A cost-effective method of forming a hydrophobic coating on a substrate and coated substrates are disclosed. Specifically, the method comprises applying amorphous powders of an alloy to the substrate through a cold spray process. Also provided is a novel type of hydrophobic coating made of metallic glasses or amorphous alloys. The hydrophobic coatings offer advantages such as, low cost, low maintenance, and high corrosion resistance.

A backing component configured to receive and attenuate transmitted acoustic signals from a transducer element in an ultrasound probe is disclosed. The backing component has a unitary structure of a first material and a second material, and a variation in packing density of the first material across at least a portion of a thickness of the backing component. Further, a method of making a backing component for a transducer element in an ultrasound probe is disclosed. The method includes performing an additive manufacturing technique using a first material and a second material to form the backing component that has a unitary structure of the first material and the second material. Performing the additive manufacturing technique involves varying a packing density of the first material across at least a portion of thickness of the backing component.

Provided is a method of forming a conductive polymer composite. The method includes forming a mixture. The mixture includes a first thermoplastic polymer, a second thermoplastic polymer and a plurality of metal particles. The first thermoplastic polymer and the second thermoplastic polymer are immiscible with each other. The plurality of metal particles include at least one metal that is immiscible with both the first thermoplastic polymer and the second thermoplastic polymer. The method includes heating the mixture to a temperature greater than or equal to a melting point of the metal.

A method of producing a cellular structure via an additive manufacturing technique includes the steps of: providing a feedstock material to an additive manufacturing printer device; dispensing the feedstock material from the printer device; and controlling the dispensing of the feedstock material to form at least one layer of the cellular structure according to a first predetermined gradient. In some aspects, the cellular structure comprises an array of cells surrounded, respectively, by walls, and arranged to create a non-uniform relative density and/or cell geometry across a width and/or a height of the cellular structure. An article of manufacture produced by such methods includes a cellular structure configured to produce a controlled collapse with selectable dynamic stiffness characteristics by altering the distribution and geometry of cells within the cellular structure, while being able to maintain a substantially similar static stiffness characteristic.

In injection-molding a conductive material, prolongation of an injection molding cycle and occurrence of defective appearance of a molded article are reduced, and the molded article is given uniform conductivity. An injection molding apparatus has a heating injection means which heats a conductive material to a temperature that allows the conductive material to melt and flow, and which injects the conductive material to a mold. The mold has a plurality of conductive portions at least at a portion of a surface defining a cavity, the conductive portions being insulated from each other. A predetermined voltage is applied to the conductive portions. A static mixer is provided in an area including a tip portion of the heating injection means and a flow path of the conductive material.

An extruded thermoplastic product having a surface abrasive to insects. The extruded product is formed from a dry powder composition being comprised of a thermoplastic polymer, a plurality of pelletized diatomaceous earth, and a plurality of expandable microballoons. The composition is mixed and heated in an extrusion machine before being forced into a die of selected profile. Cooling the material immediately after being removed from the die allows the diatomaceous earth to remain at the surface of the material. The material with the surface abrasive to insects is used is used as a component in a product, such as conventional weatherization products, for placement in a building opening that insects use as ingress to the building. Products contemplated for use with the extrusion include door sweeps, door and window seals, and thresholds.

A punch pin hole inspection apparatus and method uses a punch and a die capable of checking defects or damage, specifically pin holes or microcracks, due to shaping immediately after finishing shaping a laminate sheet into a battery case using the punch.

A method includes injection molding a preform using a two phase injection system having a first phase in which a material is injected into the preform and a second phase in which the material is injected into the preform. The preform is disposed in a mold. The preform is blow molded into an intermediate article. The intermediate article is trimmed to form a finished container. The first phase includes injecting a material into the preform to form a single layer of the preform and the second phase includes injecting the material to form inner and outer layers and an intermediate layer between the inner and outer layers. The inner and outer layers include the material and the intermediate layer includes at least one additive. Finished containers are disclosed.

Provided is a method of forming a conductive polymer composite. The method includes forming a mixture. The mixture includes a first thermoplastic polymer, a second thermoplastic polymer and a plurality of metal particles. The first thermoplastic polymer and the second thermoplastic polymer are immiscible with each other. The plurality of metal particles include at least one metal that is immiscible with both the first thermoplastic polymer and the second thermoplastic polymer. The method includes heating the mixture to a temperature greater than or equal to a melting point of the metal.

A decorative resin composition containing a metal pigment having an average thickness of not more than 600 nm dispersed in a blend of a low-density polyethylene (LDPE) having a density of not less than 0.910 g/cm.sup.3 but less than 0.930 g/cm.sup.3 and a linear low-density polyethylene (LLDPE) having a density of 0.910 to 0.925 g/cm.sup.3.