A tubular wall, which may be employed in a medical catheter or medical electrical lead, is formed by stranding together a plurality of polymer fibers and at least one metal filar, wherein the stranding forms a braid matrix of the polymer fibers and a coil of the metal filar interlaced therewith. Then, while the braid matrix secures a pitch of the coil, a polymer material is extruded around an entire length of the tubular wall, and, in some cases, the extrusion process causes the plurality of polymer fibers to melt and coalesce together with one another, while the pitch of the coil is maintained. Alternately, a reflow process, which follows extrusion, causes the polymer fibers to melt and coalesce along all, or just a discrete length of the tubular wall.

A method of producing a multi-lumen elongate body for a medical device. Unlike known methods requiring a solid core of material inserted into each lumen to maintain patency of the lumens during manufacture, the present method obviates the need for a solid core within one or more minor lumens, which saves cost and production complexity. One or more material overlay and mesh overlay steps may be used to produce the multi-lumen elongate body, but only the main lumen may include a solid core therein during all manufacturing steps. The one or more minor lumens may each be defined by a lumen tube having a sufficient stiffness to withstand external pressure during all manufacturing steps without the need for a solid core within.

A method is provided in which suitable carbon-fiber scrap is fed, together with a plastic polymer, to a pulverizer and extruder in order to produce a carbon-fiber polymer mass therefrom and to impregnate the mass with a resin. A regrind prepreg, which is given suitable forms and/or lengths, is thus obtained. The regrind prepregs thus obtained can then be given an approximately final form in an additional step by way of an extrusion process.

An assembly for reshaping an elongated plasticized article includes a heated fixture upon which the elongated article is supported in adhering fashion to a contoured upper surface. Following heating, the article is transferred to a cooling fixture exhibiting a further contoured upper surface and, upon subsequent cooling, the article exhibits a final multi-dimensional extending profile matching the contoured upper surface of the cooling fixture. A further variation of the assembly includes an elongated and bowed track supporting a fixed jig at an end thereof. A slidable jig is traversable along the track and actuated by a ram in directions towards and away from the first jig. Upon a first length extending portion of the article being pre-secured to the slidable jig, a first forward feed direction of the article results in an end extending portion communicating within a multi-dimensional cavity establishing a contoured surface withing the fixed jig, subsequent rearward displacement of the slidable jig causes forcible reshaping of the elongated article as it is stretched and drawn against the contoured surface of the fixed jig.

A carousel system includes a platform and a plurality of material delivery systems mounted on a periphery of the platform, each respective material delivery system including a first gear and an extruder nozzle head. The carousel system also includes a carousel rotatably mounted on the platform, a first motor adapted to cause the carousel to rotate from a first radial position to a second radial position, a second motor mounted on the carousel, a drive shaft coupled to the second motor, and a second gear coupled to the drive shaft. Engagement of the second gear with one of the first gears causes the corresponding material delivery system to force an amount of a selected material into the corresponding extruder nozzle head, heat the selected material to soften the selected material, and deposit the selected material on a surface. Each material delivery system provides material having a respective color. The carousel system may be used in a 3D printing system.

An assembly and process for forming a two stage extruded pipe having a central inner sleeve and a pair of outer attached lobes. The central sleeve shaped (also termed a grout receiving tube) is produced in an initial extrusion operation, following which it enters a cross head operation where a pair of outer lobes are attached to cross sectional exterior surface locations according to a second stage extrusion operation so as to be integrally formed therewith. Other steps include cooling of the dual stage extruded pipe, as well as sectioning and stacking the pipe. Additional steps include forming elongated slots or apertures into the central sleeve portion of the finished extrusion, such in non-interfering fashion with the individual passageway defining and lobes.

A two-layer mono-axially oriented film includes a first layer of an opaque beta-nucleated microvoided propylene-based polymer; and a second layer containing a dark pigment that is adapted for use in a thermal printer in which the thermal print-head contacts the exposed surface of the first layer. The dark pigment of the second layer pigment has a color contrasting with the color of the first layer and can contain a carbon black. The first layer includes microvoids and may be made transparent upon the application of heat by collapsing the voids of the first layer or upon the application of ultra-sonic energy.

An assembly and process for forming a two stage extrusion of an elongated marine dock from a plasticized material, such as including but act limited to extruding a first generally L shaped bracket from a first more rigid thermoplastic, following which a cross head die arrangement is utilized in order to extrude a secondary arcuate and flexible material in extending fashion from a lower side of the L bracket. The secondary/flexible elastomer is extracted in an open flexed position relative to the first extruded bracket, and further such that, following completion, can be flexed into a closed engagement with an upper perpendicularly extending side of the bracket.

A nozzle for printing three-dimensional parts with an additive manufacturing system, the nozzle comprising a nozzle body having an inlet end and a tip end offset longitudinally from the inlet end, a tip pipe for extruding a flowable material, an inner ring extending circumferentially around the tip pipe at the outlet end, an outer ring extending circumferentially around the inner ring, at least one annular recessed groove located circumferentially between the inner ring and the outer ring.

A two-layer mono-axially oriented film includes a first layer of an opaque beta-nucleated microvoided propylene-based polymer; and a second layer containing a dark pigment that is adapted for use in a thermal printer in which the thermal print-head contacts the exposed surface of the first layer. The dark pigment of the second layer pigment has a color contrasting with the color of the first layer and can contain a carbon black. The first layer includes microvoids and may be made transparent upon the application of heat by collapsing the voids of the first layer or upon the application of ultra-sonic energy.