Systems and methods are provided for a caul plate having a feature for removal. One embodiment is a caul plate for forming a composite part. The caul plate includes a body that includes a lower surface which faces the composite part, and an upper surface that is opposite to the lower surface. The caul plate also includes a groove in the upper surface to accept a tool to slide the caul plate laterally from the composite part.

An additive manufacturing method includes removing material from a sheet to create a plurality of individual layer segments formed, placing at least two first layer segments adjacent to each other at the same height to form a first layer having a hollow interior, the at least two first layer segments defining a first portion of an exterior of a part, and placing at least one second layer segment above the at least two first layer segments to form a second layer having a hollow interior, the at least one second layer segment defining a second portion of the exterior of the part. The method includes attaching the first layer to the second layer and removing material from the first layer and from the second layer to form the part having a continuous surface that extends along the first layer and the second layer.

A method for manufacturing a roll mold by cutting a roll, includes generating a control waveform based on a signal corresponding to a rotary position of the roll, and making a plurality of cuts on a surface of the roll by, while the roll is rotated, reciprocating a cutting blade in a radial direction of the roll in accordance with the control waveform. Making the plurality of cuts includes at each of a plurality of predetermined locations, making a predetermined number of cuts of predetermined depth based on the control waveform. Generating the control waveform includes generating a control waveform dictating that the predetermined locations, the predetermined depths, or both are randomly selected. Generating the control waveform includes generating a control waveform dictating that, when multiple cuts are made at a predetermined location, each subsequent cut will have a smaller depth than a preceding cut.

The disclosure provides for a process for manufacturing a tread molding element configured to mold at least a portion of a tire tread, the process comprising the following successive steps of providing a first tread molding element that can be a 3D-printed element made of a plastic composition A; forming a reverse mold of the first tread molding element, wherein the reverse mold is made of a plastic composition B comprising one or more elastomers; heating the reverse mold to a temperature above 50° C. when the first tread molding element is a 3D-printed element made of a plastic composition A; and casting a second tread molding element from the reverse mold to obtain a second tread molding element; wherein the second tread molding element is made from a plastic composition C comprising one or more thermosetting resins.

There is disclosed a tool for manufacturing a composite component, the tool comprising: a skin composed of fibre reinforced plastic and defining a layup surface for the composite component, the skin having a plurality of passageways extending from the layup surface to an opposing surface of the skin; a backing secured to the skin, the backing and the skin defining a cavity therebetween; a support core disposed within the cavity and comprising a gas-permeable material in fluid communication with the passageways; and a conduit extending through the backing such that the conduit is in fluid communication with the gas-permeable material.

A method of fabricating an optical element, comprises fabricating a three-dimensional mold having a relief pattern complementary to a pattern of the optical element to be fabricated, contacting the relief pattern with a solidifiable transmissive material, and solidifying the material thereby forming a transmissive substrate having the pattern thereupon. The method also comprises contacting the transmissive substrate with one or more substances wherein a difference in refractive indices between the substance(s) and the transmissive substrate is less than about 0.1.

A method for manufacturing a fiber-reinforced hollow structural component includes introducing a mold core and fibers with a matrix material into a molding tool. A first fiber unit is located between the mold core and the molding tool to at least partially form a component wall. The matrix material is cured to form the hollow structural component and the mold core is flushed out of the hollow structural component to form a component cavity. At least one channel may extend through the mold core so that after the matrix material has cured and the mold core has been flushed out, a reinforcing strut is formed. A related hollow structural component is also disclosed.

Tooling formed from a 3D printed scaffold includes a 3D printed scaffold a casting material hardened within the scaffold; and a forming surface defined by the scaffold. A method forming the tooling includes 3D printing a tooling scaffold, wherein the scaffold defines a void volume and a forming surface, filling the void volume with casting material, and hardening the casting material.

A fabrication method involving the use of additive material fabrication methods to create a shell representative of a desired part, the additive material shell being used in one or more molding fabrication methods in which a second material is provided into a cavity of the shell.

A method for producing three-dimensional molded parts by means of layering, the moisture content of the build material mixture being able to be regulated.