An LWRT plus fabric injection overmolding process for the direct injection molding of thermoplastic features onto the B-side of a formed, finished Light Weight Reinforced Thermoplastic panel. The panel having an A-side finish cloth, non-woven, TPO, Vinyl or similar material placed into the injection molding press and injection molding tool, and then the features are injection molded onto the panel without damaging the A-side finish.

The following configuration is adopted for the purpose of solving reduction in strength and rigidity at a weldline which is a problem of an injection molding body, and enabling free design such as thin wall molding or complex shape molding of the injection molding body. That is, there is provided an integrally molded body in which a substrate for reinforcement (a) having a discontinuous fiber (a1) and a resin (a2) and an injection molding body (b) having a discontinuous fiber (b1) and a resin (b2) are integrated, the substrate for reinforcement (a) covering a part or all of a weldline of the injection molding body (b) to be integrated with the injection molding body (b), the ratio of thickness Ta of the substrate for reinforcement (a) to thickness T of a weldline part of the integrally molded body satisfying relational expression: in a case of Ea≠Ebw,
Ta/T≤((Ebw−√(Ea.Math.Ebw))/(Ebw−Ea)) in a case of Ea=Ebw,
Ta/T≤0.5 wherein, Ta: Thickness of substrate for reinforcement (a), T: Thickness of weldline part of integrally molded body, Ea: Flexural modulus of substrate for reinforcement (a) in width direction of weldline, and Ebw: Flexural modulus of weldline of injection molding body (b) in width direction of weldline.

A method for manufacturing a blade made of composite material for a turbine engine, in particular of an aircraft, the steps of injecting a resin in order to impregnate a fibrous preform woven in three dimensions and polymerizing the resin so as to form the blade that includes an airfoil, one longitudinal end of which is connected to a platform. The platform includes pressure and suction portions connected to the airfoil by a fillet, wherein a separation is formed in the fibrous preform between the pressure and suction portions. The method further includes reinforcing a leading edge of the airfoil; and reinforcing the fillets by integration of a metal reinforcement on at least one part of the pressure and suction portions of the platform and in the separation.

A metal and composite thermoplastic sandwich overmold adapted to achieve predetermined performance requirements without having to add metal and mass penalty to the assembly, and process to manufacture same. This is achievable by using the thermoplastic material that allows for a predetermined improved ribbing pattern that is connected to a base material. The ribbing can transfer load due to improved connection to the base material. There is provided increased plastic surface and edge encapsulation on the non-visible side of the part and the capability to provide well connected ribbing.

In an injection/compression-molding process, an assemblage of fiber-bundle-based preforms are placed in a mold cavity of a mold tool. The mold is then fully closed, but not pressurized. An injection charge, which includes resin and optionally short fibers, is placed in a plunger cavity that is in fluidic communication with the mold cavity. The injection charge is liquefied and injected into the mold cavity, pressurizing it to a pressure suitable for compression molding. If not previously liquefied, the resin in fiber-bundle-based preform is liquefied and, under the applied pressure, the resins and fibers are consolidated and then cooled to form a part.

Metal rib overmolding joining including creating geometrical features in reinforcements for interconnecting a three-dimensional metal reinforcement to a metal base plate of an overmolding part in order to transfer load forces. Interlocked reinforcement is pre-assembled or assembled in an injection molding tool. Geometric features are positioned and joined creating a connection geometry that is overmolded. The joints created between the metal reinforcements are done without a welding process.

A three-dimensional overmolding and process for manufacturing same. The three-dimensional overmolding has a three-dimensional structure with overmolding, which gives significant performance benefits. Assembly and joining of reinforcements is done before the overmolding or in the injection molding tool. The three-dimensional overmolding meets predetermined structural requirements without requiring secondary operations and at a lower mass and cost. The structural benefits are due to the three dimensional shape in combination with the benefit of the overmolding process.

A three-point suspension link for a chassis of a vehicle comprises two load-introducing elements, a central load-introducing element, two core profiles and a supporting winding. The three-point suspension link has two arms and a central bearing area. Each arm is connected to the central bearing area. Each arm has one of the load-introducing elements which is arranged at an end of the corresponding arm opposite the central bearing area. Each arm has a core profile which is spatially arranged between the load-introducing element and the central load-introducing element. The supporting winding surrounds the core profiles and the central load-introducing element in a subarea and is operatively connected to the core profiles, the load-introducing elements and the central load-introducing element.

A lightweight suspension assembly for a vehicle includes a suspension upright or knuckle provided with a bearing connection interface for receiving at least part of a wheel bearing, and with a first molded portion made of a first polymeric material; the assembly further includes at least one arm having a second molded portion made of a second polymeric material, and at least one joint member coupling the arm to the suspension upright/knuckle in such a manner to allow a relative rotation between the arm and the suspension upright/knuckle about at least one rotation axis (B); the first and second molded portions are arranged onto a first surface and, respectively, a second surface of the joint member, in such a manner that the first and second molded portions are coupled in a non-releasable manner to the joint member.

A device to thermoform a composite component and injection over-moulding a shape on one face of the composite component in a mould. The mould includes a paired shaping die and punch between them defining a closed cavity. The shaping die is mounted on a transfer device. The transfer device includes a loading/unloading station to load/unload a blank onto/from the shaping die, and an injection and mould-closure station to close the mould and to inject between the punch and the shaping die. The shaping die includes a network of inductors to heat its moulding surface and a cooling network to cool the moulding surface by a circulation of a fluid. The loading/unloading station includes a placement device to place a radiating element facing the moulding surface of the shaping die.