In an example method of forming a waveguide part having a predetermined shape, a photocurable material is dispensed into a space between a first mold portion and a second mold portion opposite the first mold portion. A relative separation between a surface of the first mold portion with respect to a surface of the second mold portion opposing the surface of the first mold portion is adjusted to fill the space between the first and second mold portions. The photocurable material in the space is irradiated with radiation suitable for photocuring the photocurable material to form a cured waveguide film so that different portions of the cured waveguide film have different rigidity. The cured waveguide film is separated from the first and second mold portions. The waveguide part is singulated from the cured waveguide film. The waveguide part corresponds to portions of the cured waveguide film having a higher rigidity than other portions of the cured waveguide film.

A tube includes at least one fluoropolymer layer, the tube having an inner surface and an outer surface, wherein the at least one fluoropolymer layer includes a fluoropolymer having a heat shrink temperature of less than 250° C., wherein the outer surface of the tube is crosslinked and the inner surface of the tube is not crosslinked.

A method and apparatus for cutting a Non-Crimp Fabric for improving edge stability and reducing stitch retraction is disclosed. The part of the NCF to be cut is treated with a binder and heated to activate the binder and therefore bind the tows and stitches together. By treating only the cutting path the drapability of the wider fabric is maintained. This may be achieved by heating only the part of the NCF to be cut, or applying binder to only the part of the NCF to be cut. The NCF may be compressed and cooled before cutting to improve binding action. A ply cutter may be adapted to carry out the invention by including a heat source and optionally a binder dispenser, compressor and cooler.

Methods for machining a composite material substrate are discloses comprising integrating a predetermined pattern area having a disbond material for the purpose of creating a disbond region into the composite material substrate at a predetermined thickness, detecting the disbond region and forming a plurality of recesses in the composite material substrate by removing a machined plug from the composite material substrate to form recesses positioned at locations corresponding to the predetermined pattern area, and composite components comprising the recesses machined according to such methods.

Disclosed herein is a cure tool for managing a thermal cycle of a composite component. The cure tool, in certain examples, includes a base plate comprising a work surface, for supporting the composite component, and a back surface opposite the work surface. The cure tool also includes one or more fins protruding from the back surface of the base plate and in thermal communication with the base plate. The cure tool additionally includes one or more heating elements coupled to each of the one or more fins and configured to selectively provide heat to the base plate.

An additive manufacturing system is disclosed that comprises two or more lasers for precisely heating a fiber-reinforced thermoplastic feedstock and a fiber-reinforced thermoplastic workpiece in preparation for depositing and tamping the feedstock onto the workpiece. The system employs feedforward, a variety of sensors, and feedback to ensure that the feedstock and workpiece are properly heated.

Provided herein are methods of forming and optimizing cured features on a surface including controlling the surface upon which the cured features are applied. Additionally, a system for forming and processing the topographical features on the membrane is also described, along with mechanical features at specific system stations. More particularly, provided herein are methods of forming and optimizing topographical features applied to a membrane surface by controlling the membrane surface and by controlling the direction and magnitude of pressure applied to the membrane (substrate), as well as initially partially curing the topographical features, followed by fully curing of the topographical features to form the membrane having topographical spacing features formed thereon.

Composite laminate structures are produced using partially cured parts. Partial curing of the parts is achieved by applying a catalyst to regions of the parts that are to be fully cured. These regions cure at a lower-than-normal temperature while remaining regions of the part remain uncured, allowing them to be co-bonded or co-cured to other structures.

Disclosed herein are systems and methods for manufacturing a part. An example method comprises heating a consolidated laminate sheet, comprising multiple plies each made of fibers embedded in a thermoplastic resin, to a heated temperature below a melting temperature of the thermoplastic resin to form a heated consolidated laminate sheet. The method also comprises forcing the heated consolidated laminate sheet against a contoured forming surface of a mold until a shape of the heated consolidated laminate sheet corresponds with a contoured shape of the contoured forming surface of the mold.

A shaped object production method includes a first preparation step (S30) of preparing a molding sheet that includes a base, a thermally expansive layer laminated on a first main surface of the base, the thermally expansive layer including a thermally expandable material, and a brushed layer laminated on a surface of the thermally expansive layer on a side that is opposite to the base, the brushed layer including fiber; a first heat conversion layer laminating step (S40) of laminating a heat conversion layer that converts electromagnetic waves into heat onto a surface of the molding sheet on a side that is opposite to the brushed layer; and a first unevenness forming step (S50) of forming an unevenness on the surface of the thermally expansive layer on the side that is opposite to the base by irradiating the heat conversion layer with electromagnetic waves, thereby causing the thermally expandable material to expand.