailer after the mailer is inserted between the divergent surfaces. The cutting element cuts off a portion of the mailer and to forms a cut end of the mailer as the mailer is moved through the slot in a sliding direction. The fusing device applies pressure to an exterior of the cut end of the mailer and applies heat to the cut end of the mailer as the mailer is moved through the slot. The pressure and the heat applied by the fusing device cause portions of the cut end to fuse together to close the mailer.

A hybrid preform comprises a bundle of unidirectionally aligned fibers, and at least one partial cut that extends part of the way, but not all of the way, through a transverse cross section of the bundle of fibers at least one location along the length of the bundle.

A handrail has a thermoplastic body having a generally C-shaped cross section, a stretch inhibitor in the thermoplastic body above a T-shaped slot and a slider fabric layer. The handrail includes first and second end portions, each comprising a forward part extending from an end surface of the end portion and a rear part adjacent the forward part. A method of forming a joint can include: providing cuts to separate a top section of the thermoplastic body from a base section including shoulder portions; for each end portion, removing at least shoulder portions from the forward part thereof, to leave a central portion including a forward part at the slider fabric layer and a layer of thermoplastic; cutting the forward parts to a required shape; and assembling the first and second end portions together to form a spliced joint for moulding.

A process of constructing an air tight and water tight seam, comprising cutting a sheet of selected material into two or more panels, sealing the panels at respective selected edges using an ultrasonic machine to form a seam, overlaying the seam with a tape made of the same selected material, and sealing the tape and seam using a radio frequency (RF) welding machine.

A method and apparatus for cutting a Non-Crimp Fabric for improving edge stability and reducing stitch retraction is disclosed. The part of the NCF to be cut is treated with a binder and heated to activate the binder and therefore bind the tows and stitches together. By treating only the cutting path the drapability of the wider fabric is maintained. This may be achieved by heating only the part of the NCF to be cut, or applying binder to only the part of the NCF to be cut. The NCF may be compressed and cooled before cutting to improve binding action. A ply cutter may be adapted to carry out the invention by including a heat source and optionally a binder dispenser, compressor and cooler.

The disclosed forming apparatus includes a frame. The frame defines a vertical axis, a horizontal axis, and a longitudinal axis. A carriage is movably connected to the frame. A first stomp foot is movably connected to the carriage such that it may move along the vertical axis. A first end effector is movably connected to the carriage. The first end effector is controlled by an actuator. The disclosed method for forming a composite part includes applying at least one ply of composite material over a forming surface of a forming tool and deforming the at least one ply of composite material over the forming surface of the forming tool with a forming apparatus.

Systems, methods, and devices are provided for the creation of predictable and accurate defects in a fiber tow of an Automated Fiber Placement (AFP) process, with such artificial defects being useful to support calibration of an in situ inspection system used in the AFP process. Various embodiments include methods for creating such artificial defects that support calibration of an in situ inspection system of an AFP system or process. Various embodiments may also include a defect stencils for an AFP system or process.

Composite structures and methods of forming composite structures may include at least one ply of material extending along a length of the composite structure. The at least one ply of material includes sections of material extending along the length of the composite structure.

An apparatus and method for joining pipes includes a plate for melting mating surfaces of the pipes to be joined. Additionally, the apparatus utilizes a vacuum in order to push the first and second pipes together in lieu of hand or mechanical pressure which may be inconsistent. Additionally, the vacuum allows the pipes to be joined to settle on each other in order to create a pressure about a periphery of the end of the pipe being joined to the other pipe. The consistent pressure creates a very strong joint between the first and second pipes.

A system for forming a thermoplastic may comprise a mandrel configured to receive a thermoplastic charge. The mandrel may rotate about a mandrel axis. A series of rollers may be located circumferentially about the mandrel and configured to apply radially inward pressure. A heating element may be located upstream of the series of rollers.