A method is disclosed for additively manufacturing a composite structure. The method may include discharging a composite material to form a first layer having a first void, and discharging the composite material adjacent the first layer to form a second layer having a second void. The method may further include discharging a material into the first and second voids to lock the first and second layers together.

A support element for a seat includes a body and a covering covering at least a portion of the body, the covering being made of a covering material. The body includes at least one portion having a plurality of discrete structural elements and a plurality of bonding fibers, the bonding fibers having a central core and a sheath covering the core, the sheath being made of a material that melts when subjected to a melting temperature, the body being overmolded onto at least a portion of the covering.

This fiber-reinforced resin molded article has: a sheet molding compound layer; a continuous fiber reinforcing material layer; and a harrier layer, wherein the barrier layer is interposed between the sheet molding compound layer and the continuous fiber reinforcing material layer.

Provided are methods for preparing modified natural fiber composite feedstocks. In some embodiments, the presently disclosed methods include hydrolyzing agricultural fiber material, optionally soybean hulls, under conditions and for a time sufficient to remove some or all of the arabinose from the agricultural fiber material to produce an arabinose-deficient hydrolyzed product; hydrolyzing the arabinose-deficient hydrolyzed product under conditions and for a time sufficient to remove some or all of the xylose from the arabinose-deficient hydrolyzed product to produce a hydrolyzed fiber material; and combining a thermoplastic copolyester (TPC) with up to 35 wt. % by weight of the hydrolyzed material, whereby a modified fiber composite feed stock is prepared. Also provided are methods for isolating xylose removed from arabinose-deficient hydrolysates, modified fiber composites prepared by the presently disclosed methods, method for 3D printing structure using the modified fiber composites, methods for improving at least one characteristic of modified TPC composites, and methods for improving fused filament fabrication (FEE) processes.

The present invention relates to methods of manufacturing moulded products, for example building panels, and in particular, but not exclusively, to manufacturing a panel comprising natural stone or rock set into a polymeric layer. The method of manufacturing a moulded product as described herein comprises at least one article being set into a polymeric layer, followed by placing the at least one article and particulate ferrous material in a container so that at least a portion of the or each article is embedded in the particulate ferrous material, introducing a polymeric material into the container to form the moulded product, and removing the moulded product from the container.

A method for manufacturing an integrated hull by using 3D structure type fiber clothes and 3D vacuum infusion process includes: sequentially stacking at least one first fiber cloth, at least one core material and at least one second fiber cloth on a mold; deploying structural materials on the second fiber cloth; stacking the third fiber clothes to cover the structure materials and a part of the second fiber cloth, whereby the first fiber cloth, the core material, the second fiber cloth and the third fiber clothes are formed to a lamination; determining a pipe arrangement of vacuum pipes and first and second resin pipes; deploying a vacuum bag on the lamination and covering the first and second resin pipes and the vacuum pipe; executing the 3D vacuum infusion process; curing the resin; and executing a mold release process to complete an integrated hull.

In one or more embodiments, one or more systems, methods, and/or processes may place a first outer layer, a core layer, and a second outer layer in a mold; and may heat the mold to at least thirty degrees Celsius above a glass transition temperature (Tg) for a period of time. In one or more embodiments, the polycarbonate fibers may be between eight and ten deniers per filament. In one or more embodiments, the Tg may be no more than 105 degrees Celsius. In one or more embodiments, the one or more systems, methods, and/or processes may further allow the first outer layer, the core layer, and the second outer layer to cool below the Tg, after the period of time. For example, after the layers cool, a shear modulus of the core layer may be in a range of 0.9868 megapounds per square inch (msi) to 2.2730 msi.

A method for manufacturing, layer-upon-layer, an integral composite aeronautical structure, wherein the method comprises: (a) providing an additive manufacturing tool comprising a depositing mold shaping an aerodynamic surface and at least one head configured to be moved over the depositing mold and to deposit fibrous material reinforcement and/or meltable material; (b) depositing fibrous material reinforcement embedded within meltable material onto the depositing mold, at least one layer of a lower aerodynamic face-sheet being built thereby; (c) depositing meltable material onto at least a portion of the outer layer of the lower aerodynamic face-sheet, at least one layer of core structure being built thereby; and (d) depositing fibrous material reinforcement embedded within meltable material onto at least the outer layer of the core structure, at least one layer of an upper aerodynamic face-sheet being built thereby; wherein steps (b), (c) and (d) are performed using Additive Manufacturing technology.

Provided is a method for producing a gear including an intermediate product forming process of solidifying a fluid material to form a gear intermediate product, and a tooth forming process of cutting the gear intermediate product to form teeth.

The present invention provides a method for manufacturing a press-molded body, the method having a step for disposing an X material inside a mold, a step for closing the mold and extruding a Y material, which is a kneaded material, into the mold after pressure has begun to be applied to part of the X material, and a step for cold-pressing and integrally molding the X material and the Y material inside the mold, wherein: the X material includes reinforcing fibers FA, having a weight-average fiber length Lw.sub.A, and a thermoplastic resin R.sub.X; the Y material includes reinforcing fibers FB, having a weight-average fiber length Lw.sub.B, and a thermoplastic resin R.sub.Y; Lw.sub.B<Lw.sub.A; Lw.sub.A is 1 mm or greater and 100 mm or less; the X material has a spring-back amount greater than 1.0 and less than 14.0; the press-molded body has an vertical plane part and a top plane part; during the cold pressing, the Y material is caused to move from a region other than a vertical plane portion to the vertical plane portion; and a thickness t1 of the vertical plane portion and a thickness t2 of the top plane portion satisfy t1>t2.