A method for producing a molded article of the present invention includes a step of preparing a pellet raw material containing a resin and raw fibers, a step of cutting the pellet raw material to obtain a plurality of pellets each containing the resin and fibers produced by cutting the raw fibers, a step of opening the fibers contained in each pellet; and a step of molding the pellets after being opened to obtain the molded article. According to the present invention, it is possible to easily produce a molded article (e.g., a back plate of a brake pad) having excellent mechanical strength. Further, According to the present invention, it is also possible to provide a molded article and a back plate each having excellent mechanical strength, and a brake pad having high reliability.

In some examples, a method includes depositing a mixture including a resin and an additive powder via a print head of a three-dimensional printing system to form a carbon fiber preform including a plurality of individual carbon fiber layers, wherein each individual layer of the plurality of individual carbon fiber layers includes a plurality of carbon fibers and the mixture of the resin and the additive powder.

A preform for a composite may include a plurality of fibrous layers consolidated together and forming the preform extending along a longitudinal axis. The plurality of fibrous layers includes at least one first fibrous layer and at least one second fibrous layer. The at least one first fibrous layer includes a plurality of first segments, and the least one second fibrous layer includes a plurality of second segments. At least one first segment of the plurality of first segments includes a plurality of reinforcing fibers extending at an angle relative to a radial direction extending from the longitudinal axis. At least one second segment of the plurality of second segments includes a plurality of reinforcing fibers extending at an angle + relative to the radial direction. is greater than 0 and less than 90.

A support structure of a 3D printer may include a printable surface that receives a heated bead of material and can support one or more extruded layers of material from the 3D printer. The support structure may include at least one inlet adjacent to the printable surface and one or more outlets that exit onto the printable surface. The one or more outlets are hermetically sealed to the inlet. The support structure may also include an injection mechanism operatively coupled to the at least one input.

There is disclosed a method of manufacturing a backing plate for carrying a friction material to form a brake pad unit of a disc brake assembly. The method comprises moulding a composite backing plate precursor within a mould such that a side of the backing plate is configured as a friction material mounting surface defining a moulded engagement feature. There is also disclosed a composite backing plate for carrying a friction material to form a brake pad unit of a disc brake assembly. There is also disclosed a brake pad unit comprising the composite backing plate.

A support structure of a 3D printer may include a printable surface that receives a heated bead of material and can support one or more extruded layers of material from the 3D printer. The support structure may include at least one inlet adjacent to the printable surface and one or more outlets that exit onto the printable surface. The one or more outlets are hermetically sealed to the inlet. The support structure may also include an injection mechanism operatively coupled to the at least one input.