In one aspect, there is a method of making a pre-cured laminate having a total number of plies in a mold, the mold having a cavity with a periphery defined by a forward edge, an aft edge, and outboard ends. The method includes selecting a first plurality of resin impregnated plies that continuously extend beyond the periphery of the cavity, the first plurality of resin impregnated plies includes at least 50 percent of the total number of plies; laying the plies in a mold; compacting the plies in a mold; and pre-curing the plies to form a pre-cured laminate, which can extend beyond the periphery of the cavity. In an embodiment, a pre-cured laminate includes a first plurality of resin impregnated plies that continuously extend beyond the periphery of the cavity.

The method includes: a formed body forming step of forming each of a plurality of honeycomb-segment formed bodies by extrusion; an aggregate formation step of forming a honeycomb-segment aggregate by applying a fluid bonding material to side faces of the honeycomb-segment formed bodies, and arranging the honeycomb-segment formed bodies so that the side faces are brought into contact with each other; an aggregate shaping step of shaping the honeycomb-segment aggregate by performing a press treatment to the side faces of the honeycomb-segment aggregate; and a drying/firing step of drying and firing the honeycomb-segment aggregate, wherein the aggregate shaping step are performed while keeping the water amount of each of the honeycomb-segment formed bodies to be 30 mass % or more, each of the honeycomb segments has cell density that is 620 cells/cm.sup.2 or more, and the press treatment is performed with a contact pressure of 0.005 kg/cm.sup.2 or more.

A modular mold for producing a panel including a panel of fiber reinforced material. The panel is configured to form hollow cells having an undulated trapezoidal cross-section. The mold includes at least three molding bars for forming each hollow cell. One of the molding bars has a trapezoidal cross shape. The other two molding bars have a triangular cross shape. The trapezoidal molding bar is located between the two triangular molding bars. The three molding bars when put together its cross-section forms the shape of the trapezoidal cross-section of the hollow cell.

Freeform, additive manufacturing equipment, processes and products, including residential, commercial and other buildings. A movable extruder places extrudate that solidifies in open space to create scaffolding or skeletons of buildings and other products. Elongated extrudate elements are fused to each other or connected by other means to form a cellular structure. Filler material such as polymeric insulating foam may simultaneously or thereafter be placed within the cellular structure to contribute desired strength, rigidity, insulative, barrier or other properties. Finish materials may also be applied.

A method of producing a cellular structure via an additive manufacturing technique includes the steps of: providing a feedstock material to an additive manufacturing printer device; dispensing the feedstock material from the printer device; and controlling the dispensing of the feedstock material to form at least one layer of the cellular structure according to a first predetermined gradient. In some aspects, the cellular structure comprises an array of cells surrounded, respectively, by walls, and arranged to create a non-uniform relative density and/or cell geometry across a width and/or a height of the cellular structure. An article of manufacture produced by such methods includes a cellular structure configured to produce a controlled collapse with selectable dynamic stiffness characteristics by altering the distribution and geometry of cells within the cellular structure, while being able to maintain a substantially similar static stiffness characteristic.

Provided are a lubricating material which is made of a non-fluorine-based compound and thus has a surface that is slippery enough for liquid such as water or oil, a lubricant-holding base material which holds a fluorine-based lubricant and thus can be used as a lubricating material, and methods for producing the same. A slippery film has a holding base and a lubricant. The holding base has pillar structure portions and fluorine-containing portions, and the fluorine-containing portions are provided on outer surfaces of a plurality of pillar portions in the pillar structure portion. The lubricant is a fluorine-based liquid, and the fluorine-containing portion has a CF bond. The lubricant is loaded into a region surrounded by a plurality of the pillar portions and is held in this region.

Methods and machine for manufacturing vertically oriented core of multiwalls and multiwalls comprising such core. Multiwalls or cores of multiwalls with transversely oriented flutes in their core are sliced perpendicularly relative to the axis of rotation of the flutes. The slices are bent relative to the origin multiwall or core, packed together, welded or fused or mechanically pressed to each other and their top and bottom surfaces leveled to provide a vertically oriented shortened flutes that form the core. The top and bottom surfaces of the core are then laminated. Machine configurations are also provided for continuous manufacturing of vertically oriented cores of multiwalls.

A method and system for manufacturing a conical shaped acoustic structure. A sheet of acoustical material is cut to form individual pieces using a cutter system. Each individual piece in the individual pieces has a flat pattern for the conical shaped acoustic structure. An individual piece is positioned around a mandrel with a conical shape using an actuator system. Two edges of the individual piece are positioned for joining. The two edges of the individual piece positioned around the mandrel are joined to form the conical shaped acoustic structure.

A method for the production of objects including at least one honeycomb panel is performed by setting up a honeycomb panel and engraving it in such a way as to create a deposition path with a predetermined depth. A filler material is applied along the deposition path so as to fill it at least partially.

A 3D printed structure of an elastic material having a first wall and a second wall may be provided. In one implementation, the 3D printed structure may include a first layer having a first portion of a first wall part and a first portion of a second wall part. The first portion of the first wall part may include a primary structural layer and the first portion of the second wall part may include a first flexible layer. The 3D printed structure may also include a second layer having a second portion of the first wall part and a second portion of the second wall part. The second portion of the first wall part may include a second flexible layer. The primary structural layer and the first flexible layer may have a first rigidity and a second rigidity, respectively, the first rigidity being greater than the second rigidity.