A femoral head prosthesis is a multilayer composite having a metal neck stem component thread or press fit into a hollow rigid shell of metal or ceramic, a polymeric core filling the interior volume under the hollow rigid shell and around a forward part of the neck stem, and a smooth, void-free polymeric articulation layer of at most 12 mm over the exterior of the shell. The prosthesis is formed by a polymeric molding process wherein polymerizing resin or heated thermoplastic material is flowed in a mold through a set of holes through the hollow shell into the interior volume and around the shell's exterior. Once the resin has cured or the thermoplastic cooled, the stem, core, shell and articulation layer collectively form an integral prosthesis of a desired head diameter matching a patient's anatomy.

A process produces a tubular hybrid molding made of a plastics foam element that exhibits temperature-dependent shrinkage and a fiber-plastics composite. The method includes inserting the plastics foam element, unhardened first and second fiber-plastics composite sections into a mold, where the plastics foam element has open pores at locations in contact with the fiber-plastics composite. The plastics foam element and the fiber-plastics composite sections are shaped by the mold. The mold is exposed to a first temperature to minimize the viscosity of the resin in the fiber-plastics composite. The mold is exposed to a second temperature to harden the fiber-plastics composite and to achieve mechanical fixing of the plastics foam element thereon. The mold is exposed to a third temperature to shrink the plastics foam element and cause its shape to conform to that of the mold and achieve a final shape of the said element.

A gasket for compressible placement between a first surface and a second surface is disclosed. In one embodiment, the gasket has a cellular metal skeleton, such as a woven metallic skeleton, encapsulated in a viscoelastic, pliable, deformable tacky polymer body, which may contain graphene or other filler. The skeleton has multiple strands, which connect to form multiple interconnected cells or pores. The void space is substantially filled in the manufacture of the gasket, with the tacky uncured polymer. The uncured polymer will set up or cure, and then the gasket may be used.

A construct for a hockey blade that includes a foam core. The foam core includes a first core face, a second core face, and a bottom core edge and a top core edge. Multiple pins are injected into the foam core, and one or more layers of resin preimpregnated tape are wrapped around the foam before forming a hockey blade structure in a heated mold.

A method for manufacturing a lightweight part including a porous metal matrix having a functional resin bonded thereto is disclosed. The method includes a porous metal matrix preparation step of preparing a porous metal matrix; a base layer deposition step in which while a nozzle of a FDM (Fused Deposition Modeling) 3D printer moves along a first predetermined movement coordinate path, the nozzle heats and extrudes a resin filament toward a surface of the porous metal matrix to infiltrate a molten resin into closed pores or depressions in the surface of the porous metal matrix, thereby forming a base layer bonded to the surface of the porous metal matrix; and a build layer deposition step in which while the nozzle moves along the first set movement coordinate path or a predetermined second set movement coordinate path different from the first set movement coordinate path, the nozzle heats and extrudes the resin filament toward the base layer such that one or more flat or curved build layers are deposited on the base layer, wherein the resin filament is made of a functional resin material.

A construct for a hockey blade that includes a foam core. The foam core includes a first core face, a second core face, and a core edge. A first layer of resin preimpregnated tape is wrapped continuously around the first core face, the core edge and the second core face. A thread is placed along the first layer of preimpregnated tape. A second layer of resin preimpregnated tape wrapped continuously around the first layer of resin preimpregnated tape.

A construct for a hockey blade that includes a foam core. The foam core includes a first core face, a second core face, and a bottom core edge and a top core edge. Multiple pins are injected into the foam core, and one or more layers of resin preimpregnated tape are wrapped around the foam before forming a hockey blade structure in a heated mold.

The present application relates to a hybrid component and a method for producing the same. The proposed hybrid component comprises a basic element (2) having at least one portion which is formed as a laminate (3) from a plastics foam and a fiber composite plastic.

A composite structure (10) including a fiber injection molded portion (14); an insert material (16); and an optional outer layer (12), where the fiber injection molded portion (14) at least partially surrounds the insert material (16). The present teachings also contemplate a method of forming the composite structure (10), including positioning the insert material (16) into a mold and injecting fibers into the mold by a fiber injection molding process or blow molding process.

A housing includes one or more rigid portions and one or more flexible portions. The one or more rigid portions are formed by a foam metal. The one or more flexible portions are formed by a polymer elastomer and securely coupled to the one or more rigid portions.