3D fabrics have multiple layers including an outer dimensional layer of traditional fabric and a liner layer integrated with outer layer. The 3D fabrics have variable depth, typically ranging from between about 0.25 inches to about 2.0 inches. The 3D fabrics are produced from a molding process that creates the outer dimensional layer while adhering it to the liner layer. The 3D fabrics have unique visual properties which make them desirable for a variety of applications.

A bicycle saddle manufacturing method includes the steps of expanding a foamable material to form the foamable material into a semi-finished saddle body, and performing a thermoforming process to form the semi-finished saddle body into a saddle in a forming mold. As a result, the bicycle saddle manufacturing method of the present invention can avoid waste of material and environmental pollution.

In an embodiment, a dielectric substrate comprises an unsintered polytetrafluoroethylene; and a high dielectric constant filler, wherein the dielectric constant of the high dielectric constant filler is greater than or equal to 35; wherein the dielectric substrate has a specific gravity of greater than or equal to 90% of a calculated theoretical density of the dielectric substrate, wherein the theoretical specific gravity is calculated based on a measured specific gravity of the high dielectric constant filler, the specific gravity of the unsintered polytetrafluoroethylene, and the relative weight fractions of the unsintered polytetrafluoroethylene and the high dielectric constant filler; and wherein the dielectric substrate has a dielectric constant of greater than or equal to 11.5 as determined at a frequency of 10 GHz.

Systems and methods are provided for enhancing edge breathers for composite manufacturing. One exemplary embodiment is an apparatus that includes an edge breather to facilitate manufacturing of a composite part. The edge breather includes a body, ridges disposed along a length of the body that each define an arc which is perpendicular to a lengthwise axis of the body, and openings disposed along the body that enable air to enter a hollow interior that runs along the length of the body. The arcs defined by the ridges resist compressive loads applied to the edge breather and prevent the hollow interior from collapsing under pressure applied to the edge breather by a vacuum bag during manufacturing of the composite part.

A tether for attachment to a damper device is formed to include a heated, reshaped enlarged bulbous end.

A composite part is cured out-of-autoclave using an inductively heated, stand-alone tooling. The part in placed on a tool and is covered by a heating blanket. One side of the part is heated by inductive coil circuits in the tool, and the other side of the part is heated by inductive coil circuits in the blanket.

A method for receiving and ejecting molded articles includes: (a) drawing air from a cooling tube cavity into an air channel through a plate bore to draw at least a portion of a molded article into the cavity; (b) moving a valve within the plate bore from a first position for conducting air from the cavity to the air channel to a second position for reducing air flow through the plate bore relative to the first position; and (c) when the valve is in the second position, urging pressurized air from the air channel to the cavity through the plate bore to assist ejection of the molded article from the cavity.

A method of manufacturing an aerofoil blade includes the steps of providing: an aerofoil sub-assembly having a pair of aerofoil skins, wherein at least one of the skins is formed to have on its outer face an outer primary relief feature formed proud of the adjacent region of the outer face and an outer secondary relief feature projecting from the outer primary relief feature; arranging the aerofoil sub-assembly in a cavity die mould; and performing a hot forming process to form an internal cavity between the respective aerofoil skins by inflating the sub-assembly to conform the outer faces of the respective skins to the cavity die mould, whereby in conforming the respective outer faces of the skins to the cavity die mould, the outer primary and secondary relief features are transferred to the inner face of the respective skin to form respectively inner primary and secondary relief features.

An aircraft propeller blade including a streamlined structure constituted by at least one piece of fiber reinforcement obtained by three-dimensionally weaving yarns and densified by a matrix, together with a spar including an enlarged portion extending outside the fiber reinforcement and forming the root of the blade, and a shaping portion present in a housing arranged inside the fiber reinforcement. The fiber reinforcement includes a non-interlinked zone forming the housing inside the fiber reinforcement. The non-interlinked zone opens out into the bottom portion and into the rear edge of the fiber reinforcement so as to form an opening for inserting the shaping portion of the spar into the housing of the fiber reinforcement. The opening present in the rear edge of the fiber reinforcement extends over a height that is less than the height of the housing.

A single-layer 3D fabric of traditional camouflage synthetic fabric with outwardly extending random hollow tunnels therein with weldments in the fabric layer intermittently along the tunnels to hold the outwardly extending hollow tunnels in place. The tunnels have variable depth, typically ranging from between about 0.25 inches to about 2.0 inches. The 3D fabric is produced from a molding process that creates the outer dimensional layer. The 3D fabrics have unique visual properties which make them desirable for a variety of applications.