The present invention relates to a hybrid cowl cross bar manufactured through an improved method of performing an insert injection molding without applying hydraulic pressure to the inside of a metal pipe during injection molding in order to simplify a manufacturing process of a hybrid cowl cross bar and to secure rigidity of the cowl cross bar. According to an aspect of the present invention, a reinforcing material is inserted into a metal pipe that is a material of a cowl cross bar. The metal pipe may be made of a material such as aluminum, magnesium, or steel, like a conventional cowl cross bar. The reinforcing material may be manufactured by extruding a synthetic resin or a composite material (for example, PP+GF50%). A rib may be formed inside the reinforcing material to increase a capability to resist injection pressure when the metal pipe is insert-injected and to secure rigidity.

The invention concerns a method for the production of a composite profiled section (3) comprising a core (1) and a shell (2), in particular intended for use as a reinforcing element or reinforcing rod in a, preferably thermoplastic, plastic material and/or for use as a reinforcing rod for a spring clip (11), wherein the shell (2) has shell fibres (4) which are laid around the circumference of the core (1), wherein, subsequent to the application of the shell fibres (4) to the core (1), at least one supporting fibre (5) is wound around the shell fibres (4) applied to the core (1) by means of a winding device for the production of a preformed pre-composite profiled section (6). As an alternative and/or in addition thereto, a method for producing an aforementioned composite profiled section (3) is provided, wherein the core (1) is produced continuously by foam extrusion with at least one extruder.

A composite prepreg laminate such as a hat type-stringer is formed on a contoured mandrel using a combination of mechanical sweeping and vacuum forming.

A device for forming a composite laminate (10) for obtaining a Z-shaped profile (1) including: a grip module (5) comprising two plates (6) configured to enclose and grip between the two plates (6) a first portion of the composite laminate (10) that will form a first flange (3), and a feed module (7) comprising two plates (8) configured to enclose between the two plates (8) a second portion of the composite laminate (10), wherein the feed module (7) is configured to heat the portion of the composite laminate (10) located between its two plates (8) and to be movable with respect to the grip module (5) parallel to the plane of the web (2) of the composite profile (1) once formed to a second position in which the two plates (8) enclose the portion of the composite laminate (10) that will form a second flange (4).

A method and an extrusion- or pultrusion device (1) for forming a profile product (2) made from a material in a production direction (Y), said device comprising: a rotating die (3), extending in a radial (R) direction and a width direction (X), having two opposite first and second side walls (5, 6) and an outer circumferential surface (4) extending in the width direction (X) there between, wherein the rotating die (3) comprises a first side portion (23) in connection to the first side wall (5) and a second side portion (25) in connection to the second side wall (6) and a mid-portion (22) extending between the first and second side portions (23, 25), and a profile definition zone (7) having a longitudinal direction (Y) coinciding with the production direction (Y), a height direction (Z) and a width direction (X) being perpendicular to the height direction (Z), comprising a through channel (8) comprising a first channel section (9) followed by a second channel section (10) downstream the first channel section (9) with reference to the production direction,
wherein the rotating die (3) is rotatable about an axis extending across the production direction (Y) and arranged to allow the outer circumferential surface (4) to, while the rotating die (3) rotates, exert a pressure onto a surface of the material when fed through the profile definition zone (7).

A system for pultruding a beam, such as a pultruded beam of natural fibers, comprises a pulling mechanism continuously pulling on a preform of yarns including a thermoplastic matrix and fibers, the pulling mechanism being downstream of the system. A sequence is provided in the system and has a pre-heating module to pre-heat the preform. A first die has a tapering channel portion heated such that the preform reaches a desired low viscosity temperature for resin in the thermoplastic matrix to impregnate the fibers. A vacuum module has a vacuum cavity to remove air from the preform exiting the first die. A second die has a tapering channel portion heated such that the preform is at the desired low viscosity temperature for resin in the thermoplastic matrix to further impregnate the fibers. A cooling module to cool the beam before the beam reaches the pulling mechanism. A system for pultruding beams is also provided.

A desired shape can be easily realized, and a decrease in strength can be inhibited. A method for producing a composite material includes: an insertion step of inserting an inner member in which a second reinforcing fiber is impregnated with a resin into a space of an outer member that is formed of a woven first reinforcing fiber extending in an undulating manner, the outer member including an opening that is provided at at least one end portion and the space that communicates with the opening; and a composite material forming step of forming a composite material in which the outer member and the inner member are joined to each other by curing the resin of the inner member to join the outer member and the inner member to each other.

A method of forming a three-dimensional object (e.g. comprised of polyurethane, polyurea, or copolymer thereof) is carried out by: (a) providing a carrier and an optically transparent member having a build surface, the carrier and the build surface defining a build region therebetween; (b) filling the build region with a polymerizable liquid, the polymerizable liquid comprising a mixture of: (i) a light polymerizable liquid first component, and (ii) a second solidifiable component that is different from the first component; (c) irradiating the build region with light through the optically transparent member to form a solid blocked polymer scaffold and advancing the carrier away from the build surface to form a three-dimensional intermediate having the same shape as, or a shape to be imparted to, the three-dimensional object, with the intermediate containing the second solidifiable component; and then (d) contacting the three-dimensional intermediate to water to form the three-dimensional object.

A method of forming a three-dimensional object, wherein said three-dimensional object is an insert for use between a helmet and a human body, is described. The method may use a polymerizable liquid, or resin, useful for the production by additive manufacturing of a three-dimensional object, comprising a mixture of (i) a light polymerizable liquid first component, and (ii) a second solidifiable component that is different from said first component.

A forming tool for forming a semi-finished product comprising reinforcement fibers and being conveyed to the forming tool in a continuous process. The forming tool comprises at least one pressure bag configured to be pressurized during a forming step of the semi-finished product, during which the semi-finished product is sandwiched between a forming surface of a forming element and the at least one pressurized pressure bag, such that the semi-finished product substantially takes on the shape of the forming surface. Further, a forming apparatus and a forming method for forming a semi-finished product comprising reinforcement fibers are provided.