In an exemplary embodiment, a system for forming a flexible mat having an open mesh embedded in and interconnecting a plurality of blocks of a hardened paste includes a rotating drum having a plurality of mold cavities about an outer periphery thereof that receive a hardenable paste; a sheet of the open mesh that is fed over the mold cavities so that the mesh is embedded in the hardenable paste deposited in the mold cavities; and a flexible sheet that is placed against the outer periphery of the drum over the mold cavities containing the hardenable paste and the sheet of open mesh of the rotating drum to retain the hardenable paste within the mold cavities and retain the open mesh embedded in the hardenable paste as the hardenable paste solidifies to form the flexible mat.

A three-dimensional electronic, biological, chemical, thermal management, and/or electromechanical apparatus can be configured by depositing one or more layers of a three-dimensional structure on a substrate. Such a three-dimensional structure can include one or more internal cavities using an additive manufacturing system enhanced with a range of secondary embedding processes. The three-dimensional structure can be further configured with structural integrated metal objects spanning the internal cavities (possibly filled with air or even evacuated) of the three-dimensional structure for enhanced electromagnetic properties.

Continuous fiber tow structures are used to form lattice reinforcing bodies to be embedded in a molded polymer matrix. The lattice structures are formed and shaped to reinforce a portion of a predetermined three-dimensional article. Optionally, some or all of the tow members of the structure may be formed with internal vascular passages for passage of a heat transfer fluid through the structure in the function of the molded polymer article. A liquid polymer is molded around the lattice structure, fully embedding the structure. The liquid polymer which may contain short-reinforcing fibers, is then solidified to form the composite reinforced polymer article. And connections may be made to the composite article for the flow of the fluid through vascular passages in the lattice structure within the article.

A production method for a resin molding (1) inserted a 1st plate (10) having many through holes (10a) and a 2nd plate (11) having many through holes (11a), which are arranged in parallel and facing each other during a manufacturing process, comprising a 1st plate process and a 2nd plate process.

The 1st plate process in which, the 1st plate (10) moves to the 2nd plate (11) side from a 1st plate start position (U0) and returns a 1st plate end position (P3) near the 1st plate start position (U0) in a cavity filled with a molten resin (4) kept to a high pressure.

The 2nd plate process in which, the 2nd plate (11) moves to the 1st plate (10) side from a 2nd plate start position (V0) and returns a 2nd plate end position (P4) near the 2nd plate start position in the cavity.

This makes it possible to spread the molten resin (4) to even a shielded area with a reciprocal plate motion. That is, the molten resin (4) is able to pass through holes (10a, 11a) back and forth with the reciprocal plate motion and reach the shielded area finally.

Therefore, the molten resin (4) spread through the surface of the 1st plate (10) and the 2nd plate (11), and a resin wettability of these plates are improved. And as a result, the resin molding (1) strength against a distortion is improved.

In an exemplary embodiment, a flexible mat forming system includes a rotating drum having a plurality of mold cavities about an outer periphery thereof; a hopper positioned adjacent the drum, the hopper shaped to receive a hardenable paste and deposit the hardenable paste into successive mold cavities of the plurality of mold cavities facing the hopper, as the drum rotates relative to the hopper; wherein the hopper includes an opening shaped and positioned to align with the mold cavities facing the hopper; and a sheet of mesh material that is fed between the hopper and the mold cavities facing the hopper.

The present disclosure may be embodied as a method for creating a restriction pattern from a mask material having a strain (.sub.mask) an for mapping elastomeric membrane having a strain (.sub.membrane) into a target 3D shape. The method may include discretizing the target 3D shape into a plurality of radial segments, and a radial strain (.sub.r) is determined for each radial position (r) on each radial segment of the plurality of radial segments. A restriction pattern is determined, wherein the restriction pattern comprises a quantity of mask material for each position r to provide a composite strain (.sub.mask,.sub.silicone). In some embodiments, the method further includes depositing a first membrane layer into a mold and placing mask material into the first membrane layer according to the determined restriction pattern. The first membrane layer is cured.

Techniques for inlaying a composite material within a tooling shell are disclosed. In one aspect, an additively manufactured tooling shell is provided, into which a composite material is inlaid and cured. A surface of the tooling shell is provided with indentations or another mechanism to enable adherence between the composite material and the tooling shell. The resulting integrated structure is used as a component in a transport structure.

A flexible mat forming system may include an elongate, rotatable drum having a plurality of transverse rows of mold cavities about an outer periphery thereof, an elongate hopper positioned adjacent the drum, the hopper shaped to receive a hardenable paste and deposit the hardenable paste along a facing row of the plurality of transverse rows of mold cavities, a spool assembly for feeding a sheet of mesh material between the hopper and the facing row, and a retaining plate extending partially about the outer periphery of the drum and positioned on a downstream side of the elongate hopper, the retaining plate spaced sufficiently close to the outer periphery to retain the mesh material against the outer periphery of the drum and the hardenable paste within the mold cavities adjacent the retaining plate.

A reinforcing article (10, 100, 200) includes a porous substrate layer (105, 205) and a plurality of parallel first continuous fiber elements (12, 114, 212) spaced apart from each other and extending along a first direction and fixed to the porous substrate (105, 205). Each first continuous fiber element (12, 114, 212) includes a plurality of parallel and co-extending continuous fibers (22, 122, 222) embedded in a thermoplastic resin (24, 124, 224).

Continuous fiber tow structures are used to form lattice reinforcing bodies to be embedded in a molded polymer matrix. The lattice structures are formed and shaped to reinforce a portion of a predetermined three-dimensional article. Optionally, some or all of the tow members of the structure may be formed with internal vascular passages for passage of a heat transfer fluid through the structure in the function of the molded polymer article. A liquid polymer is molded around the lattice structure, fully embedding the structure. The liquid polymer which may contain short-reinforcing fibers, is then solidified to form the composite reinforced polymer article. And connections may be made to the composite article for the flow of the fluid through vascular passages in the lattice structure within the article.