Multilayer riblet applique and methods of producing the same are described herein. One disclosed example method includes applying a first high elongation polymer material to a web tool, where the web tool is to be provided from a first roll, and heating, via a first heating process, the first high elongation polymer material. The disclosed example method also includes applying a second high elongation polymer material to the first high elongation polymer material, and heating, via a second heating process, the second high elongation polymer material. The disclosed example method also includes applying, via a laminating roller, a support layer to the second high elongation polymer material.

A recoating unit (40) serves for equipping or retrofitting a device (1) for additive manufacturing of a three-dimensional object (2) by selectively solidifying a building material (15), preferably a powder, layer by layer. The device (1) comprises a recoater (16) movable across a build area (8) for applying a layer (31b, 32b) of the building material (15) within the build area (8) and a solidification device (20) for selectively solidifying the applied layer (31b, 32b) at positions corresponding to a cross-section of the object (2) to be manufactured. The device (1) is formed and/or controlled to repeat the steps of applying and selectively solidifying until the object (2) is completed. The recoating unit (40) comprises at least two recoating rollers (41, 42) spaced apart from each other in a first direction (B1) and extending into a second direction transversely, preferably perpendicularly, to the first direction. At least one of the recoating rollers (41, 42), preferably both of the recoating rollers (41, 42) are formed adjustable in a third direction perpendicular to the first direction and the second direction in the recoating unit (40).

A recoating unit (40) serves for equipping or retrofitting a device (1) for additive manufacturing of a three-dimensional object (2) by selectively solidifying a building material (15), preferably a powder, layer by layer. The device (1) comprises a recoater (16) movable across a build area (8) for applying a layer (31b, 32b) of the building material (15) within the build area (8) and a solidification device (20) for selectively solidifying the applied layer (31b, 32b) at positions corresponding to a cross-section of the object (2) to be manufactured. The device (1) is formed and/or controlled to repeat the steps of applying and selectively solidifying until the object (2) is completed. The recoating unit (40) comprises at least two recoating rollers (41, 42) spaced apart from each other in a first direction (B1) and extending into a second direction transversely, preferably perpendicularly, to the first direction. At least one of the recoating rollers (41, 42), preferably both of the recoating rollers (41, 42) are formed adjustable in a third direction perpendicular to the first direction and the second direction in the recoating unit (40).

In embodiments, a flexible mat forming system includes a rotating drum having a plurality of mold cavities; a hopper that receives a hardenable paste and deposits the hardenable paste into the mold cavities as the drum rotates relative to the hopper; and a sheet of mesh material that is fed between the hopper and the mold cavities facing the hopper. The hopper includes a plurality of side walls and a bottom panel having an opening, wherein the plurality of walls and the bottom panel define an interior chamber; and an auger rotatably mounted in the interior chamber and having a plurality of radially extending protrusions along a length thereof, the radially extending protrusions including angled surfaces to displace the material received in the interior chamber along a length of the interior chamber to fall through the opening into the mold cavities.

In embodiments, a flexible mat forming system includes a rotating drum having a plurality of mold cavities; a hopper that receives a hardenable paste and deposits the hardenable paste into the mold cavities as the drum rotates relative to the hopper; and a sheet of mesh material that is fed between the hopper and the mold cavities facing the hopper. The hopper includes a plurality of side walls and a bottom panel having an opening, wherein the plurality of walls and the bottom panel define an interior chamber; and an auger rotatably mounted in the interior chamber and having a plurality of radially extending protrusions along a length thereof, the radially extending protrusions including angled surfaces to displace the material received in the interior chamber along a length of the interior chamber to fall through the opening into the mold cavities.

A method for forming a microneedle array, wherein the microneedle array includes a base surface and an elongated body portion terminating in a sharp tip, and is attached to a polymeric backing layer, includes the steps of: charging a first liquid comprising sugar and an active drug to a microneedle mold; drying the first liquid; optionally charging a second liquid comprising sugar to the microneedle mold and drying the second liquid; adhering a polymeric backing layer to the base surface of the microneedles formed in the microneedle mold to form the microneedle array. A powder coating method, and apparatus for conducting the methods and producing the product are included also.

A method for forming a microneedle array, wherein the microneedle array includes a base surface and an elongated body portion terminating in a sharp tip, and is attached to a polymeric backing layer, includes the steps of: charging a first liquid comprising sugar and an active drug to a microneedle mold; drying the first liquid; optionally charging a second liquid comprising sugar to the microneedle mold and drying the second liquid; adhering a polymeric backing layer to the base surface of the microneedles formed in the microneedle mold to form the microneedle array. A powder coating method, and apparatus for conducting the methods and producing the product are included also.

A composite core material and methods for making same are disclosed herein. The composite core material comprises mineral filler discontinuous portions disposed in a continuous encapsulating resin. Further, the method for forming a composite core material comprises the steps of forming a mixture comprising mineral filler, an encapsulating prepolymer, and a polymerization catalyst; disposing the mixture onto a moving belt; and polymerizing said encapsulating prepolymer to form a composite core material comprising mineral filler discontinuous portions disposed in a continuous encapsulating resin.

In an exemplary embodiment, a flexible mat forming system includes a rotating drum having a plurality of mold cavities about an outer periphery thereof; a hopper positioned adjacent the drum, the hopper shaped to receive a hardenable paste and deposit the hardenable paste into successive mold cavities of the plurality of mold cavities facing the hopper, as the drum rotates relative to the hopper; wherein the hopper includes an opening shaped and positioned to align with the mold cavities facing the hopper; and a sheet of mesh material that is fed between the hopper and the mold cavities facing the hopper.

In an exemplary embodiment, a flexible mat forming system includes a rotating drum having a plurality of mold cavities about an outer periphery thereof; a hopper positioned adjacent the drum, the hopper shaped to receive a hardenable paste and deposit the hardenable paste into successive mold cavities of the plurality of mold cavities facing the hopper, as the drum rotates relative to the hopper; wherein the hopper includes an opening shaped and positioned to align with the mold cavities facing the hopper; and a sheet of mesh material that is fed between the hopper and the mold cavities facing the hopper.