A three-dimensional object production process and system comprising providing a thermoset printing apparatus comprising a mixing chamber to receive and mix at least a first reactive component and a second reactive component to provide a thermosetting material, an extrusion nozzle, at least one actuator coupled to the extrusion nozzle, and a controller, wherein the controller generates a printing path for the 3D printing process, executes a translation start command, a flow start command, a translation command, a flow command, a translation stop command, a flow stop command, and a reverse translation command to the thermoset printing apparatus during the 3D printing process, identifies an at least one discontinuity in the printing path, executes the flow stop command before the extrusion nozzle reaches the at least one discontinuity, executes the translation stop command before the at least one discontinuity, and executes a reverse translation command

The present invention relates to a thermosetting material for use in a 3D printing process comprising: a) at least one epoxy resin A, b) at least one elastomer-modified epoxy resin B, c) at least one resin C with a dynamic viscosity of below 4 Pas at 150° C., d) at least one of a curing agent D capable of reacting with A, B and optionally C, e) and optionally additional compounds,
wherein the glass transition temperature of the uncured material is at least 30° C., preferably at least 40° C. as measured with DSC at a heating rate of 20° C./min.

The invention further relates to a method of producing a cured 3D thermoset object and the use of the above-mentioned thermosetting material in a 3D printing process.

An encapsulated polymeric article is disclosed. The encapsulated polymeric article may include a polymer substrate and a metallic outer shell at least partially encapsulating the polymer substrate. The encapsulated polymeric article may be fabricated by a method comprising: 1) providing a mandrel in a shape of the encapsulated polymeric article, 2) shaping the metallic outer shell on the mandrel, 3) removing the mandrel from the metallic outer shell, and 4) molding the polymeric substrate into the metallic outer shell through a port formed in the metallic outer shell to provide the encapsulated polymeric article.

A low-profile fluid manifold includes a tunable passive flow control system through intricate internal flow channels. The low-profile fluid manifold is manufactured using stereolithography (SLA) additive manufacturing to rapidly produce and tune the intricate flow channels to achieve the desired flow characteristics. Further, SLA additive manufacturing is used to build up inlet and outlet orifices in the flow direction, creating sealing surfaces for parallel oriented seals and sealing surfaces. The low-profile fluid manifold is manufactured to be air and liquid tight at the required operating pressures, temperatures, and environments, without the use of traditional fittings.

A first tooling die and a second tooling die are movable with respect to each other. The first tooling die and the second tooling die form a die cavity. The first tooling die and the second tooling die comprise a plurality of stacked metal sheets. A plurality of air gaps is defined between adjacent stacked metal sheets. A first smart susceptor material is within the die cavity and connected to the first tooling die. The first smart susceptor material has a first Curie temperature. A second smart susceptor material is within the die cavity and associated with the second tooling die. The second smart susceptor material has a second Curie temperature lower than the first Curie temperature. A flexible membrane is between the second tooling die and the first smart susceptor material. The flexible membrane is configured to receive pressure.

A fiber-reinforced resin composite material has a longitudinal direction, and includes a first stack, a second stack, a ridge, a flat surface, and a connection. The ridge extends in the longitudinal direction. The flat surface is continuous to the ridge. The connection is where the first and second stacks are coupled. The first and second stacks are joined to each other in a direction intersecting the longitudinal direction. Fibers of at least one of first fiber-reinforced resin sheets included in the first stack, fibers of at least one of second fiber-reinforced resin sheets included in the second stack, or both intersect the ridge. The connection includes the first and second fiber-reinforced resin sheets that are overlapped alternately, and includes ends of the first fiber-reinforced resin sheets, ends of the second fiber-reinforced resin sheets, or both that are shifted from each other to allow the connection to have a gradually-varied thickness.

Method of moulding a moulding material to form a moulded part of carbon fibre-reinforced resin matrix composite material in which a sheet moulding compound is moulded which can provide panels, for example for use as vehicle body panels, which have the combination of very low thickness, very light weight, very low warping and surface defects, and very low anisotropy with regard to localised fibre and resin distribution and their associated appearance and mechanical properties.

A mold for producing a metal-resin composite by press-forming a metal member and integrally molding the metal member that is press-formed and a resin material includes an upper mold and a lower mold that sandwich the metal member and the resin material. The upper mold includes a first press surface for press-forming the metal member and a second press surface for integrally molding the metal member and the resin material. A distance between the first press surface and the lower mold is shorter than a distance between the second press surface and the lower mold.

A pressure vessel includes a vessel body including a cylindrical-shaped straight body portion with a spiral-shaped projection portion formed at an outer peripheral surface of the straight body portion, and a covering portion that comprises a fiber bundle wrapped onto the outer peripheral surface of the straight body portion in a spiral pattern running parallel to the projection portion so as to cover the outer peripheral surface of the straight body portion.

A piston for a heavy duty diesel engine including a composite layer forming at least a portion of a combustion surface is provided. The composite layer has a thickness greater than 500 microns and includes a mixture of components typically used to form brake pads, such as a thermoset resin, an insulating component, strengthening fibers, and an impact toughening additive. According to one example, the thermoset resin is a phenolic resin, the insulating component is a ceramic, the strengthening fibers are graphite, and the impact toughening additive is an aramid pulp of fibrillated chopped synthetic fibers. The composite layer also has a thermal conductivity of 0.8 to 5 W/m.Math.K. The body portion of the piston can include an undercut scroll thread to improve mechanical locking of the composite layer. The piston can also include a ceramic insert between the body portion and the composite layer.