An upper case manufacturing method using an axial draw mold, in molding of an upper case made of a synthetic resin and including an inclined cylindrical portion. A fixed mold is provided with a first half body, and a movable mold is provided with a second half body. The first half body and the second half body abut against each other in an inclined plane. The first half body has a first flat surface at both ends on the inner diameter side of the inclined cylindrical portion in the inclined plane, and the second half body has a second flat surface at both ends on the inner diameter side of the inclined cylindrical portion in the inclined plane. The first flat surface and the second flat surface are flat surfaces that prevent the occurrence of undercutting when the upper case is removed from an injection molding mold.

A method for manufacturing a gear assembly of a gearbox in a wind turbine includes providing a pin shaft of the gear assembly. The method also includes depositing material onto an exterior surface of the pin shaft of the gear assembly via an additive manufacturing process driven by a computer numerical control (CNC) device to form a bearing that circumferentially surrounds and adheres to the pin shaft. Further, the method includes providing a gear circumferentially around the bearing to form the gear assembly.

By using a forming die having a fixed die and a movable die moving along a parting surface on the fixed die and by moving the movable die along the parting surface, to press and hold a sintered part between the movable die and the fixed die, to form a cavity around the sintered part except parts which abut on the fixed die and the movable die by the forming die, and to fill the cavity with melted material which becomes an exterior part, so that the sintered part and the exterior part are integrated by insert molding.

By using a forming die having a fixed die and a movable die moving along a parting surface on the fixed die and by moving the movable die along the parting surface, to press and hold a sintered part between the movable die and the fixed die, to form a cavity around the sintered part except parts which abut on the fixed die and the movable die by the forming die, and to fill the cavity with melted material which becomes an exterior part, so that the sintered part and the exterior part are integrated by insert molding.

The present invention provides a method for manufacturing an air bearing with discreet orifices designed to facilitate a non-contact interface between surfaces. The process involves using a mold wherein wires or filaments are placed to form air channels within a cast. Various materials, such as silicone, steel, and composites, can be used for the mold. After casting and curing the material, the wires are removed, leaving precisely defined channels that allow air to flow through, creating a cushion of air that maintains a gap between the bearing and the surface it operates on. This gap can be adjusted by changing the air pressure or the number of channels. The bearing components may be further machined or secured in a housing connected to an air source, enabling the bearing to hover and operate efficiently in various applications. The invention allows for multiple configurations of the air channels to optimize airflow distribution as required.

Methods of making composite articles wherein at least a portion of a hardsurface wear protection applied to a composite article includes matrix composite and hard elements with channels between the hard elements. A layered preform coating mat may be applied over a substrate of the composite article and then fused thereto to form channels between hard elements in the coating mat. The channels may extend over the entire outer surface of the composite article or only over a portion thereof. A hybrid layered preform coating mat may include a depressed section adapted for receiving a perforated braze preform inlay. When the coating mat is fused to the substrate, channels may be formed between the hard elements in the depressed section, but not in a non-depressed section.