Systems and methods for embedding electronics in a housing using additive manufacturing are provided. In certain embodiments, a system includes a housing made using an additive manufacturing process. The system also includes at least one electronics assembly that is embedded into the housing during the additive manufacturing process, wherein one or more electronic components on the at least one electronic assembly are isolated from the material used to form the housing. Further, the system includes an electrical connector coupled to at least one electronic component in the one or more electronic components, wherein the electrical connector provides an electrical connection between the at least one electronic assembly and system electronics that are outside the housing, wherein the electronic assembly is environmentally sealed within the housing from the environment outside the housing.

A crank arm for a bicycle may include a body extending along a body axis and having a first body end and a second body end axially spaced apart from the first body end. The insert may also include an insert provided toward the first body end. The insert may include a base portion having a radially outer surface. At least one extension may extend outwardly from the radially outer surface and may be encased within a corresponding recess in the body whereby relative planar movement between the body and the at least one extension in a first plane. The retaining portion may have a retaining portion width measured in the first direction and the retaining width may be greater than the throat width thereby inhibiting relative radial movement between the at least one extension and the recess and preventing radial extraction of the extension from the corresponding recess.

A crank arm for a bicycle may include a body extending along a body axis and having a first body end and a second body end axially spaced apart from the first body end. The insert may also include an insert provided toward the first body end. The insert may include a base portion having a radially outer surface. At least one extension may extend outwardly from the radially outer surface and may be encased within a corresponding recess in the body whereby relative planar movement between the body and the at least one extension in a first plane. The retaining portion may have a retaining portion width measured in the first direction and the retaining width may be greater than the throat width thereby inhibiting relative radial movement between the at least one extension and the recess and preventing radial extraction of the extension from the corresponding recess.

Disclosed is a method for producing components from fiber-reinforced thermoplastic. The method involves manufacturing a multitude of semifinished products, each of which includes a plurality of impregnated fabric layers that are joined to one another only locally, as well as a frame structure having at least one cutout. The semifinished products are consolidated using a consolidation device, an inlay element being placed in each cutout before the semifinished products are consolidated.

Systems and methods for embedding electronics in a housing using additive manufacturing are provided. In certain embodiments, a system includes a housing made using an additive manufacturing process. The system also includes at least one electronics assembly that is embedded into the housing during the additive manufacturing process, wherein one or more electronic components on the at least one electronic assembly are isolated from the material used to form the housing. Further, the system includes an electrical connector coupled to at least one electronic component in the one or more electronic components, wherein the electrical connector provides an electrical connection between the at least one electronic assembly and system electronics that are outside the housing, wherein the electronic assembly is environmentally sealed within the housing from the environment outside the housing.

A crank arm for a bicycle may include a body extending along a body axis and having a first body end and a second body end axially spaced apart from the first body end. The crank arm may also include an insert provided toward the first body end. The insert may include a base portion having a radially outer surface. At least one extension may extend outwardly from the radially outer surface and may be encased within a corresponding recess in the body whereby relative planar movement between the body and the at least one extension in a first plane orthogonal to the radial direction is restrained. The retaining portion may have a retaining portion width measured in a first direction and the retaining width may be greater than a throat width thereby inhibiting relative radial movement between the at least one extension and the recess and preventing radial extraction of the extension from the corresponding recess.

Devices, systems, and methods of improving paste flow during the manufacture of wind turbine blades are provided. When the first turbine blade half is aligned with the second turbine blade half, a gap is formed between the first shell and the bond cap. The assembly includes a first mold half corresponding to the first turbine blade half and a second mold half corresponding to the second turbine blade half. When the first mold is aligned with the second mold, a second gap is formed. A first barrier is disposed within the first gap and a second barrier disposed within the second gap thereby fluidly sealing a volume defined by the first gap and the second gap to direct adhesive paste flow along the blade span between the adjoining leading and trailing edges.

A bicycle wheel has a wheel frame. The wheel frame is a hollow and annular frame and is composited by multiple equally sized wheel bars. Each one of the wheel bars has two halves connected to each other to form the wheel bar, and each one of the two halves being made by laminating, heating and forming a thermoplastic prepreg. The equally sized wheel bars are connected to each other to form the bicycle wheel.

A prepreg laminate is described that is a fiber-reinforced plastic material having high rigidity, lightweight properties and excellent moldability, where the prepreg laminate is obtained by a prepreg (A), in which non-continuous reinforcing fibers are impregnated with a thermosetting resin or thermoplastic resin, and a prepreg (B), in which non-continuous reinforcing fibers are impregnated with a thermoplastic resin, being laminated adjacent to each other, and by the prepreg (A) being disposed on at least one surface, at least some combinations of the prepreg (A) and the prepreg (B) adjacent to each other forming an overlap region that satisfies at least one of the requirements (1) and (2) as defined.

Systems and methods for embedding electronics in a housing using additive manufacturing are provided. In certain embodiments, a system includes a housing made using an additive manufacturing process. The system also includes at least one electronics assembly that is embedded into the housing during the additive manufacturing process, wherein one or more electronic components on the at least one electronic assembly are isolated from the material used to form the housing. Further, the system includes an electrical connector coupled to at least one electronic component in the one or more electronic components, wherein the electrical connector provides an electrical connection between the at least one electronic assembly and system electronics that are outside the housing, wherein the electronic assembly is environmentally sealed within the housing from the environment outside the housing.