A system for thermoforming an object is provided. The system includes a mold and a pressure-box. The mold has a surface that defines a shape of the object and includes two or more portions of differing porosities. The pressure-box is operative to generate a pressure differential across the surface. The two or more portions apply the pressure differential at different loads, based at least in part on the differing porosities, to a material disposed onto the surface so as to form the object by deforming the material into the shape.

Disclosed is a manufacturing method of a sheet molded article, including the steps of: thermoforming a molding sheet with a first mold, thereby molding a molded article including a body portion provided with a shape transferred from the first mold, and a peripheral edge portion surrounding the body portion; and removing the molded article from the first mold, and inverting the body portion front-to-back.

The present disclosure is directed to a method for creating a vacuum forming mold assembly. The method includes forming a plurality of support plates. Each support plate includes a surface defining a shape corresponding to a cross-section of at least a portion of the mold cavity. The method also includes removably coupling a mold body to the plurality of support plates to form the mold assembly. The mold body conforms to the shape of the surface of each support plate after being removably coupled to the plurality of support plates such that the mold body defines at least a portion of a mold cavity of the mold assembly. The mold body defines at least one of one or more vacuum manifolds or one or more fluid passages.

A method of forming a protective film on at least one electronic module is provided. The method includes the following steps. A protective material is disposed on at least one electronic module such that the protective material and the electronic modules are in contact with each other. The electronic modules and the protective material disposed on the electronic modules are disposed in a chamber, and a first ambient pressure is provided in the chamber. The protective material in the chamber is heated to a first temperature to soften the protective material disposed on the electronic modules. After the protective material is softened, a second ambient pressure greater than the first ambient pressure is provided in the chamber, wherein a gas in the chamber directly pressurizes the protective material such that the protective material conformally covers a top of the electronic modules. The protective material conformally covering the top of the electronic modules is heated to a second temperature to solidify the protective material conformally covering the top of the electronic modules to form a protective film conformally covering the top of the electronic modules.

A process for injection molded microcellular foaming various flexible foam compositions from biodegradable and industrially compostable bio-derived thermoplastic resins for use in, for example, footwear components, seating components, protective gear components, and watersport accessories wherein a process of manufacturing includes the steps of: producing a suitable thermoplastic biopolymer or biopolymer blend; injection molding the thermoplastic biopolymer or biopolymer blend into a suitable mold shape with inert nitrogen gas; controlling the polymer melt, pressure, temperature, and time such that a desirable flexible foam is formed; and utilizing gas counterpressure in the injection molding process to ensure the optimal foam structure with the least amount of cosmetic defects and little to no plastic skin on the outside of the foamed structure.

Disclosed are a three dimensional injection molding apparatus and an injection molding method which are capable of manufacturing an injection molded product having patterns, colors, and textures which are high quality by injection molding after completely removing a gas included in a melted resin, and transferring a surface layer for expressing the patterns, colors, and textures to the injection molded product.

A method for manufacturing an object is disclosed. The method includes the step of obtaining a preform of the object, with the preform having a first panel having a planar portion and at least one second panel. The second panel has an orientation which is different from that of the first panel. The planar portion of the first panel of the preform is thermoformed so as to have a protruding element. The thermoforming is done in a selective manner such that the at least one second panel is not thermoformed. The invention is also directed to a thermoforming device for performing the thermoforming.

A vacuum thermoforming apparatus including: a molding machine on which a window base material is mounted; and a pressure supply machine coupled to the molding machine and configured to supply a pneumatic pressure toward the molding machine. The molding machine includes a mounting part having a curved surface-shaped mounting surface, and a coupling part having a structure for coupling with the pressure supply machine and a curved portion along the shape of the mounting part. The pressure supply machine includes: a cover part facing the mounting surface; and a side wall extending from the cover part to define an inner space in the pressure supply machine, the side wall having a curved upper surface so as to engage with the coupling part.

A tie rod that includes a central section, a first tapered section, and a second tapered section. A thermoplastic tube extends the length of the tie rod. The first tapered section includes a first insert positioned within the thermoplastic tube. The second tapered section includes a second insert positioned within the thermoplastic tube. A channel extends through the tie rod along the central section, the first tapered section, and the second tapered section.

The invention is a system and method for forming a dental appliance. A control module may be configured to receive data concerning a dental model and determine a toolpath for creating a pre-cut substrate based on the data. A cutting module may be configured to create the pre-cut substrate based on the toolpath. A forming module may be configured to apply a second substrate to the pre-cut thermoforming substrate received from the cutting module and form a dental appliance from the pre-cut substrate and the secondary substrate. The method may include receiving data concerning a dental model, determining a toolpath for cutting a substrate into a pre-cut thermoforming substrate based on the data, pre-cutting a first substrate based on the toolpath to form a pre-cut substrate, applying a second substrate to the pre-cut substrate, and thermoforming a dental appliance from the pre-cut substrate and the second substrate.