A mandrel for processing a part is described that includes a solid mandrel body with an elastomeric material, and hollow micro-particles embedded within the solid mandrel body in a uniform distribution. The hollow micro-particles deform in response to a change in a processing environment resulting in a distribution of voids in the solid mandrel body. A method for fabricating a composite part is also described that includes placing a base composite layer into a cavity of a tooling surface, inserting the mandrel into the cavity, applying a skin to the mandrel and the base composite layer forming a package, enclosing the package in a vacuum bag and curing the base composite layer and the skin such that during curing the hollow micro-particles deform resulting in the distribution of voids in the solid mandrel body, and removing the mandrel from the cavity of the tooling surface following the curing.

Lightweight and strong components may be manufactured using self-skinning foam material compositions by the processes described herein. One or more mandrels may be inserted into a molding tool, and a self-skinning foam material composition may be injected into the molding tool. After closing the molding tool, the self-skinning foam material composition may expand and cure to form a component, and one or more skins may be formed on exterior and/or interior surfaces of the component. For example, an external skin may be formed on an exterior surface of the component in contact with surfaces of the molding tool, and one or more internal skins may be formed on one or more interior surfaces of negative space spars of the component in contact with surfaces of the one or more mandrels.

An inner mandrel for forming a variable taper component includes a master insert and a plurality of interlocking pieces. The master insert includes opposed tapered edge faces, each tapered edge face defining at least one locking feature, a first surface having a variable taper and a plurality of recesses configured to receive a portion of the variable taper component, and a tapered second surface opposite the first surface. Each interlocking piece includes opposed tapered edge faces, one of the opposed tapered edge faces defining a locking feature and another of the opposed tapered edge faces defining a receiving feature to engage the locking feature of an adjacent interlocking piece, a first surface defining a variable taper and a plurality of recesses configured to receive a portion of the variable taper component, and a tapered second surface opposite the first surface.

A guard for providing a cut-resistant pathway through a body orifice or incision to circumferentially protect tissue at the margin is provided. The guard is made of flexible, cut-resistant mesh material having a plurality of interwoven thermosetting filaments. The guard has a central lumen and at least one flared end. The flared end, which serves to anchor the guard in the body opening, is deformable into a reduced configuration to facilitate its insertion and removal. The layer of mesh stretches laterally to increase the diameter of the central lumen. The flexibility and expandability of the guard allows the guard to conform to body openings of different sizes. The guard may include a drawstring to cinch the flared distal end from the proximal end. The guard is thermoset with the flared distal end that is biased to spring back to its normal, undeformed configuration when released from a deformed configuration.

A method and system for manufacturing composite parts free of wrinkles and mark-offs from bagging compression. The method can include placing composite material around a rigid mandrel and sealing opposing end of an elastomeric hollow membrane within a rigid external vessel. Then the method can include inflating the hollow membrane from a natural state to an inflated state. In the natural state, the hollow membrane can have a cross-section smaller than the cross section of the rigid mandrel with the composite material thereon. The method can then include inserting the rigid mandrel and the composite material into the membrane while it is in the inflated state, followed by releasing the membrane from the inflated state to naturally contract toward its natural state. Then the method can include heating the composite material to a cure temperature while the composite material is compressed by the membrane.

A bladder mandrel package, used to manufacture a composite structure, includes a mandrel and a wrap ply, surrounding the mandrel to form a wrapped mandrel. The bladder mandrel package also includes a first radius filler, coupled to the wrap ply at a first radius of the wrapped mandrel, and a second radius filler coupled to the wrap ply at a second radius of the wrapped mandrel. The mandrel, the wrap ply, the first radius filler, and the second radius filler are consolidated to from the bladder mandrel package.

A layup mandrel including a rib structure comprising ribs defining a lofted surface; and a skin attached to and supported by the rib structure. The skin has a surface having a curvature of the lofted surface; the ribs are disposed to at least partially shape the curvature molding a part pressed against the surface during curing of the part; and the part comprises or consists essentially of a composite material.

Disclosed is an injection molding method for a degradable intravascular stent with a flexible mold core structure. The injection molding method includes the following steps: Step 1, winding a metal rod with a flexible metal film, and applying an inward bending stress to the flexible metal film; Step 2, fixing the flexible metal film to the metal rod, and processing a complementary structure of the degradable intravascular stent on the surface of the flexible metal film; Step 3, performing injection molding processing; Step 4, ending the injection molding, removing the mating body of the flexible metal film and the metal rod and the degradable intravascular stent formed on the surface of the flexible metal film by injection molding, performing cooling, separating the metal rod from the flexible metal film, withdrawing the metal rod, and then removing the flexible metal film to obtain a formed degradable intravascular stent.

A composite tube comprising a region of greater diameter forming a bellow. The bellow has a first side and a second side spaced apart in the axial direction of the tube. Each side of the bellow comprises at least one hole and the at least one hole on the first side is offset in relation to the at least one hole on the second side. The holes in the bellow provide increased flexibility, thereby allowing a greater amount of bending or articulation in the shaft. The holes reduce the amount of material in the sides of the bellow, thereby reducing the material stiffness and thereby increasing the flexibility.

A tool for forming a composite structure may include two or more segments formed from a polymer material. The tool may further include a crush insert disposed between the two or more segments. The tool may also include a support shaft coupled between the two or more segments. A method of forming a mandrel may include forming segments of the mandrel through an additive manufacturing process. The method may further include assembling the segments relative to one another. The method may also include positioning a crush insert between each of the segments. A method of fabricating a composite structure is also disclosed.