The disclosure relates to methods of forming three-dimensional (3D) polymeric articles and additive manufacturing apparatuses for the same. The methods include providing a polymeric solution comprising a polymer dissolved in a solvent; providing a non-solvent, wherein the solvent is miscible in the non-solvent, and the polymer is insoluble in the non-solvent; and injecting the polymeric solution into the non-solvent in a pre-determined 3D pattern to provide a 3D polymeric article.

A system for fabricating composite parts efficiently. Pre-impregnated (prepreg) composite material is drawn as a sheet from a roll and fed by advancement rollers into a stamping and molding station in which a piece of the prepreg material is cut, on a mold, from the sheet. Pressure is applied to cause the prepreg material to conform to a surface of the mold, and the prepreg is cured with ultraviolet light. Additional layers of prepreg may be cut and cured on any layers that have already been cured on the mold. The complete part may be removed from the mold with ejector pins. Scrap prepreg may be recycled in a recycling station that separates reinforcing fiber from uncured resin.

A method of manufacturing an inductor element includes preparing an insert member including a winding portion where a conductor is wound in a coil shape. A plurality of preliminary green compacts is obtained by conducting a preliminary compression molding of a granule containing a magnetic powder and a resin at a pressure of 2.5×10.sup.2 to 1×10.sup.3 MPa. The insert member and the plurality of preliminary green compacts are integrated so that a joint interface of the plurality of preliminary green compacts is formed intermittently.

A molding method for a composite sheet used for manufacturing a thermosetting resin prepreg sheet in which a thermosetting resin material is impregnated into a fiber sheet includes: bringing a resin transfer sheet in which the thermosetting resin material of a predetermined thickness is carried on one surface of a transfer sheet into contact with one surface of the fiber sheet to be stacked on the fiber sheet. The resin transfer sheet and the fiber sheet in the stacked state are subjected to a heating treatment or heating and pressurizing treatment. The resin transfer sheet and the fiber sheet in the heated and stacked state is subjected to a cooling treatment or cooling and pressurizing treatment so that the thermosetting resin material is transferred to the fiber sheet and the thermosetting resin material is made to adhere to one surface side of the fiber sheet.

Provided is a production method of an FRP precursor. The method includes: a pre-coating step of applying a resin varnish having a filler content of 5 vol % or less in a solid content thereof, to a sheet-shaped aggregate, and a melt-pasting step of melt-pasting a pair of resin films, each having a filler content of 30 vol % or more, to both surfaces of the aggregate, after the pre-coating step.

An additive manufacturing method includes removing material from a sheet to create a plurality of individual layer segments formed, placing at least two first layer segments adjacent to each other at the same height to form a first layer having a hollow interior, the at least two first layer segments defining a first portion of an exterior of a part, and placing at least one second layer segment above the at least two first layer segments to form a second layer having a hollow interior, the at least one second layer segment defining a second portion of the exterior of the part. The method includes attaching the first layer to the second layer and removing material from the first layer and from the second layer to form the part having a continuous surface that extends along the first layer and the second layer.

A control surface for an aircraft comprise a first skin, a second skin bonded to the first skin, and a stiffening structure located between the first skin and the second skin. The stiffening structure may be formed by forming a plurality of fiber-mandrel sections, stacking the plurality of fiber-mandrel sections to form a fiber-mandrel assembly, and depositing an outer fiber ply around a perimeter of the fiber-mandrel assembly. The control surface may be formed by forming a part layup over a first mold surface, contacting the part layup with a second mold surface, and curing the part layup. Forming the part layup over a first mold surface may include locating a first fiber ply over the first mold surface, locating a plurality stiffening structure assemblies over the first fiber ply, and locating a second fiber ply over the plurality stiffening structure assemblies.

A lens includes a cover part and a light-shielding part. The cover part includes a lens part, a connection part, and a flange part which are formed of a thermosetting first resin and continuous to one another. The light-shielding part covers an outer lateral side of the connection part and is formed of a second resin having a greater light-absorptance or a greater light-reflectance than the first resin.

Method for manufacturing a wood composite, comprising the steps of providing an reactive composite mixture (4) by mixing a reactive binder and vegetable fibres; supplying the reactive composite mixture to an extruder (5), discharging of the composite mixture from the extrusion device via an extrusion discharge (6) to a curing mould (8); filling the pores of the vegetable fibres with the reactive binder while simultaneously expensing the air from the pores at extrusion process conditions; reacting of the reactive binder around the vegetable fibres and in the pores of the vegetable fibres into a wood composite at the temperature of the extrusion process conditions.

A process for producing a molded part from a highly filled thermosetting starting material including: introducing the starting material into a prepressing tool; producing a preform from the starting material, the starting material being brought to a prepressing temperature by the prepressing tool and being compressed with a prepressing force to form the preform; removing the preform from the prepressing tool and introducing the preform into a finish pressing tool; and producing a finished part from the preform, the preform being brought to a finish pressing temperature by the finish pressing tool and being compressed with a finish pressing force to form the finished part. Here, the prepressing temperature is lower than the finish pressing temperature and the finish pressing temperature is at least as high as an onset temperature of a curing reaction of the starting material.