A system for forming a structural member which includes a first collimated light source and a reservoir containing a volume of photo-monomer resin wherein the first collimated light source is positioned spaced apart from the photo-monomer resin. The system further includes a first face sheet structure defining at least one bore which extends through the first face sheet structure wherein a portion of the first face sheet structure is positioned under a surface of the volume of photo-monomer resin such that photo-monomer resin is positioned within the bore.

A method and system are disclosed. A method of printing onto a base having an upper surface spaced from a lower surface by a base thickness includes dispensing a yarn from a nozzle of a printing system and selectively attaching the yarn to a first attachment region. The step of dispensing the yarn includes dispensing a heat-moldable material and a melt-resistant material. The step of selectively attaching the yarn to the first attachment region includes moving the nozzle into the first attachment region. The step of moving the nozzle into the first attachment region reduces the base thickness by a prodding distance. The heat-moldable material bonds to the first attachment region.

A method and system are disclosed. A method of printing onto a base having an upper surface spaced from a lower surface by a base thickness includes dispensing a yarn from a nozzle of a printing system and selectively attaching the yarn to a first attachment region. The step of dispensing the yarn includes dispensing a heat-moldable material and a melt-resistant material. The step of selectively attaching the yarn to the first attachment region includes moving the nozzle into the first attachment region. The step of moving the nozzle into the first attachment region reduces the base thickness by a prodding distance. The heat-moldable material bonds to the first attachment region.

Provided is a fiber-reinforced resin molded body that has continuous voids and includes a carbon fiber nonwoven fabric and a thermosetting resin, in which the continuous voids have a porosity of 50% by volume to 97% by volume, and contact points of discontinuous carbon fibers constituting the carbon fiber nonwoven fabric are immobilized by the thermosetting resin having a substantially spherical shape of 40 m to 300 m in diameter. Also provided is a method of producing a fiber-reinforced resin molded body, the method including the following steps in the order mentioned: the preform forming step of forming a preform including a carbon fiber nonwoven fabric in a molding die; the injection preparation step of forming a closed space in which the preform is arranged; the injection step of injecting a liquid thermosetting resin into the closed space; the porosity adjustment step of allowing the carbon fiber nonwoven fabric to expand in the thickness direction; and the curing step of maintaining the preform at a temperature equal to or higher than a curing temperature of the thermosetting resin. According to this method, a fiber-reinforced resin molded body that includes a carbon fiber nonwoven fabric and a thermosetting resin is simply produced.

Resiliently flexible articles include a resiliently flexible element, a first rigid element, and a second rigid element. The resiliently flexible element is formed of a fiber reinforced polymeric composite. The first rigid element is formed of a first thermoplastic composition and at least a portion of the first rigid element is bonded, such as by an overmolding process, onto a first portion of the resiliently flexible element. Similarly, the second rigid element is formed of a second thermoplastic composition and at least a portion of the second rigid element is bonded, such as by an overmolding process, onto a second portion of the resiliently flexible element. The resiliently flexible articles can be useful as springs, limbs, living hinges, and the like.

The present teachings generally provide a system comprising a pultruded profile and a two-part system with a first component including one or more epoxy resins and a second component including one or more phosphate esters such that mixing the first component and second component forms an activatable material that activates at a temperature of about 0 C. to about 50 C. The activatable material is extruded onto the pultruded profile such that residual heat from pultrusion in the pultruded profile activates the activatable material.

The present disclosure describes a method of making a composite product (20) by additive manufacturing. The method includes providing an additive manufacturing apparatus having a build platform, the build platform having a planar face on which the product is formed; securing a fabric (22) sheet to the planar face (11) to provide a planar fabric surface thereon; additively manufacturing an intermediate object on the planar fabric surface in the apparatus (12) by light polymerizing a dual cure resin to produce an intermediate object on the build platform, the intermediate object including the fabric (22) sheet having the three-dimensional object (21) adhered thereto; and concurrently with or following the additively manufacturing step, further curing the intermediate object to produce a composite object including the fabric sheet having the three-dimensional object adhered thereto. Composite object and products are also described herein.