Described is a heated gaseous welder system and associated methods of welding plastic with the heated gaseous welder system. The heated gaseous welder system includes a welding tool and a welder control unit. The welder control unit includes a gaseous control system and a heater control system. The gaseous control system is configured to selectively supply a gas to the welding tool and control at least one characteristic of the gas supplied to the welding tool. The heater control system is configured to selectively control power supplied to the welding tool.

A tool head for electric heating tool includes a body detachably set in the electric heating tool, a conductive component set mounted in the body and electrically connected to the power supply of the electric heating tool, and two heating elements set on the body. The two heating elements each contain a resistor. The two resistors are electrically connected to the conductive component set and the heating elements, so that the two heating elements generate heat, which can facilitate assembly, reduce damage, and improve technical effects such as diversified construction methods.

A method including receiving a model of a composite structure having an inconsistency. The model includes a pre-calculated heating model that specifies areas of the inconsistency for which corresponding different amounts of heating are applied to an uncured composite material that is applied to the inconsistency. A design for heating elements of varying density across the areas is generated from the model. The design is configured to cause the heating elements in a first sub-area of a heat blanket system to generate a first amount of heat in a third area in the areas, and to cause the heating elements in a second sub-area of the heat blanket system to generate a second, different amount of heat in a fourth area of the areas. The heating elements are printed according to the design on a blanket to manufacture the heat blanket system.

A method including receiving a model of a composite structure having an inconsistency. The model includes a pre-calculated heating model that specifies areas of the inconsistency for which corresponding different amounts of heating are applied to an uncured composite material that is applied to the inconsistency. A design for heating elements of varying density across the areas is generated from the model. The design is configured to cause the heating elements in a first sub-area of a heat blanket system to generate a first amount of heat in a third area in the areas, and to cause the heating elements in a second sub-area of the heat blanket system to generate a second, different amount of heat in a fourth area of the areas. The heating elements are printed according to the design on a blanket to manufacture the heat blanket system.

A method of repairing a sandwich structure includes: removing a damaged portion of a core and a damaged portion of a first facesheet to form an open volume; filling the open volume with an ultraviolet-curable photomonomer; partially curing the ultraviolet-curable photomonomer to form a plurality of photopolymer waveguides by utilizing ultraviolet light; and arranging a replacement facesheet on the damaged portion of the first facesheet and over the photopolymer waveguides.

This disclosure provides economical and effective methods and apparatus for repairing scratches and scuffs on refillable bottle surfaces that minimally contaminates the bottle during the refurbishing process. In one aspect, the method comprises the steps of: a) adding at least one fluid into the polymeric packaging material such as a bottle to form at least a partially filled packaging material; and b) applying at least one heat source to an exterior surface of the at least partially filled packaging material to form a repaired polymeric packaging material. Apparatus and recycling systems that incorporate this method are also disclosed.

This disclosure provides economical and effective methods and apparatus for repairing scratches and scuffs on refillable bottle surfaces that minimally contaminates the bottle during the refurbishing process. In one aspect, the method comprises the steps of: a) adding at least one fluid into the polymeric packaging material such as a bottle to form at least a partially filled packaging material; and b) applying at least one heat source to an exterior surface of the at least partially filled packaging material to form a repaired polymeric packaging material. Apparatus and recycling systems that incorporate this method are also disclosed.

A method of forming a build in a powder bed includes emitting a plurality of laser beams from selected fibers of a diode laser fiber array onto the powder bed, the selected fibers of the array corresponding to a pattern of a layer of the build; and simultaneously melting powder in the powder bed corresponding to the pattern of the layer of the build. An apparatus for forming a build in a powder bed includes a diode laser fiber array including a plurality of diode lasers and a plurality of optical fibers corresponding to the plurality of diode lasers, each optical fiber configured to receive a laser beam from a respective diode laser and configured to emitting the laser beam; a support configured to support a powder bed or a component configured to support the powder bed at a distance from ends of the optical fibers; and a controller configured to control the diode laser fiber array to emit a plurality of laser beams from selected fibers of the diode laser fiber array onto the powder bed, the selected fibers of the array corresponding to a pattern of a layer of the build and simultaneously melt the powder in the powder bed corresponding to the pattern of the layer of the build.

A method of forming a build in a powder bed includes emitting a plurality of laser beams from selected fibers of a diode laser fiber array onto the powder bed, the selected fibers of the array corresponding to a pattern of a layer of the build; and simultaneously melting powder in the powder bed corresponding to the pattern of the layer of the build. An apparatus for forming a build in a powder bed includes a diode laser fiber array including a plurality of diode lasers and a plurality of optical fibers corresponding to the plurality of diode lasers, each optical fiber configured to receive a laser beam from a respective diode laser and configured to emitting the laser beam; a support configured to support a powder bed or a component configured to support the powder bed at a distance from ends of the optical fibers; and a controller configured to control the diode laser fiber array to emit a plurality of laser beams from selected fibers of the diode laser fiber array onto the powder bed, the selected fibers of the array corresponding to a pattern of a layer of the build and simultaneously melt the powder in the powder bed corresponding to the pattern of the layer of the build.

A method is provided for managing the temperature of heat sensitive material located near a repair patch being thermally cured on a composite skin using a heating blanket. The method comprises configuring an assembly of thermally conductive cooling blocks to fit within a space between the heating blanket and the heat sensitive material. The assembly of thermally conductive cooling blocks is then installed against the skin within the space, forming a heat sink that conducts a portion of heat out of the composite skin away from the heat sensitive material.