A composite structure for stab protection includes layers of flat structures placed on top of each other, and an embedding material, wherein, in at least some of the layers placed on top of each other, the flat structures of adjacent layers are offset relative to one another, the flat structures of the composite structure are at least partially embedded in the embedding material, and the composite structure includes separated connecting elements, wherein before they are separated, the separated connecting elements have connected at least some of the flat structures of adjacent layers with one another.

A helmet manufacturing method involves: producing a shell and a protector, the shell having two opposing cheek-protecting portions, the protector having a jaw-protecting portion and a neck-protecting portion connected to the jaw-protecting portion; putting the shell and the protector in a die such that bottom edges of the cheek-protecting portions of the shell connect to a top edge of the neck-protecting portion of the protector; introducing a foam material into the die, apply heat and pressure to the foam material such that the foam material expands and binds to an inner side of the shell and an inner side of the protector; and taking a helmet finished product out of the die. Therefore, both the jaw-protecting portion of the integrally-formed protector and the helmet finished product are reinforced.

A method and apparatus for protecting a structure. The method comprises identifying an exterior shape of the structure; generating a model of a mask based on the exterior shape of the structure; and forming the mask using a three dimensional printer based on the model.

A method of making a foamed article comprises (a) milling a block or sheet of thermoplastic polymer to form a precursor; (b) crosslinking the thermoplastic polymer; (c) heating the precursor to a first temperature to soften the thermoplastic polymer; (d) infusing the thermoplastic polymer with at least one inert gas at a first pressure that is sufficient to cause the at least one inert gas to permeate into the softened thermoplastic polymer; and (e) while the thermoplastic polymer is softened, reducing the pressure to a second pressure below the first pressure to at least partially foam the precursor into a foamed article, wherein the foamed article is substantially the same shape as the precursor.

A method of producing high modulus and strength polymer materials includes compressive rolling a semicrystalline polymer material in at least two different axial directions of the material; and axially orienting at least a portion of the compressive rolled material to a draw ratio less than the ultimate elongation or the elongation % at break of the material.

A method and apparatus is presented. A portion is cut from a thermoplastic sheet of a first thermoplastic material based on a three dimensional model. The portion is secured to a mold. The portion and the mold are heated under vacuum to form a structure. The structure may take the form of a protective covering. In some illustrative examples, the mold may be formed of a second thermoplastic material based on the three dimensional model using additive manufacturing.

An armor plate is provided having a lamination of an embedded reinforcement basalt fiber mesh within a laminated cast metal alloy; and at least two layers of an aramid fiber. A process to make the armor plate can include suspending a basalt weave within a mold; heating aluminum 6061 or 7075 alloy to a molten state; pouring the molten aluminum into the mold; cooling the resultant matrixed aluminum to ambient temperature; and laminating at least two layers of ballistic fiber to the matrixed aluminum.

A method of manufacturing an equine protective covering by applying a stamp comprises a profiled shape with a predetermined temperature and pressure to the interior side of the cushion assembly. The first synthetic fabric layer and the second neoprene layer are permanently bonded. The second neoprene layer is plastically deformed such that the profiled shape of the stamp is permanently transferred to the second neoprene layer. The plastic deformation of the second neoprene layer is such that the perforations remain open.

The disclosure provides, in certain embodiments, a method of manufacturing hard surface apparatus using natural and/or recycled fibrous materials. The method described in certain embodiments allows the creation of a protective case, including, but not limited to, protective containers for a myriad of uses, such as hard cases, bags, backpacks, briefcases, instrument cases, car toppers, snowboard carriers, fishing rod cases, laptop cases, phone cases, and the like. In certain embodiments, the method described herein allows the creation of hard surface apparatuses such as kayaks and canoes, flooring and tiles, bathtubs and sinks, kitchen ware, and the like.

A screen protector installation tray can include an alignment tray and a screen protector retained within the alignment tray. Also, a method for applying a mobile device screen protector to a mobile device, including retaining a screen protector within an alignment tray, applying the alignment tray to the mobile device, interfacing the screen protector with a screen of the mobile device, transferring the glass screen protector from the alignment tray to the mobile device, and removing the alignment tray. Additionally, a mobile device screen protector installation kit, including an alignment tray, a screen protector, and instructions for applying a screen protector to a screen of a mobile device.