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.

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.

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.

A single-station additive manufacturing and thermoforming machine includes a heated bed forming a perforated print surface, a print head pivotable between a stowed position and a range of printing locations relative to the heated bed, and a thermoforming subassembly. The thermoforming subassembly is vertically movable relative to the heated bed to position a thermoforming sheet at a raised location to be heated to a plastic state, and a lowered position for vacuum forming over one or more printed parts upon the heated bed. The disclosure provides a fluid process between additive manufacturing and thermoforming where no interaction is needed from an operator in between additive manufacturing process stopping and thermoforming starting. The device can be easily increased in size to allow for larger parts to be manufactured and formed, while also providing a print bed that allows for air topass through for vacuum thermoforming, while also being heated.

The present invention relates to a film structure comprising an outer layer, a core and an inner layer (or sealant layer). The outer layer comprises a polyolefinic material having a Vicat softening temperature of 85° C. or greater, and a total crystallinity in the range of 25 to 45%. The core comprises a linear low density polyethylene having a density of 0.925 g/cm.sup.3 or less, and a melt index of 4.0 g/10 min or less. The inner layer comprises linear low density polyethylene having a density of from 0.865 to 0.926 g/cm.sup.3 and a melt index of less than 4.0 g/10 minutes. The films of the present invention have less than 25% of polyethylenes having a density of 0.930 g/cm.sup.3 or greater. Further, the films of the present invention can be characterized by the substantial absence of polyamide, polyester, ethylene vinyl acetate, ionomers, polyvinyl chloride, and/or cyclic olefin polymers.

A method for forming a three-dimensional curved surface on a laminated substrate is provided. In the method, the laminated substrate is brought into close contact with an elastic sheet. Here, the laminated substrate comprises a support substrate and a conductive layer on the support substrate, and the support substrate comprises a resin substrate comprising a thermoplastic resin. The elastic sheet is deformed while the laminated substrate is in close contact with the elastic sheet. The laminated substrate is brought into close contact with a temperature-controlled mold to soften the resin substrate.

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.