The present application discloses and claims a method to make a flexible ceramic fibers (Flexiramics) and polymer composites. The resulting composite has an improved mechanical strength (tensile) when compared with the Flexiramics respective the nanofibers alone. Additionally a composite has better properties than the polymer alone such as lower fire retardancy, higher thermal conductivity and lower thermal expansion. Several different polymers can be used, both thermosets and thermoplastics. Flexiramics has unique physical characteristic and the composite materials can be used for numerous industrial and laboratory applications.

Methods for making an osteoimplant are provided. In one embodiment the method includes applying a mechanical force to an aqueous slurry of insoluble collagen fibers to entangle the insoluble collagen fibers so as to form a semi-solid mass of entangled insoluble collagen fibers; and lyophilizing the semi-solid mass of entangled collagen fibers to form the osteoimplant. An osteoimplant containing entangled insoluble collagen fibers is also provided.

A method of joining workpieces includes the steps of bringing a first workpiece and a second workpiece together, induction heating a susceptor material, and pressing the workpieces together. Each workpiece may include a thermoplastic material, and the workpieces are brought together at a joint interface so that a protrusion of the first workpiece is aligned with a receptacle of the second workpiece. The susceptor material is in contact with the thermoplastic material of the first workpiece during heating such that the thermoplastic material of the first workpiece softens. The step of pressing is performed while the thermoplastic material of the first workpiece is softened, thereby reshaping the first workpiece where the susceptor material is in contact with the thermoplastic material of the first workpiece. The protrusion is deformed to form an interlock with the receptacle at the joint interface.

A method of joining workpieces includes the steps of bringing a first workpiece and a second workpiece together, induction heating a susceptor material, and pressing the workpieces together. Each workpiece may include a thermoplastic material, and the workpieces are brought together at a joint interface so that a protrusion of the first workpiece is aligned with a receptacle of the second workpiece. The susceptor material is in contact with the thermoplastic material of the first workpiece during heating such that the thermoplastic material of the first workpiece softens. The step of pressing is performed while the thermoplastic material of the first workpiece is softened, thereby reshaping the first workpiece where the susceptor material is in contact with the thermoplastic material of the first workpiece. The protrusion is deformed to form an interlock with the receptacle at the joint interface.

The present disclosure is directed to an apparatus and method for manufacturing a composite component. The apparatus includes a mold onto which the composite component is formed. The mold is disposed within a grid defined by a first axis and a second axis. The apparatus further includes a first frame assembly disposed above the mold and a plurality of machine heads coupled to the first frame assembly within the grid in an adjacent arrangement along the first axis. At least one of the mold or the plurality of machine heads is moveable along the first axis, the second axis, or both. At least one of the machine heads of the plurality of machine heads is moveable independently of one another along a third axis. A second frame assembly is moveable above the mold along the first axis, the second axis, or both. The second frame assembly includes a holding device. The holding device affixes to and releases from an outer skin to place and displace the outer skin at the mold.

The present disclosure is directed to an apparatus and method for manufacturing a composite component. The apparatus includes a mold onto which the composite component is formed. The mold is disposed within a grid defined by a first axis and a second axis. The apparatus further includes a first frame assembly disposed above the mold and a plurality of machine heads coupled to the first frame assembly within the grid in an adjacent arrangement along the first axis. At least one of the mold or the plurality of machine heads is moveable along the first axis, the second axis, or both. At least one of the machine heads of the plurality of machine heads is moveable independently of one another along a third axis. A second frame assembly is moveable above the mold along the first axis, the second axis, or both. The second frame assembly includes a holding device. The holding device affixes to and releases from an outer skin to place and displace the outer skin at the mold.

An armor plate and method of making an armor plate is provided having the steps of: suspending a carbon fiber weave within a mold; heating aluminum 6061 or 7075 alloy to a molten state; pouring the molten aluminum into the mold having ceramic particulates in the range of 1 to 60 percent by volume of the molten aluminum and in the range of 3-44 microns in diameter; cooling the resultant matrixed aluminum to ambient temperature; and laminating at least two layers of ballistic fiber to the matrixed aluminum

Provided is a resin composition from which a three-dimensional molding can be produced at an appropriate speed and with high dimensional accuracy, wherein the obtained three-dimensional molding has high strength. This resin composition is used in a method for producing a three-dimensional molding composed of a cured product of a liquid resin composition by selectively irradiating the liquid resin composition with active energy rays. The resin composition includes at least: a first polymerizable compound, in a liquid state at room temperature, having radical polymerizability; a second polymerizable compound, in a liquid state at room temperature, having no radical polymerizability; and a filler, wherein the surface of the filler is covered with the second polymerizable compound.

A computer-controlled system for forming composition-controlled objects using 3D printing includes two or more liquid reactant reservoirs, and a mixing sub-system for mixing the two or more liquid reactant compositions, which in turn includes a flow control sub-system to control a mass ratio of the mixed two or more liquid reactant compositions. The computer-controlled system further includes a scanning sub-system that, under control of the computer, causes relative motion of a mixed liquid reactants nozzle over a substrate; thereby depositing the mixed liquid reactant compositions onto the substrate. The system still further includes an illuminations system, operated under control of the computer, to polymerize the deposited mixed liquid reactant compositions.

Methods for making an osteoimplant are provided. In one embodiment the method includes applying a mechanical force to an aqueous slurry of insoluble collagen fibers to entangle the insoluble collagen fibers so as to form a semi-solid mass of entangled insoluble collagen fibers; and lyophilizing the semi-solid mass of entangled collagen fibers to form the osteoimplant. An osteoimplant containing entangled insoluble collagen fibers is also provided.