A method for making objects by forming a thermoformable sheet material includes forming the objects by interaction of a die assembly and a forming assembly. The method further includes, compressing and crushing a first portion of the sheet material by a crushing punch device before forming the objects and maintaining the first portion crushed during the forming operation to reduce the thickness thereof and to orientate chains of molecules that compose a structure of the sheet material at the first portion, in order to weaken the structure and the first portion. The first portion is thus easily perforable, tearable and breakable.

The disclosure relates to punch die apparatus, related thermoforming press apparatus, and methods for thermohydroforming die-punched parts formed therefrom, in particular from sheet blank substrates such as polymer composite materials and metals. The disclosure further relates to thermohydroforming blanks incorporating a vacuum-sealed outer film, in particular polymer composite blanks which can be used in combination with the disclosed apparatus. The apparatus and methods are particularly suitable for thermohydroforming parts with complex deep drawn geometries yet which retain relatively smooth outer surfaces and internal material structure. The apparatus and methods provide a fast and efficient means for composite part manufacturing.

An apparatus including: a plurality of forming molds, each mold including: a leading edge; a trailing edge; a mold face; a plurality of first recesses in the mold face positioned across the mold face, each first recess in fluid communication with a first vacuum duct; a leading face extending from the leading edge in a direction away from the mold face; a trailing face extending from the trailing edge in a direction away from the mold face; wherein at least a portion of the leading face is recessed relative to the mold face proximal the leading edge or at least a portion of the trailing face is recessed relative to the mold face proximal the trailing edge; wherein the plurality of forming molds is arranged leading edge to trailing edge as a first mold belt.

A thermoforming device includes: a base configured to hold a substrate; a hot plate including a heating surface facing vertically downward; a sheet transport portion that supplies a sheet onto the heating surface of the hot plate; and a substrate supply portion configured to attach the substrate to the base and detach the substrate from the base, and to dispose the substrate at a substrate supply position positioned in a lower area of the sheet which is opposite to a side of the sheet in which the heating surface is provided. In the thermoforming device, heating of the sheet using the hot plate and attachment and detachment of the substrate with respect to the base are performable at the same time, and the sheet heated and softened by the hot plate is attached to the substrate at the substrate supply position.

A method for manufacturing a part for an aircraft seat includes positioning a heating frame around a stacked structure, locally heating an edge of the stacked structure using a heating frame, externally heating the entire stacked structure, positioning the stacked structure inside a thermoforming mould provided with cutting punches, closing the thermoforming mould and applying a vacuum to the interior of the thermoforming mould, to simultaneously perform, during the same step of shaping the first cover and the second cover, a step of heat sealing an edge of the first cover to an edge of the second cover, bonding the first cover and the second cover to the foam core, and cutting the stacked structure along the circumference thereof using cutting punches.

Systems, apparatus, and methods for double-sided imprinting are provided. An example system includes first rollers for moving a first web including a first template having a first imprinting feature, second rollers for moving a second web including a second template having a second imprinting feature, dispensers for dispensing resist, a locating system for locating reference marks on the first and second webs for aligning the first and second templates, a light source for curing the resist, such that a cured first resist has a first imprinted feature corresponding to the first imprinting feature on one side of the substrate and a cured second resist has a second imprinted feature corresponding to the second imprinting feature on the other side of the substrate, and a moving system for feeding in the substrate between the first and second templates and unloading the double-imprinted substrate from the first and second webs.

A method for producing a tub-shaped sanitary object made of plastic with a visible side and a bottom, including the following steps: providing a plastic sheet to be molded to form the sanitary object; providing a forming device having a frame arrangement including a first frame with a first frame-shaped bending structure and a second frame with a second frame-shaped bending structure, wherein the plastic sheet is to be formed by bending structures; arranging and attaching the heated plastic sheet to the first frame; inserting the second frame into the open first frame into a forming end position so that the second frame takes along the plastic sheet with its bending structure when it is inserted, wherein the plastic sheet is formed into a tub shape by both the first and the second bending structure; and, cooling the formed plastic sheet.

Systems, apparatus, and methods for double-sided imprinting are provided. An example system includes first rollers for moving a first web including a first template having a first imprinting feature, second rollers for moving a second web including a second template having a second imprinting feature, dispensers for dispensing resist, a locating system for locating reference marks on the first and second webs for aligning the first and second templates, a light source for curing the resist, such that a cured first resist has a first imprinted feature corresponding to the first imprinting feature on one side of the substrate and a cured second resist has a second imprinted feature corresponding to the second imprinting feature on the other side of the substrate, and a moving system for feeding in the substrate between the first and second templates and unloading the double-imprinted substrate from the first and second webs.

A method of forming a decorative article comprising placing a decorative cover sheet comprising an untextured skin layer, a cushion foam layer and an adhesive layer in a mold space between a front mold half and a rear mold half, placing a substrate on the rear mold half, heating a textured front mold surface and the skin layer with a first heater arrangement between the front mold half and the cover sheet, heating the cover sheet and the substrate with a second heater arrangement between the cover sheet and the rear mold half, forming the skin layer of the decorative cover sheet into contact with the textured front mold surface, forming into the skin layer a textured surface from the textured front mold surface, pressing the substrate against the adhesive layer of the decorative cover sheet, and bonding the cover sheet to the substrate with the adhesive layer.

A thermoforming assembly includes a lower mold part (20) and an upper mold part (34). The two mold parts are able to move in a substantially vertical direction between an open position and a closed position. Retaining members (28) are able to hold a sheet of softened thermoplastic (10) in a substantially horizontal mean plane Pm between the two mold parts. The retaining members include a plurality of rods (28) mounted mobile in the lower mold part (20). The rods (28) project out from the lower mold part (20) when the two mold parts (20, 34) are in the open position, to hold the sheet of softened thermoplastic (10) in the substantially horizontal mean plane Pm and accompany it as the mold closes.