A method of making a mold, the mold having an interior cavity for containing a first material and a second material, wherein the mold comprises a first port configured to receive the first material, a second port configured to receive the second material, and a first channel for directing the second material to within the first material, the method includes: determining an electronic file having data representing a shape of an ear; processing the electronic file to create an electronic model of the mold, the electronic model of the mold having sprue features; and creating the mold based on the electronic model of the mold.

Systems and methods for reusable molding devices in accordance with embodiments of the invention are disclosed. In one embodiment, a reusable molding device is provided comprising: an array comprising a plurality of pixel pins, which are arranged to form a two-dimensional plane and which are each linearly movable to create an impression of a surface of an object, a first pixel guide plate, a second pixel guide plate, a first clamp pressure plate, a second clamp pressure plate, a first clamp screw, wherein the first clamp screw moves the first clamp pressure plate towards the first side of the array, a second clamp screw which moves the second clamp pressure plate towards the second side of the array, a pressure clamp frame enclosing the first and second pixel guide plates and the first and second clamp pressure plates, and a top pressure plate, which includes an injection entrance bore.

In an embodiment a nanostamping method includes forming a nanostructure in a layer of optical embossing material on a first carrier substrate by a forming stamp having a nano-relief, wherein the nanostructure comprises a plurality of nano-elevations which are connected via an embossing material base, generating a coated nanostructure by covering the nano-elevations with a filler material layer, wherein the filler material layer and the optical embossing material comprise different refractive indices, applying a second carrier substrate on the coated nanostructure, detaching the first carrier substrate and removing a material of the embossing material base.

Process and mold embodiments are described herein for creating polyurethane molds that allow for the production of manhole bases.

An imprinting method includes the steps of: adding a soluble material to a master mold; solidifying the soluble material to form a soluble mold; positioning an adhesive on a side of the soluble mold opposite to the master mold; attaching a taking device to the adhesive; removing the taking device from the master mold together with the soluble mold; positioning the soluble mold on a polymer layer; applying a first high temperature and a pressure to the soluble mold to form a transferred pattern corresponding to a convex-concave pattern of the soluble mold on the polymer layer and separate a support plate and a tape of the taking device; applying a second high temperature to the soluble mold to solidify the polymer layer; and dissolving the soluble mold by using a solvent to separate the solidified polymer layer and the support plate.

Systems and methods for rapid mold tooling fabrication using active self-shaping non-Newtonian fluids is provided. The rapid mold fabrication system includes one or more molding units between which molds are formed using compression or injection molding process. Each molding unit includes an array of hydraulic pillars that controllably adjust the position of mold preform layers, and an expandable fluid chamber between the end of the pillars and the preform layer against which a mold is formed. A control system is also provided for controlling the volume of STF within the chamber and for transitioning the STF from a liquid to a solid phase through application of an electrical stimulus. A method is also provided for manufacturing a mold using the system. A method is also provided for measuring the geometric properties of objects using the rapid mold fabrication system.

Provided are a production method of a mold having a recessed pattern, and a manufacturing method of a pattern sheet having good accuracy and excellent productivity. The production method of a mold includes: a step of preparing an electroform having a protruding pattern and a mold having a first mold and a second mold forming a cavity; a step of fixing the electroform excluding an end portion of the electroform to the first mold; a clamping step of clamping the electroform excluding the end portion of the electroform and a region of the protruding pattern between the first mold and the second mold to form the cavity; and an injection step of filling the cavity with a resin.

A functional polymeric cutting edge structure and methods for manufacturing cutting edge structures using polymeric materials are provided. A razor blade for use in a razor cartridge or a blade box for assembly in a razor cartridge frame may be formed using the present invention.

A technique for capturing a three-dimensional digital image of a customized shape for a wheelchair seat and back and subsequently producing a seat and back from the image. The captured image may include one or more datum points therein to provide a reference plane for the seat and back. The datum points may be in a color-coded layer located relative to the bottom edge of the seat. The color code may indicate the size of the user and seat at a coarse level. The customized shape may be captured from a shape capture bag or bags that capture one or both of the shape of the user's back and bottom. The shape capture bag used to capture the shape of the user's bottom, for use in manufacturing the seat, may be enhanced by a pre-formed layer that contains a contour or one or more components that together form a contour that biases the shape capture bag toward the shape of the user's bottom when gravity is acting upon the user to sink into a cushioned seat.

A method of forming a master mold (52), comprising: a) forming a plurality of microstructure portions (42) in a substrate formed of a first material by a first micromachining process, each microstructure portion comprising a shaft (40) and a distal tip (38); b) in preparing a negative mold (46) of the plurality of microstructure portions, wherein the mold is formed of a second material and comprises a plurality of cavities (48) corresponding to each microstructure portion in the plurality of microstructure portions (42); c) electroplating a metal (50) onto the negative mold to fill each cavity in the plurality of cavities and to form abase layer (54) extending from the negative mold; d) forming a proximal section (56) for each of the microstructures in the base layer using a second micromachining process (e.g. mechanical micromachining); and e) before or after said step d), removing the negative mold from the metal to form a master mold.