A method is described for manufacturing a molded product having a recessed/protruding part from a molded substrate (A) including reinforcing fibers and a matrix resin by press molding, the method comprising: a step (I) of placing the molded substrate (A) between molds including an upper mold and a lower mold and deforming the molded substrate (A) in an in-plane direction by heating and pressing the molds; and a step (II) of deforming the molded substrate (A) in an out-of-plane direction by depressurizing the molds subsequent to the step (I), wherein a deformation rate ratio T represented by the following formula (1) is within a range of 0.1 to 1:

T=X/Z (1)

where X and Z are as defined.

A method for producing a fiber-reinforced resin shaped product, by clamping and press-molding a molding material containing reinforcing fibers and a thermoplastic resin as a matrix in molds having an upper mold and a lower mold. The method includes: disposing the molding material heated in a plastic state, between the upper mold and the lower mold; initiating the clamping to apply a force in a substantially clamping direction to a certain site of the molding material; starting deformation of the molding material in the substantially clamping direction; applying a force in the substantially clamping direction to a fixing site which is at least a part of a substantially outer peripheral end portion of the molding material but is different from the certain site; pressing and fixing the fixing site, and completing the clamping to obtain a fiber-reinforced resin shaped product having an edge portion.

A method of forming a fiber reinforced article comprising following steps: 101) providing a composite preform comprising of thermoplastic polymer matrix and reinforcing fibers, wherein the preform comprises an initial volume and initial fiber orientation, 102) loading the preform inside a radial molding apparatus comprising of at least three adjacent die segments next to each other forming a mold cavity in an initial position having an initial volume, 103) molding the preform by moving the die segments, which are in direct contact with each other during the initial position and movement and a compressed position, and which are perpendicular to a common longitudinal axis of the preform, wherein the initial volume of the mold cavity decreases and the die segments compress the preform to a form defined by the mold cavity in the compressed position having a final volume, which is smaller or equal to the initial volume of the preform, 104) opening the mold cavity, and 105) removing the obtained fiber reinforced article, which comprises a tailored fiber orientation, from the mold cavity, wherein the continuous reinforcing fibers follow to a surface contour of said article.

Systems and methods are provided for securing laminates to mandrels. One embodiment is a method for facilitating layup of preforms, the method including selecting a mandrel that includes at least one receptacle, disposing a first vacuum bag atop the mandrel that covers the receptacle, selecting a Ply Location Template (PLT) that includes a securement element, aligning a portion of the securement element with the receptacle, pressing the portion of the securement element downward into the first vacuum bag and driving the portion of the securement element into the receptacle, and abutting a preform against the PLT.

Systems and methods are provided for securing laminates to mandrels. One embodiment is a method for facilitating layup of preforms, the method including selecting a mandrel that includes at least one receptacle, disposing a first vacuum bag atop the mandrel that covers the receptacle, selecting a Ply Location Template (PLT) that includes a securement element, aligning a portion of the securement element with the receptacle, pressing the portion of the securement element downward into the first vacuum bag and driving the portion of the securement element into the receptacle, and abutting a preform against the PLT.

A multi-part compression mold for forming a complex part having a desired fiber alignment, and methods therefor, are disclosed. The multi-part mold comprises at least three sections. Specific arrangements of fiber-bundle-based preforms are introduced to more than one of the mold sections of the multi-part mold, and subjected to compression molding. The arrangements of preforms, in conjunction with the multi-part mold, result in a complex part having fibers that substantially align with anticipated principle stress vectors that arise in the complex part, when in use.

A synthetic roofing tile or panel is provided that includes one or more features enhancing the impact resistance and other desirable properties as well as the ease of installation and/or use of the roofing tile or panel on a building structure. The roofing tile is formed in an improved color variation process is provided with regard to the manufacture of a synthetic material roofing tile in order to effectively simulate the appearance of the natural material represented by the synthetic roofing tile. The roofing tile also can be compression molded such as in a method for manufacturing a synthetic roofing tile or panel is provide in which a number of inserts representing the desired appearance for the roofing tile or panel can be utilized in the manufacturing process to provide roofing tiles or panels with the desired appearance. The inserts can be interchanged within the molds in order to provide different appearances to roofing tiles or panels formed using the same molds.

An imprint apparatus for forming a pattern of an imprint material on a substrate using a mold includes a plurality of alignment scopes and a control unit. The control unit controls aligning of a shot region of the substrate and the mold based on outputs from the plurality of alignment scopes. Each of the plurality of alignment scopes outputs information indicating a relative position of a first mark selected from a plurality of first marks in the shot region and a second mark selected from a plurality of second marks on the mold. The control unit controls aligning of the shot region and the mold based on information excluding incorrect information from a plurality of pieces of information output from the plurality of alignment scopes.

There is disclosed an in-mould labelling process for the manufacture of a labelled article comprising the steps of: feeding a labelstock web into a mould; forming an article in the mould such that the formed article contacts and effectively adheres to a label of the labelstock web; detaching the adhered label from the labelstock web; and removing the formed and labelled article from the mould.

A forming assembly configured to form a wick is disclosed. The forming assembly includes an expandable tube and a forming shell assembly. The expandable tube is hydraulically expandable to an expanded configuration. A wick mesh is configured to be wrapped about the expandable tube. The forming shell assembly includes a first forming shell comprising a first recess defined therein and a second forming shell comprising a second recess defined therein. The first recess and the second recess cooperate to define an outer diameter of the wick. The expandable tube and the wick mesh are positionable between the first recess and the second recess. The expandable tube and the forming shell assembly are configured to deform the wick mesh and form the wick based on the expandable tube hydraulically expanding towards the expanded configuration.