The disclosure relates to forming shaped thermoplastic articles having smooth peripheries. Many thermoplastic articles have sharp edges formed upon molding or cutting the article from a feedstock sheet. Such sharp edges can damage thin plastic films or flesh which they contact, and smoothing the edges is desirable. Described herein are methods of forming a smooth periphery for such sharp-edged articles by rolling over the sharp edge. The smoothing operation is performed by forming a deflectable flange including a bend region separated from the potentially sharp peripheral edge by a spacer, deflecting a portion of the deflectable flange, and softening at least one bent portion of the deflectable flange to yield a smooth periphery upon cooling.

A method of manufacturing a structure is provided in which a burr portion can be more reliably cut. In a burr portion shaping step, the burr portion is sucked to an engaging portion by a suction part to shape the burr portion along the engaging portion, and in a cutting step, ae movable portion is moved relative to first and second split molds with the burr portion being shaped along the engaging portion, thereby the burr portion is cut from a molded main body along a cutting line.

Cushions, methods, and manufacturing systems for making the same are disclosed. The cushions may be foamless such as being made from a body of entangled and/or intertwined polymeric strands. The manufacturing systems may include a die such as die bars having a plurality of orifices that cooperate with a plurality of receptacles and actuators for discharging a plurality of fasteners from the receptacles, through the die into the cushions. In a refinement, the die may be heated such that a skinned over membrane is created in the cushion to retain the plurality of fasteners. A trim cover may cooperate with the plurality of fasteners such that it is attached to the cushion.

There is disclosed a method of manufacturing an article, the method comprising the steps of: providing a material; heating the material; restricting an edge or region of the material within a frame element; moving a mould towards the frame or vice versa such that the material is in contact with the mould.

A material processing method and a molding machine therefor are described. The molding machine comprises a pressing module, a heating module, and an air supplying module. The method comprises: placing material to be processed within a material molding space of the molding machine, and supplying air to an air passage provided in the material by the air supplying module; heating the material by the heating module according to a preset heating parameter; and pressing the material by the pressing module according to a preset pressing parameter.

The disclosure relates to forming shaped thermoplastic articles having smooth peripheries. Many thermoplastic articles have sharp edges formed upon molding or cutting the article from a feedstock sheet. Such sharp edges can damage thin plastic films or flesh which they contact, and smoothing the edges is desirable. Described herein are methods of forming a smooth periphery for such sharp-edged articles by rolling over the sharp edge. The smoothing operation is performed by forming a deflectable flange including a bend region separated from the potentially sharp peripheral edge by a spacer, deflecting a portion of the deflectable flange, and irreversibly bending, without heating, at least one bent portion of the deflectable flange to yield a smooth periphery upon cooling.

An apparatus for roll forming thermoplastic composites comprises a plurality of thermoplastic composite material spools, a plurality of thermoplastic composite material rollers, a plurality of sheet metal spools, a plurality of welding rollers, an oven, a forming roller, a pair of pinch rollers. The thermoplastic composite material spools retain plies of thermoplastic composite material. The plies flow through the thermoplastic composite material rollers to form a layup. The sheet metal spools retain metal sheets. The metal sheets and the layup flow through the welding rollers to form a metal composite material laminate. The oven heats the metal composite material laminate. The forming roller imparts a curvature to the metal composite material laminate. The pinch rollers receive the metal composite material laminate from the forming roller, pull the metal composite material laminate, and output the metal composite material laminate in a heated and compressed state.

The present invention relates to a product forming method, a product, and a shoe. The product forming method comprises the following steps: (1) placing a film on a bottom mold, and fixing the film between the bottom mold and a middle frame; (2) placing an outer housing material on the film, and suctioning the film, so that the film is internally recessed in the direction of the bottom mold, and then performing first curing molding to obtain a molded outer housing; and (3) placing an inner liner material on the molded outer housing, performing second curing molding to obtain a molded inner liner, and demolding to obtain the product.

The disclosure relates to forming shaped thermoplastic articles having smooth peripheries. Many thermoplastic articles have sharp edges formed upon molding or cutting the article from a feedstock sheet. Such sharp edges can damage thin plastic films or flesh which they contact, and smoothing the edges is desirable. Described herein are methods of forming a smooth periphery for such sharp-edged articles by rolling over the sharp edge. The smoothing operation is performed by forming a deflectable flange including a bend region separated from the potentially sharp peripheral edge by a spacer, deflecting a portion of the deflectable flange, and softening at least one bent portion of the deflectable flange to yield a smooth periphery upon cooling.