A nested balloon is provided where each balloon is formed from tubing that optimizes the inner wall stretch thus providing maximum balloon strength. The high pressure, nested balloon is provided with layers that allow for slipping, such that the balloon has a very high pressure rating and toughness, yet excellent folding characteristics. Methods for producing such nested balloons using existing balloon forming equipment are also provided. The nested balloons can have layers with low-friction surfaces. The nested balloons are preferably manufactured using a variety of methods, including pressurized constrained annealing.

A heat welding composition and method for the repair of vehicle body components, particularly thermoplastic bumpers manufactured from polypropylene/EPDM. The composition includes a polypropylene base resin, talc filler, and optional additives, so as to be optimized for fusion-welding plastic to plastic automotive substrates. The method allows the material to be extruded into strips, applied with standard heat welding tools, and fused directly to damaged parts. The composition and method eliminate the need for structural fillers and enables OEM-grade repairs with improved durability, sustainability, and speed.

Splitting a thermoplastic weld and routing the weld around both sides of an attachment hole thereby maintaining good structure and attachment through two panels and avoiding secondary operations and secondary components. Thermoplastic welding incorporating at least one raised welding rib operable surrounding a plurality of attachment holes.

A method of joining a base component with a polymer may include irradiating the base component with laser illumination, where one or more properties of the laser illumination is selected to induce surface structures on a surface of the base component that wick a polymer component into cavities of the surface structures. For solid polymers, the method may include heating a surface of the polymer component to create a molten layer, then joining the surface of the polymer component with the surface of the base component, where the molten layer wicks into the cavities to bond the components. For liquid polymer components including polymers or polymer precursors in a liquid state, the method may include joining the liquid polymer component with the surface of the base component, where the liquid polymer component wicks into the cavities, followed by curing or drying the polymer component to bond the components.

A nested balloon is provided where each balloon is formed from tubing that optimizes the inner wall stretch thus providing maximum balloon strength. The high pressure, nested balloon is provided with layers that allow for slipping, such that the balloon has a very high pressure rating and toughness, yet excellent folding characteristics. Methods for producing such nested balloons using existing balloon forming equipment are also provided. The nested balloons can have layers with low-friction surfaces. The nested balloons are preferably manufactured using a variety of methods, including pressurized constrained annealing.