A composite material and method of producing a composite material for use in fabrication, building and construction is disclosed. A composition as disclosed herein comprises a high proportion of particulate waste material dispersed in a matrix of thermoplastic polymer and wax. A method of producing a composite material comprises melt mixing thermoplastic polymer and wax with a particulate material, thereby dispersing the particulate material in a melt mixture of the composite material.

A method for forming a fiber reinforced thermoplastic part may comprise the steps of locating a thermoplastic material over a mold tool, heating the thermoplastic material to a pliable forming temperature, conforming the thermoplastic material to a mold surface of the mold tool, and depositing a plurality of fiber strips over the thermoplastic material.

A method for forming a fiber-reinforced thermoplastic part may comprise the steps of locating a lightning strike protection layer on a mold surface of a mold tool, locating a thermoplastic layer over the mold tool, heating the thermoplastic layer to a pliable forming temperature, conforming the thermoplastic layer to a mold surface of the mold tool, and depositing a plurality of fiber strips over the thermoplastic layer.

Collapsible containers and a method of their manufacture are disclosed herein. The collapsible containers have one or more collapsible wall sections and a stiff upper and lower tier. The wall sections have living hinges and three or more tiers between the hinges. A thermoplastic elastomer layer may join separately made portions of the container together. The containers may be made by molding and overmolding. The containers include inter alia bulk liquid containers, jugs, tubs, baskets, bottles, and food containers. The method of manufacturing includes placing a container component and a matching container body comprising a stiff first tier, a stiff second tier, and a collapsible wall section in a mold; assembling the container body with the container component to close one end of the container body; and overmolding a thermoplastic layer around the container body and the container component.

Medical devices and methods for making and using medical devices are disclosed. An example medical device may include a guide extension catheter. The guide extension catheter may include a proximal member having a proximal end, a distal end, and a proximal diameter. The guide extension catheter may additionally include a collar member attached to the distal end of the proximal member, the collar member comprising a base portion and one or more ribs connected to the base portion and extending distally away from the base portion. In still some additional embodiments, the guide extension catheter may further include a distal sheath member attached to the collar member, the distal sheath member having a distal diameter larger than the proximal diameter.

Baffles for food waste disposers, systems employing such baffles, and methods of assembling, manufacturing, fabricating, or operating such baffles or baffle systems are disclosed herein. In one example embodiment, a baffle for implementation in connection with a food waste disposer includes a rim portion, a plurality of flaps, and a plurality of living hinges, wherein the rim portion, living hinges, and flaps constitute a single integrally-formed structure. The respective living hinges permit the respective flaps to be rotatable about respective axes that respectively are substantially tangent to respective locations along or proximate to the rim portion, so that the respective flaps can be rotated to respective closed positions. Either the living hinges or at least one additional component tend to cause the respective flaps to remain at the respective closed positions or to return to the respective closed positions when not at the respective closed positions.

Additive manufacturing processes, such as powder bed fusion of thermoplastic particulates, may be employed to form printed objects in a range of shapes. It is sometimes desirable to form conductive traces upon the surface of printed objects. Conductive traces and similar features may be introduced during additive manufacturing processes by incorporating a metal precursor in a thermoplastic printing composition, converting a portion of the metal precursor to discontinuous metal islands using laser irradiation, and performing electroless plating. Suitable printing compositions may comprise a plurality of thermoplastic particulates comprising a thermoplastic polymer, a metal precursor admixed with the thermoplastic polymer, and optionally a plurality of nanoparticles disposed upon an outer surface of each of the thermoplastic particulates, wherein the metal precursor is activatable to form metal islands upon exposure to laser irradiation. Melt emulsification may be used to form the thermoplastic particulates.

A method and structure for processing a plurality of prepreg sheets includes a conveyor assembly having a first conveyor, a second conveyor, and a processing zone positioned between the first and second conveyors. In an implementation, a plurality of prepreg sheets are advanced from a plurality of material supply creels into the processing zone by a first conveyor and a second conveyor turning in opposite directions. Within the processing zone, a compressive pressure is applied to the prepreg sheets by first pressure plates attached to first conveyor and second pressure plates attached to the second conveyor. A thermoplastic within the prepreg sheets is melted within the processing zone by a heater to consolidate the prepreg sheets into a consolidated laminate.

A cushioning mat comprises a plurality of cushioning bumps arranged in a plurality of rows, the bumps of each row alternating with substantially flat bottom portions. Each bump comprises a top wall and a side wall which extends from a mat base identified by the bottom portions. The top wall and the side wall define an inner bump cavity. The bumps of adjacent rows are staggered with each other. In at least a portion of the side wall a vent opening is made which places in communication the inner cavity of the bump with the outside of the bump.

A novel polymer optical waveguide and method of manufacturing is presented herein. A digitally manufactured process is described which utilizes a micro-dispensed UV optical adhesive as the contour guiding cladding, a fused deposition modeling technology for creating a core, and a subtractive laser process to finish the two ends of the optical interconnect. The optical waveguide can be printed directly on a circuit board in some embodiments. Alternatively, using a slightly modified process including a step to bond the optical fiber to the substrate, the optical interconnect can be manufactured on a flexible substrate.