A method and apparatus for the additive manufacturing of three-dimensional objects are disclosed. Two or more materials are extruded simultaneously as a composite, with at least one material in liquid form and at least one material in a solid continuous strand completely encased within the liquid material. A means of curing the liquid material after extrusion hardens the composite. A part is constructed using a series of extruded composite paths. The strand material within the composite contains specific chemical, mechanical, or electrical characteristics that instill the object with enhanced capabilities not possible with only one material.

A fiber-reinforced plastic substrate is described in which a plurality of resins having different properties are firmly compounded and that includes components [A], [B], and [C]: [A] reinforcing fibers; [B] thermoplastic resin (b); and [C] thermoplastic resin (c),
wherein the component [A] is arranged in one direction, in the fiber-reinforced plastic substrate, a resin area including the component [B] and a resin area including the component [C] are present, the resin area including the component [B] is present on a surface of one side of the fiber-reinforced plastic substrate, and a distance Ra.sub.(bc) between Hansen solubility parameters of the component [B] and the component [C] satisfies formula (1):
Ra.sub.(bc)={4(DBDC).sup.2+(PBPC).sup.2+(HBHC).sup.2}.sup.1/28
wherein Ra.sub.(bc), DB, DC, PB, PC, HB and HC are as defined.

A ball bat includes a continuous tape of fiber material wrapped around the longitudinal axis in a helix extending along the longitudinal axis. Interlaminar interfaces between adjacent turns of the tape are oriented obliquely relative to the longitudinal axis. In some embodiments, the ball bat includes a preform structure, the tape being wrapped around the preform structure. In some embodiments, the ball bat includes a flared element on the preform structure. An end of the continuous tape may be positioned on an angled surface of the flared element. An outer skin may be positioned over the tape. Methods of making ball bats may include attaching a first end of a fiber tape to a flared element on a preform structure or a mandrel and wrapping the fiber tape around the preform structure or mandrel in a helix extending along the longitudinal axis of the preform structure or mandrel.

A shaping method for shaping a stack produced by layering and forming into a flat shape a plurality of sheet-shaped composite materials includes a first shaping step of shaping the stack along a fold line extending along the longitudinal direction of the stack such that a first region and a second region, which are disposed to sandwich the fold line, form a first bending angle, and a second shaping step of shaping along the fold line the stack shaped via the first shaping step such that the first region and the second region form a second bending angle that is smaller than the first bending angle. In the first shaping step and the second shaping step, the stack is shaped in a state wherein the first region is maintained below the softening temperature of the resin material, while the second region is being heated to the softening temperature or higher.

A mandrel mold tool for forming a mandrel includes a plurality of mandrel mold tool members that are configured for fastening together to form a mandrel mold tool having an internal compartment. The plurality of mandrel mold tool members each include an outer wall, an inner wall adjacent the outer wall, and an interior portion between the outer wall and the inner wall. The interior portion has a sparsely-infilled structure that is substantially permeable to fluids. The outer wall has a port for receiving a hardening fluid. The inner wall has a plurality of through-holes such that the hardening fluid, upon being introduced via the port, passes through the interior portion and the plurality of through-holes for hardening a sacrificial mold disposed in the internal compartment.

A method and apparatus for constructing a tubular assembly (24) comprising an inner portion (21) and a further portion (22) surrounding the inner portion, the further portion being formed from a strip (50) of material comprising two opposed longitudinal marginal side portions (53). The apparatus (100) comprises an assembly station (106) having a wall (122). The apparatus (100) comprises means for advancing the inner portion (21) along a first path (111) extending past the wall, and means for advancing the strip (50) along a second path (112) and causing the strip to encircle the wall and thereby wrap about and surround the inner portion (21). The two marginal side portions (53) are disposed in overlapping relation on the side of the wall opposed to the first path (111). The apparatus (100) further comprises a system (131) for affixing the two longitudinal marginal side portions (53) together in overlapping relation to assemble the strip (50) into a tubular configuration about the inner portion (21), whereby the strip in the tubular configuration provides the further portion (22).

A method for manufacturing a composite part includes forming an initial radius filler on a composite panel. The initial radius filler is formed from a plurality of plies of composite material stacked on the composite panel. The method includes forming a radius of curvature on at least one side of the initial radius filler, positioning a composite stiffener on the composite panel, wherein the composite stiffener is contoured to define a radius gap when joined with the composite panel, positioning the composite stiffener against the at least one side of the initial radius filler, compressing the composite stiffener, composite panel, and initial radius filler via vacuum bag, and heating the initial radius filler to at least one of a cure temperature, a melting temperature, or a fusing temperature to form, from the initial radius filler, a radius gap filler in the radius gap.

A one-piece gunstock for firearm and the relevant manufacturing method are described, said one-piece gunstock being composed of a frame (1) having two half-shells (1a, 1b) extended longitudinally and defining a recess inside the frame (1), a plurality of seats (31,32) and a space (42) for housing respective mechanical components formed between said half-shells and delimited by a transversal structural connection element (33) of said half-shells (1a, 1b), characterized in that said half-shells (1a, 1b) and said transversal connection element (33) are made in a single piece of an advanced composite material by a vacuum-bag moulding technology.

A method and apparatus for the additive manufacturing of three-dimensional objects are disclosed. Two or more materials are extruded simultaneously as a composite, with at least one material in liquid form and at least one material in a solid continuous strand completely encased within the liquid material. A means of curing the liquid material after extrusion hardens the composite. A part is constructed using a series of extruded composite paths. The strand material within the composite contains specific chemical, mechanical, or electrical characteristics that instill the object with enhanced capabilities not possible with only one material.

A method and apparatus for the additive manufacturing of three-dimensional objects are disclosed. Two or more materials are extruded simultaneously as a composite, with at least one material in liquid form and at least one material in a solid continuous strand completely encased within the liquid material. A means of curing the liquid material after extrusion hardens the composite. A part is constructed using a series of extruded composite paths. The strand material within the composite contains specific chemical, mechanical, or electrical characteristics that instill the object with enhanced capabilities not possible with only one material.