A substructure and its method of use eliminates core crush during the manufacturing of a hybrid sandwich-structured composite panel. The substructure is used in the manufacturing of the hybrid sandwich-structured composite panel by positioning a core of the composite panel in a cavity of the substructure and positioning the substructure and the core between layers of composite material where the substructure protects the core from core crush as the hybrid sandwich-structured composite panel is subjected to vacuum pressure and heat during autoclaving and then cured.

Freeform, additive manufacturing equipment, processes and products, including residential, commercial and other buildings. A movable extruder places extrudate that solidifies in open space to create scaffolding or skeletons of buildings and other products. Elongated extrudate elements are fused to each other or connected by other means to form a cellular structure. Filler material such as polymeric insulating foam may simultaneously or thereafter be placed within the cellular structure to contribute desired strength, rigidity, insulative, barrier or other properties. Finish materials may also be applied.

A method for manufacturing a sound absorption structure comprising a cellular panel, a porous layer positioned on a cellular panel first face, a reflective layer positioned on a cellular panel second face and a plurality of acoustic elements positioned in the cellular panel. The method comprises the steps of producing, for each acoustic element, a recess in the cellular panel opening out onto the first and second faces of the cellular panel, inserting the acoustic elements into their recesses, laying an anchoring layer on the second cellular panel face, curing or polymerization at a first pressure to connect each acoustic element to the cellular panel and/or to the anchoring layer, putting in place the porous layer and the reflective layer, and curing or polymerization at a second pressure to connect the porous layer and the reflective layer to the cellular panel.

A foam structural material includes a first core material and a reinforcing material. The first core material has a first portion of a linear groove part formed along an edge of the first core material. The reinforcing material has a first side fitted to the first portion of the linear groove part. The first portion of the linear groove part includes a first engagement plane. The first engagement plane is engaged with the reinforcing material and has one or a plurality of projections formed thereon.

The object of the invention can be a method of manufacturing a product in the form of a sandwich comprising a core and outer layers. The outer layers may be composed of composite material comprising a fiber-reinforced polymeric matrix. The method uses an insert of heat-resistant material, for example silicone. The object of this invention can be to provide a method of manufacturing a sandwich that dissociates the choice of material of the core of the sandwich from the choice of the material of the outer layers.

Disclosed are three-dimensional parts, such as orthotics and prosthetics, having sinusoidal wave pattern infill structures first and second boundary walls. Also disclosed are printers or systems configured to manufacture such parts, as well as methods of manufacturing such parts. The sinusoidal wave pattern infill structures are formed between, and normal to, the first and second boundary walls and are configured to provide locally tunable structural properties in different regions of the part.

A system and process of printing a package of expanded material (e.g., expanded starch, foam or other expanded material). The expanded material can be heated and extruded, poured, sprayed, or otherwise applied in malleable form that sets up to become a porous protective covering for an item to be packaged. In an example, a layer of expanded material is laid down, and the item in a protective covering (e.g., a plastic bag, sleeve, coating, etc.) is positioned on the layer of expanded material. Additional layers or expanded material may be applied, thereby encasing the item. The top surface of the expanded material may be flattened, such as by operation of a roller, press, or cutter. The top surface may be sprayed with a shellac sealant, paint, or other coating, to allow printing of a label on the top surface.

This shaping structure (1) comprises two shaping sheets (5, 7) facing each other at a distance from one another. According to the invention, the shaping structure (1) further comprises a macroporous spacer sheet (9), the spacer sheet (9) being arranged between the two shaping sheets (5, 7) and being corrugated in such a way as to form a series of alternating even peaks (18) and odd peaks (20) distributed in a first direction (D1) of the shaping structure, at least one of the even peaks (18) being attached to the first shaping sheet (5), at least one of the odd peaks (20) being attached to the second shaping sheet (7), each peak (18, 20) attached in this way defining an attachment surface (22, 26) for attachment to the shaping sheet (5, 7) to which this peak (18, 20) is attached.

A composite laminate structure includes a cellular core and a first laminate layer coupled to the cellular core. The first laminate layer includes a first thermoplastic layer and a first fiber-reinforced polymer layer, where a first surface of the first fiber-reinforced polymer layer is thermally consolidated to a second surface of the first thermoplastic layer. A first surface of the first thermoplastic layer is directly in contact with and bound to a first surface of the cellular core by temperature reduction of the first thermoplastic layer below a glass transition temperature of the first thermoplastic layer while the cellular core is pressed against the first thermoplastic layer when the first thermoplastic layer is above the glass transition temperature of the first thermoplastic layer and the cellular core is below a temperature where materials of the cellular core flow or degrade.

A method of forming a cored composite laminate, the method including forming a first recess in a first coupling surface of a first layer of the cored composite laminate, forming a second recess in a second coupling surface of a second layer of the cored composite laminate so that when the first layer of the cored composite laminate and the second layer of the cored composite laminate are coupled, the first recess and the second recess form a cavity through the cored composite laminate, and disposing a shape memory alloy member in the cavity, so that the shape memory alloy member supports the cored composite laminate during curing of the cored composite laminate.