A three-dimensional object comprises substantially planar or flat substrate layers that are folded and stacked in a predetermined order and infiltrated by a hardened material. The object is fabricated by positioning powder on all or part of multiple substrate layers. On each layer, the powder is selectively deposited in a pattern that corresponds to tiles that each have a slice of the object. For each slice, powder is deposited in positions that correspond to positions in the slice where the object exists, and not deposited where the object does not exist. The tiles of each substrate layer are folded and aligned in a predetermined order. Multiple folded substrate layers mat be combined into a single stack. The powder is transformed into a substance that flows and subsequently hardens into the hardened material in a spatial pattern that infiltrates positive regions, and does not infiltrate negative regions, in the substrate layers.

A twin sheet core structure made up of two sheets of plastic that have been thermoformed to define arrays of cavities having floors opening to surfaces defined by orthogonally intersecting ribs wherein the sheets are fused together to form a single structure with hollow areas between sheets.

An appliance and methods are described that include embodiments of a mandibular advancement or positioning device which can use elastic bands to pull the jaw forward. The appliance has an upper plastic tray conforming to the patient's upper teeth and including 3D printed sets of retention hooks coupled to the upper plastic tray via being encased in plastic, one on the right and one on the left anterior buccal portion of an upper plastic base. The appliance also has a lower plastic tray conforming to the patient's lower teeth including mandibular dentition, and includes having a 3D printed bite pad which opens the bite vertically. The lower tray also has a set of 3D printed plastic retention hooks encased in plastic extending outwardly from the teeth, one on the right and one on the left of the posterior buccal portion of the lower plastic base. Elastic bands of different lengths and strengths are attached to both the top and bottom retention hooks on both sides of the trays to pull the mandible forward for treatment.

A thermoforming method includes heating a thermoplastic panel to a forming temperature, and compressing the thermoplastic panel between a first tool and a second tool, wherein the thermoplastic panel is bent about a first axis extending along a first direction with respect to the thermoplastic panel in response to being compressed between the first tool and the second tool. The thermoplastic panel may then be cooled to a hardened temperature and disposed between a third tool and a fourth tool. The method further includes heating the thermoplastic panel to the forming temperature, and compressing the thermoplastic panel between the third tool and the fourth tool, wherein the thermoplastic panel is bent about a second axis extending along a second direction with respect to the thermoplastic panel in response to being compressed between the third tool and the fourth tool.

A method for manufacturing a rotor blade component of a rotor blade includes feeding a flat sheet of material into a thermoforming system, wherein the material comprises at least one of a thermoplastic or thermoset material. The method also includes heating the flat sheet of material via the thermoforming system. Further, the method includes shaping the heated flat sheet of material via at least one roller of the thermoforming system into a desired curved shape. Moreover, the method includes dispensing the shaped sheet of material from the thermoforming system. In addition, the method includes cooling the shaped sheet of material to form the rotor blade component.

A system for forming a thermoplastic may comprise a mandrel configured to receive a thermoplastic charge. The mandrel may rotate about a mandrel axis. A series of rollers may be located circumferentially about the mandrel and configured to apply radially inward pressure. A heating element may be located upstream of the series of rollers.

In various aspects, the present disclosure pertains to thermoformed webs that comprise polymer films having one or more thermoformed cavities contained therein, the polymer films comprising a polymer blend of amorphous polyethylene terephthalate (APET) and a copolyester that comprises (a) dicarboxylic acid residues (e.g., dicarboxylic acid residues that comprise terephthalic acid residues and, optionally, one or more additional dicarboxylic acid residues) and (b) diol residues (e.g., diol residues comprising ethylene glycol residues and, optionally, one or more additional diol monomer residues). Other aspects of the disclosure pertain to methods of forming such thermoformed webs, packaged products comprising such thermoformed webs, and methods of recycling such thermoformed webs.

A method for manufacturing a thick polyimide film includes providing a first and second laminated structures. The first and second laminated structures are heated, and the heated first and second laminated structures are wound together to form a third laminated structure. The first polyamic acid gel film of the heated first laminated structure and the second polyamic acid gel film of the heated second laminated structure are overlapped and bonded together to form a third polyamic acid gel film. Two third laminated structures are wound together to form a fourth polyamic acid gel film. A dehydration ring-closure imidization reaction is applied to the fourth polyamic acid gel film by heating to obtain the thick polyimide film. A thick polyimide film manufactured by the method is also disclosed.

A method forms a butt joint between ends of first and second plies and splices the first and second plies together. The method includes the steps of: positioning a first splice edge of a first ply at a first location; positioning a second splice edge of a second ply at a second location, the second splice edge being left bare; wrapping a gum strip around the first splice edge such that the first gum strip forms a U-shaped structure in section that allows the first gum strip to extend from a first planar side of the first ply over the first splice edge to a second opposite planar side of the first ply; not wrapping a gum strip around the second splice edge; placing the first splice edge in abutting relationship to the second splice edge; and stitching the first splice edge to the second splice edge such that stitches each extend from the first planar side of the first ply, through the gum strip, to the first planar side of the second ply.

The disclosure relates to a method for producing a fiber preform, wherein: at least one dry and textile fiber material is provided; the fiber material is assembled into a plurality of individual layers; the plurality of individual layers is provided with a binder; the plurality of individual layers is layered to form a package; and a plurality of interconnected fiber preforms is formed by pressing the package. A separation of the plurality of interconnected fiber preforms and activation of the binder occur in a common process step. The disclosure furthermore relates to a corresponding system.