The method regards manufacturing devices by replication, wherein each of the devices comprises a device surface. The method comprises producing the devices from a replication material by replication using a replication tool (1), wherein the replication tool (1) comprises a tool material comprising replication sites (4) comprising a replication surface (5) each. Each of the replication surfaces (5) corresponds to a negative of the device surface of a respective one of the devices. The tool material comprises, in addition to the replication sites, one or more mitigating features (7) for reducing asymmetric form errors of the device surfaces. Replication tools (1) and methods for manufacturing these are also described.

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 template and method of using the template is disclosed. The template can include a body with a first side and a second side, and an extension. The extension can include a first surface adjacent the body, a second surface, and a third surface between the first surface and the second surface, where the first surface includes a curvature and where a portion of the curvature of the first surface is interior to the third surface. The method can include dispensing a formable material over a substrate, where the substrate includes a non-uniform surface topography. The method can also include curing the formable material contacting the second surface of the extension to form a layer over the substrate while the formable material contacting the third surface of the extension remains in a liquid state, wherein curing is performed while the template is contacting the formable material.

A template and method of using the template is disclosed. The template can include a body with a first side and a second side, and an extension. The extension can include a first surface adjacent the body, a second surface, and a third surface between the first surface and the second surface, where the first surface includes a curvature and where a portion of the curvature of the first surface is interior to the third surface. The method can include dispensing a formable material over a substrate, where the substrate includes a non-uniform surface topography. The method can also include curing the formable material contacting the second surface of the extension to form a layer over the substrate while the formable material contacting the third surface of the extension remains in a liquid state, wherein curing is performed while the template is contacting the formable material.

A product includes an aerogel having a single bulk structure, the single bulk structure having at least one dimension greater than 10 millimeters. The single bulk structure includes a plurality of pores, where each pore has a largest diameter defined as a greatest distance between pore walls of the respective pore. In addition, an average of the largest diameters of a majority of the pores is within a specified range, and the plurality of pores are distributed substantially homogenously throughout the single bulk structure.

A method of fabricating a casting, the method including applying a substrate to a sacrificial mold, the sacrificial mold including a shaped non-planar receiving surface to receive the substrate and provide a casting of the substrate having a shaped structure corresponding to the receiving surface; and subjecting the sacrificial mold and casting to freeze drying conditions and sublimating the sacrificial mold from the casting to form a cast article including the shaped non-planar structure.

A method of manufacturing a microfluidic architecture having at least one channel disposed therein. Steps can include pouring an uncured polymeric material into a mould to produce a first layer; at least partially curing the first layer; and forming the at least one channel by disposing a support material on the first layer; pouring an uncured polymeric material onto the first layer to form a second layer to thereby encapsulate the support material; and at least partially curing the second layer such that the first layer and second layer together form the microfluidic architecture; wherein the support material undergoes a phase change during the process of forming the at least one channel. The phase change of the support material enables the material to be more easily disposed and/or removed after formation of the channel.

A method of manufacturing a microfluidic architecture having at least one channel disposed therein. Steps can include pouring an uncured polymeric material into a mould to produce a first layer; at least partially curing the first layer; and forming the at least one channel by disposing a support material on the first layer; pouring an uncured polymeric material onto the first layer to form a second layer to thereby encapsulate the support material; and at least partially curing the second layer such that the first layer and second layer together form the microfluidic architecture; wherein the support material undergoes a phase change during the process of forming the at least one channel. The phase change of the support material enables the material to be more easily disposed and/or removed after formation of the channel.

The present invention relates to a material system for 3D printing, to a 3D printing process using a lignin-containing component or derivatives thereof or modified lignins, to soluble moldings that are produced by a powder-based additive layer manufacturing process and to the use of the moldings.

A seat pad with improved thermal comfort and improved vibration absorptivity and a seat pad manufacturing method for easily obtaining the seat pad are provided. In the seat pad (1), when a surface portion (2) up to 10 mm from a surface (1f) is cut out and the air permeability AR1 of the surface portion (2) is measured in compliance with JIS K 6400, the air permeability AR1 is more than 5 cc/cm.sup.2/sec and 25 cc/cm.sup.2/sec or less. The seat pad manufacturing method is a seat pad manufacturing method for obtaining the seat pad (1) by supplying a molding material into a molding die and performing foam molding. As the molding die, a molding die an inner surface of which is covered with polystyrene or polyethylene is used.