A method of placing a protective member on a workpiece includes a sheet producing step of heating a plate-shaped thermoplastic resin to soften or melt the same while gripping and pulling outer edges of the thermoplastic resin in at least four directions to produce a sheet-like protective member, and after the sheet producing step, an integrating step of heating and bringing the sheet-like protective member into intimate contact with the workpiece to integrate the workpiece and the protective member with each other.

A thermoforming device according to the present invention has a masking plate and a heater block. A plurality of the heater blocks are disposed with a space therebetween in a planar direction of the masking plate. The thickness of the masking plate is 0.2-3.0 mm. The distance of the space is 1-15 mm, and the distance of the space is set at least five times larger than the thickness of the masking plate. Heat to be transmitted to the masking plate from a high temperature heater block is more easily transmitted in the thickness direction of the masking plate than in the surface direction of the masking plate, and is more easily transmitted to the sheet than to a portion, of the masking plate, corresponding to a low temperature heater block, whereby a temperature difference is provided between different zones of the masking plate.

An apparatus for forming a window of a display panel includes a mold configured to hold a plate in a concave portion, wherein the concave portion has a predetermined shape, and a transfer part configured to sequentially transfer the mold to a heating part, a forming part, and a cooling part. The heating part includes first and second heating modules respectively positioned on top and bottom portions of the mold and configured to apply heat to the top and bottom portions of the mold. The forming part is positioned above the mold and configured to jet a high-temperature gas onto the heated plate. The cooling part includes first and second cooling modules respectively positioned on the top and bottom portions of the mold and configured to cool the top and bottom portions of the heated plate. The mold is tilted at a predetermined angle relative to a horizontal plane.

A thermoforming system and related methods for manufacturing thermoplastic parts, such as interior panels for aircraft, may include a roll-to-roll operation and a forming press having at least one selectively rotatable tool. The rotatable tool, which may include a mold and/or a die, may be multifaceted, such that different faces of the tool have different mold arrangements for different forming characteristics.

Systems and methods for providing heat to a three-dimensional article are disclosed. The method can include inserting at least a portion of the article over a form. The method can further include inserting the form and article at least partially within an article container and moving the form and article into engagement with a flexible membrane where the membrane and the article container form an airtight chamber. The method can further include exposing the airtight chamber to a pressure less than atmospheric pressure to pull the membrane against at least a portion of the article and exposing the membrane to a heated deformable media.

Articles of footwear including a thermo-molded upper having a skin composed of one or more low melting point thermoplastic polymers. The skin may include at least one of: a base layer composed of a low melting point thermoplastic polymer and a grid layer including a yarn composed of a low melting point thermoplastic polymer. The uppers may be formed by placing a skin and an inflatable bladder into a mold cavity and heating the mold to a predetermined temperature. The inflatable bladder may be inflated such that the skin is pressed against an interior surface of the heated mold cavity to cause the skin to take on the shape of the internal surface of the mold cavity, thereby forming an upper for an article of footwear.

Methods and apparatus are provided for forming a patient-specific surgical implant based on mold system. The apparatus comprises a forming tool and a mold that may be generated using imaging and processing techniques and rapid prototyping methods. The mold apparatus includes at least two non-adjacent surface features for securing an implant forming material (such as a titanium mesh) during the forming process, enabling the implant forming material to be stretched beyond its elastic and thus permanently deformed with the correct patient-specific curvature. The implant may include one or more anatomic surface features for guidance and registration when transferring the implant to a patient.

Curved lenses and methods for making curved lenses are described. One embodiment of a method of making a curved lens includes curving a lens blank made of a linear polarizer layer laminated together with a plurality of polymeric layers. The lens blank is curved by heating and pressing the lens blank between a curved rigid member and a flexible member at a pressure and maintaining the pressure for a time sufficient to allow the lens blank to conform to the shape of the curved rigid member. Methods of the invention may be used to make curved lenses with different polarization properties and curvatures.

Apparatus and methods of forming selected portions of integral sheets of material are disclosed. Unformed portions of the sheets may remain undistorted during the forming process, allowing them to contain text, art work, or other desired information without material risk of the information being degraded or becoming unintelligible during the forming process. This result may be accomplished, moreover, with less trim than usually occurs in conventional forming processes.

Mineral-filled polymer compositions and methods of forming such polymer compositions into a thermally stable article are provided. Methods of forming a polymeric article include providing a polymer composition comprising a crystallizable polymer, a mineral filler in an amount of more than about 15 wt-% based on the total weight of the polymer composition, and an impact modifier, wherein the polymer composition is at a temperature less than a crystallization temperature of the crystallizable polymer. The methods further include disposing the polymer composition in a mold, forming the polymer composition into an article within the mold, and releasing the article from the mold. The methods can include thermoforming the polymer composition in a mold, or injection molding the polymer composition in a molten form in a mold.