A vibration welding device 40 includes: a vibration welding mold that is configured including an upper mold and a lower mold divided in an up-down direction, that is fitted with a first component and a second component forming an elongated shape having a bent portion, and that is disposed with length directions of the first component and the second component along a left-right direction; plural first mold divisions that configure one of the upper mold or the lower mold, and that are divided in the left-right direction; a pressing device that is coupled to each of the plural first mold divisions, and that applies pressure to the first mold divisions; and a vibration device that is coupled to each of the plural first mold divisions, and that vibrates the first mold divisions.

One-piece, integrated vehicle fascia and energy absorbers and methods of forming the same are disclosed. The one-piece vehicle fascia may include a fascia body and an energy absorber integrally formed with the fascia body. The energy absorber may include an open lattice portion including at least one lattice wall extending rearward from a front portion of the fascia body and adjoining at least two open cells. The lattice wall thickness may be smaller at a front portion of the energy absorber than at a rear portion. The open lattice portion may be formed as a honeycomb structure. The one-piece, integrated vehicle fascia and energy absorber may be formed by an additive manufacturing process (e.g., 3D printing). The process may include building the one-piece vehicle fascia in a plurality of successive layers each having a uniform thickness.

A runner system for a multi-cavity injection molding system, the runner system having runners of reduced size.

A method of resistive implant welding carbon fiber thermoplastic composites which includes providing at least two portions of a component formed with carbon fiber material, the at least two portions of the component each have a welding surface where the at least two portions of the component are welded together. One or more conductors of copper or aluminum mesh material positioned between the welding surface of the two portions. The method includes a forming tool having at least two portions capable of moving between an open position and a closed position. The forming tool has a welding region with non-conductive metal surface areas where electric current is selectively applied to facilitate the welding together of the at least two portions of the component. The forming tool has forming regions with conductive surfaces where the two components are shaped.

Pressurized air is conveyed through a manifold into contact with the first member via apertures having hole diameters of from 0.8 to 2.5 mm that are spaced apart at a distance of from 10 to 30 mm along the manifold to achieve a turbulent air flow pattern with a Reynolds number of greater than 2200 at a temperature of between 150 and 315 C. and at an air pressure between 0.5 and 10 pounds per square inch (psi) over ambient pressure onto the outer surfaces of the first member and the second member for heat curing a curable adhesive between the members to achieve adhesive cure in 60 to 90 seconds and free of any bond-line read-out visible to an unaided normal human eye.

The present bumper impact beam includes pultruding polymer (e.g. thermoset polymer, preferably polyurethane) into continuous reinforcement (preferably carbon fibers or glass fibers), the reinforcement including fabrics selectively positioned and extending around corners for improved impact strength. The beam preferably has a 50%-70% fiber volume fraction that is relatively uniform throughout the part. A curved cooling support and/or beam design may be used to cause the cooled beam to have a sweep.

A method is disclosed for manufacturing a bumper structure. A blank made out of fiber-reinforced composite material is deep drawn in a molding tool to form a bumper cross member having a first groove. A first rib structure is molded in the first groove onto the bumper cross member in the molding tool.

Provided is a method for manufacturing a bumper reinforcement in which bonding process time is short and open time is long. A method for manufacturing a bumper reinforcement of one embodiment includes: a pre-bonding step of preparing a layered body containing, in the following order, a metal member, which is a body section, a solid adhesive mainly comprising an amorphous thermoplastic resin that is at least one of a thermoplastic epoxy resin and a phenoxy resin, and a resin member, which is a resin reinforcement; and a bonding step of heating and pressurizing the layered body to melt the solid adhesive, and bonding the metal member and the resin member. Either the epoxy equivalent of the amorphous thermoplastic resin is 1,600 or more or the amorphous thermoplastic resin does not contain epoxy groups, and the heat of fusion of the amorphous thermoplastic resin is 15 J/g or less.

A manufacturing method for a joined body, includes: bringing a first member and a second member into contact with each other, at least one of the first member and the second member being made of thermoplastic resin, and the second member having a recessed portion on a joining surface to be joined to the first member; and welding the first member and the second member together, including welding a contact portion of the first member and the second member by melting the thermoplastic resin by frictional heat generated in the contact portion by relative movement of the first member and the second member, in a state in which the first member and the second member are in contact with each other.

A top tool and a bottom tool which can be set relative to one another along an axis perpendicular to a workpiece plane are provided in an apparatus for punching and welding plastic parts. A punch die and a sonotrode are fastened to one of the tools.