An endless-fibre-reinforced plasticate is described for the additive manufacture of endless-fibre-reinforced plastic components. A plastic material is introduced via a first filling opening into a single-screw extruder and is melted. A mass flow dmF/dt of dry, endless fibre strands is introduced via a second filling opening into the single-screw extruder, impregnated with plastic melt and discharged as fibre-reinforced plasticate. Remote from the second filling opening with regard to conveying, the screw of the single-screw extruder is configured that the fibre strands are discharged substantially undamaged. The mass flow dmF/dt is kept in a first mass flow target ratio to a mass flow dmS/dt of plastic melt discharged from the single-screw extruder, or the mass flow dmF/dt is kept in a second mass flow target ratio to a mass flow dmP/dt of fibre-reinforced plasticate discharged from the single-screw extruder, the exiting endless fibre strands are substantially completely impregnated with plastic melt.

A method for forming a composite part involves forming a layup comprising (a) preforms/flat form-factor feedstock, either of which includes a plurality of fibers and a matrix precursor, and (b) a differential-melt polymer. The matrix precursor and the differential-melt polymer differ as to at least one of thermal properties and rheological properties. The layup is subjected to controlled application of heat and pressure to melt the matrix precursor and differential-melt polymer. The polymers are then cooled to form a composite part that displays properties attributable to all the constituents. As a function of a variety of factors, the resulting part can be homogenous or heterogenous, and the properties can be localized or global throughout the part.

A method for blow molding a plastic tank from thermoplastic material, wherein the plastic tank is provided with at least one connection element penetrating the wall of the plastic tank while the plastic tank is being shaped within a blow molding tool. The connection element is fitted onto a blowing needle of the blow molding tool and is positioned in the wall by punching in the blowing needle. Also disclosed is a blow molding tool for use in the method having a blowing needle formed to fit a connection element.

A thermally expandable composition includes at least one epoxy-functional polymer, at least one endothermic chemical blowing agent, at least one free radical initiator, and at least one guanidine derivative. The invention is also related to a baffle and/or a reinforcement element for hollow structures including the thermally expandable composition, to a process for manufacturing the baffle and/or the reinforcement element, to use of the baffle and/or the reinforcement element for sealing, baffling, or reinforcing of a cavity or a hollow structure, and to a method for sealing, baffling and/or reinforcing a cavity or hollow structure.

A method for manufacturing an impregnated fibrous material comprising at least one fibrous material made of continuous fibres and at least one thermoplastic polymer matrix comprises a step of pre-impregnating the fibrous material with a thermoplastic polymer matrix in powder form. This step is carried out dry in a tank comprising a fluidized bed, while keeping the level h of the powder and the mass m of the powder present in the tank substantially constant. The level h is from hi to hi−3%, during implementation of the pre-impregnation step, and hi is the initial level of the powder in the tank at the start of implementation of the pre-impregnation step, the mass m is from mi to mi±0.5% during implementation of the pre-impregnation step, and mi is the initial mass of the powder in the tank at the start of implementation of the pre-impregnation step.

The present specification relates to a joint body of different materials, and a method of manufacturing the same. The joint body includes a metal layer; and a resin layer provided on and in contact with one surface of the metal layer. The metal layer comprises two or more etching grooves and two or more burrs provided on a surface of the metal layer adjacent to the etching grooves.

A fiber reinforced thermoplastic resin molded article contains inorganic fibers (A), organic fibers (B), and a thermoplastic resin (C), the fiber reinforced thermoplastic resin molded article containing 5 to 45 parts by weight of the inorganic fibers (A), 1 to 45 parts by weight of the organic fibers (B), and 10 to 94 parts by weight of the thermoplastic resin (C), based on 100 parts by weight of the total of the inorganic fibers (A), the organic fibers (B), and the thermoplastic resin (C), the inorganic fibers (A) in the fiber reinforced thermoplastic resin molded article having a weight average fiber length (L.sub.wa) of 0.01 mm or more and 3 mm or less, the organic fibers (B) having a weight average fiber length (L.sub.wb) of more than 4 mm and 20 mm or less.

Disclosed herein are thermoplastic and thermoset composite materials, which may be used to generate dental appliances such as dental aligners, and methods of preparation and manufacture.

A system and method for forming a composite part. The apparatus comprises a sleeve that molds a composite material. The sleeve has a first face and a second face. The second face has features to mold the composite material. The first face comprises a first inclined surface having an angle less than about 90 degrees and greater than about 0 degrees.

A method for making a three-dimensional composite part with a thermoplastic matrix and continuous reinforcement. A pre-impregnated fibrous perform is obtained by three-dimensional knitting. The preform is placed on the punch or in the matrix of a tooling, defining between them a sealed closed cavity. The tooling is closed so as to apply a first pressure to the preform. The cavity is brought to the melting temperature of the polymer impregnating the preform by maintaining the first pressure. The cavity comprising the preform is cooled to a temperature suitable for demolding by maintaining the second pressure. The mold is opened and the part is demolded.