The present invention addresses the problem of providing a method for molding, using a honeycomb core, a composite material structure that is high-quality, low cost, and leaves less voids. The present disclosure addresses the problem of providing a method for molding, using a honeycomb core, a composite material structure with which it is possible to reduce dimples in a composite material skin at low cost. According to a method for molding a composite material structure of the present disclosure, an uncured composite material honeycomb sandwich panel in which prepreg is laminated on upper and lower surfaces of a honeycomb core via an adhesive is covered with a vacuum bag and placed in an autoclave. After that, the vacuum bag is evacuated and, while the evacuation is being continued, is heated and pressurized by the autoclave to cure a matrix resin of the prepreg and achieve adhesion to the honeycomb core.

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.

A honeycomb sandwich sheet or panel, based on thermoplastic polypropylene, includes a structure having two flat outer films, at the top and bottom, welded to at least two inner or central thermoformed blister films, repeated in a regular and continuous pattern, wherein the at least two inner thermoformed films are welded to each other.

A 3D printed structure of an elastic material may be provided. In one implementation, the 3D printed structure may include at least a first wall having a plurality of layers extending along a first axis. The first wall may include at least a primary structural layer, a first flexible layer, and a second flexible layer. The primary structural layer may have a first rigidity and at least one of the first flexible layer or the second flexible layer may have a second rigidity, the first rigidity being greater than the second rigidity.

A 3D printed structure of an elastic material having at least a first layer and a second layer may be provided. In one implementation, the 3D printed structure may include at least a first wall having a primary structural layer and a first flexible layer, and at least a second wall having a secondary structural layer and a second flexible layer. An axis of the 3D printed structure may intersect the first layer and the second layer and may intersect the primary structural layer and the secondary structural layer. The primary structural layer may have a first rigidity and the first flexible layer may have a second rigidity, the first rigidity being greater than the second rigidity.

A continuous honeycomb core material, a honeycomb core sandwich composite panel and a method and a device for preparing the same. The continuous honeycomb core material includes a honeycomb-core material, which includes a plurality of cells arranged in rows, and transversely adjacent cells are connected via transversely arranged connecting walls. The sidewalls of longitudinally adjacent cells are bonded via the adhesive layer. A connecting structure is arranged between two adjacent honeycomb core materials. The connecting structure includes a first connecting portion and a second connecting portion corresponding thereto. The first and second connecting portions are respectively arranged on different transverse sides of the honeycomb core material. A first connecting portion of one continuous honeycomb core material section is engaged with a second connection portion of another continuous honeycomb core material section are connected to form the connecting structure.

A composite core assembly includes a composite core structure having internal material interfaces and an attachment rail coupled to the composite core structure. The attachment rail includes a first planar surface and a second planar surface adjoined with the first planar surface. The first planar surface is arranged parallel to an internal material interface plane of the composite core structure, and the first planar portion is at least partially integrated into the composite core structure in an internal material interface plane. At least a portion of the first planar surface extends beyond a perimeter surface of the composite core structure, and the second planar surface is configured to attach to the surrounding support member. The core material does not have net edge facets or flat edges positioned next to surrounding structure, and/or may not have a structure arranged parallel to the adjacent support structure to attach to the support structure.

A method for manufacturing a cylindrical honeycomb fired body including: preparing a cylindrical honeycomb formed body; obtaining a cylindrical honeycomb dried body by drying the cylindrical honeycomb formed body; calculating predetermined parameters (E.sub.AVE1, E.sub.AVE2, E.sub.AVE3 and E.sub.AVE4) from average values of distance between a center of gravity position O and an outer peripheral contour in a plurality of predetermined angle ranges; specifying a minimum value of the predetermined parameters; obtaining a cylindrical honeycomb fired body by placing the cylindrical honeycomb dried body on a shelf plate and firing it while passing it through a continuous firing furnace, such that the direction in which the cells of the cylindrical honeycomb dried body extend vertically, and a particular location on the outer peripheral side surface determined according to the minimum value is positioned at the front.

Systems and method for fabricating a metal core truss panel with seamlessly embedded features in accordance with embodiments of the invention are illustrated. One embodiment includes a method for producing a metal core truss panel composite, the method including fabricating a sacrificial core truss panel including a plurality of interconnected truss members and at least one embedded feature, and plating the sacrificial core truss panel with a layer of metal forming a metal core truss panel including a plurality of interconnected metal truss members and at least one seamlessly embedded metal feature.

The present invention is a system and method for manufacturing a framework for a padded cushion in the shape of a kneeler pad, wherein the framework is created using a thermoforming process to make rigid and plastic top and bottom shells that are then coupled together to form a framework to which upholstery is added to thereby form a padded kneeling cushion, wherein a fabric tightening system is also installed in the framework that enables the upholstery to be stretched tighter over the framework in order to tighten the upholstery around the cushion as the upholstery loses its shape and stretches over time, and wherein a system is provided to extend a length of the kneeler pads through the addition of expansion segments in the framework.