An exemplary process includes determining a desired pore size, selecting an initial pore size greater than the target pore size, manufacturing a porous structure with the initial pore size, forging the porous structure to form a forged part having the desired pore size, and forming an orthopedic device from the forged part.

A golf club head includes a striking face, a crown and a sole. The crown and/or the sole includes an FRP member formed by a fiber reinforced plastic that contains a fiber and a matrix resin. The head has one or more characteristic mode shapes each having a natural frequency of 3000 Hz or greater and 5000 Hz or less. Of the one or more characteristic mode shapes, one characteristic mode shape that has a largest amplitude of a center of figure of the FRP member is defined as a specific characteristic mode shape, the specific characteristic mode shape has a frequency that is defined as a specific modal frequency, and the specific modal frequency has a modal damping ratio that is defined as a specific modal damping ratio. The specific modal damping ratio of the head is less than or equal to 0.6%.

Systems and methods are provided for composite part fabrication. One embodiment is a method for fabricating a composite part. The method includes selecting a tool with sides made of a core material in a desired size and shape, disposing a preform of a fiber reinforced material that surrounds the tool, resulting in a lamina assembly comprising the preform and the tool, heating the tool and the preform, co-bonding the tool to the fiber reinforced material within the lamina assembly, and hardening the preform and the tool into a hybrid composite part.

A method and apparatus for forming a radius filler. A lattice is formed of connecting elongate members having a three-dimensional shape of the radius filler. A resin is placed within the lattice.

A reusable surgical implement is provided that is formed of a core positioned within an enclosure. The core is formed of a suitable rigid, and optionally flexible material to enable the implant to conform to the desired use for the implement in a surgical procedure. The material forming the enclosure is also stretchable and flexible to accommodate the configuration and/or any flexing of the core, and is biologically inert to enable the implant to be sterilized after use for use in subsequent surgical procedures while protecting the material forming the core. The enclosure can be molded around the core in separate portions or components using multiple molding steps to form an enclosure with the desired attributes.

There is provided a mold apparatus and process whereby a warhead body can be fabricated in a single over molding process which may also include therein metal fragments, metal balls, obturators, boat tails and other aerodynamic features, metal rings and/or threads. Other molds and processes are presented whereby a warhead body may be over molded in a polymer matrix in sequential steps which may include adding therein metal balls, then fragments, and any of obturators, boat tails and other aerodynamic features, metal rings and/or threads, as desired. Still another process for fabricating a warhead body is presented whereby an insert section is first preloaded with metal fragments and covered with a skin, then the insert section is inserted into an oversized area in a mold, and polymer is then loaded around the insert section to form a unitary warhead body.

A method of forming a hybrid metal composite structure including at least one metal ply. The method includes forming at least one metal ply, forming the at least one metal ply comprising forming at least one perforation in the at least one metal ply, abrasively blasting at least one surface of the at least one metal ply to coarsen the at least one surface of the metal ply, and exposing the at least one metal ply to at least one of an acid or a base. The method further includes disposing at least one fiber composite material structure adjacent the at least one metal ply. Related methods of forming a portion of a rocket case and related hybrid metal composite structures are also disclosed.

A golf club head includes a striking face, a crown and a sole. The crown and/or the sole includes an FRP member formed by a fiber reinforced plastic that contains a fiber and a matrix resin. The head has one or more characteristic mode shapes each having a natural frequency of 3000 Hz or greater and 5000 Hz or less. Of the one or more characteristic mode shapes, one characteristic mode shape that has a largest amplitude of a center of figure of the FRP member is defined as a specific characteristic mode shape, the specific characteristic mode shape has a frequency that is defined as a specific modal frequency, and the specific modal frequency has a modal damping ratio that is defined as a specific modal damping ratio. The specific modal damping ratio of the head is less than or equal to 0.6%.

A reusable surgical implement is provided that is formed of a core positioned within an enclosure. The core is formed of a suitable rigid, and optionally flexible material to enable the implant to conform to the desired use for the implement in a surgical procedure. The material forming the enclosure is also stretchable and flexible to accommodate the configuration and/or any flexing of the core, and is biologically inert to enable the implant to be sterilized after use for use in subsequent surgical procedures while protecting the material forming the core. The enclosure can be molded around the core in separate portions or components using multiple molding steps to form an enclosure with the desired attributes.

Methods of embedding a heating circuit in an article fabricated by additive manufacturing. The methods describe techniques such as co-extruding a wire, capable of being heated, along with print material in additive manufacturing of the article, and placing a pre-shaped wire capable of being heated between adjacent layers of the article. A third method includes dispensing a wire, capable of being heated, during the additive manufacturing of the article, and compacting the wire into the printed material. An apparatus for embedding a heating circuit in an article fabricated by additive manufacturing. The apparatus contains a wire dispenser, a cutter to control the length of the wire dispensed, and a compactor capable of embedding the wire capable of being heated into the printed material. An article made by additive manufacturing is disclosed. The article contains at least one heating element embedded in the article during the additive manufacturing process.