In an aspect, there is a method of determining allowable defects for a composite component comprising identifying at least one wrinkle characteristic of a composite component wrinkle defect; making a first plurality of specimens each having a predetermined wrinkle defect representative of the composite component wrinkle defect; measuring each of the predetermined wrinkle defects in the first plurality of specimens for at least one performance metric to generate performance data; and generating an allowable wrinkle defect profile based on the performance data from the first plurality of specimens. In other aspects, there are methods of making a specimen with a predetermined wrinkle defect.

A thermoplastic prepreg includes a mat, web, or fabric of fibers and hollow glass microspheres that are positioned atop the mat, web, or fabric of fibers or dispersed therein. The thermoplastic prepreg also includes a thermoplastic polymer that is fully impregnated through the mat, web, or fabric of fibers and the hollow glass microspheres so that the thermoplastic prepreg has a void content of less than 3% by volume of the thermoplastic prepreg. The thermoplastic material is polymerized monomers and oligomers in which greater than 90% by weight of the monomers or oligomers react to form the thermoplastic material.

A production method of a modeled object includes a fixing step of fixing a thermally expandable sheet onto a tray by entirely or partially fixing a periphery of the thermally expandable sheet placed on the tray by a fixing member; a thermally expanding step of thermally expanding partially the thermally expandable sheet, which is in a state of being fixed onto the tray by the fixing step, by being heated by irradiating the thermally expandable sheet with light by an irradiation unit, while moving the irradiation unit from a first position toward a second position unit; and cooling the thermally expandable sheet, which has been thermally expanded partially by the thermally expanding step, while maintaining the state in which the thermally expandable sheet is fixed onto the tray, while returning the irradiation unit from the second position to the first position.

A system for thermoforming an object is provided. The system includes a mold and a pressure-box. The mold has a surface that defines a shape of the object and includes two or more portions of differing porosities. The pressure-box is operative to generate a pressure differential across the surface. The two or more portions apply the pressure differential at different loads, based at least in part on the differing porosities, to a material disposed onto the surface so as to form the object by deforming the material into the shape.

The present invention relates to a method for providing a product viewing window in a container. The container has at least a body ply and a liner ply, wherein the body ply has at least one aperture therethrough. The liner ply is adhered to the inner surface of the body ply and has a portion extending across the aperture, forming a window into the container. The method involves providing a window-finishing machine that comprises at least two platens and, optionally, a machine pocket positioned between them, a heating element extending through at least one of the platens, and a pressurized air device that is adapted to release pressurized air into the container through at least one of the platens. The container is engaged between the platens in an airtight manner and, optionally, the container window is positioned adjacent the inside wall of the machine pocket. The heating element heats the window of the container to the desired temperature, pressurized air is injected into the container such that the window is forced at least partially through the aperture of the container (and optionally into contact with the machine pocket wall), and the container window is then cooled to the desired temperature.

A sealing assembly for sealing a bundle of wires includes a first sheet formed of a sealant material, a second sheet disposed above the first sheet, and a third sheet disposed above the second sheet formed of the sealant material. The second sheet includes a thermally conductive material. When the bundle of wires is overlaid on the assembly in a first direction, and the assembly is wrapped in a second direction that is generally perpendicular to the first to thereby surround the wires, the second sheet facilitates enhanced thermal energy distribution of applied heat throughout the assembly to thereby more uniformly melt the sealant material and thereby fill voids between the wires.

The disclosure relates to forming shaped thermoplastic articles having smooth peripheries. Many thermoplastic articles have sharp edges formed upon molding or cutting the article from a feedstock sheet. Such sharp edges can damage thin plastic films or flesh which they contact, and smoothing the edges is desirable. Described herein are methods of forming a smooth periphery for such sharp-edged articles by rolling over the sharp edge. The smoothing operation is performed by forming a deflectable flange including a bend region separated from the potentially sharp peripheral edge by a spacer, deflecting a portion of the deflectable flange, and softening at least one bent portion of the deflectable flange to yield a smooth periphery upon cooling. The deflection can include curling the spacer at or near the peripheral edge. The methods can be performed incrementally and/or in a reciprocating fashion.

A method of laminated object additive manufacturing for veneer applications may include, but is not limited to, loading at least one veneer into a laminated object additive manufacturing device, feeding a first layer of the at least one veneer over a working surface of the laminated object additive manufacturing device, cutting the first layer of the at least one veneer to form a first portion of the veneer product, actuating the working surface, feeding an additional layer of the at least one veneer over the first layer of the at least one veneer, and cutting the additional layer of the at least one veneer to form an additional portion of the veneer product. The at least one veneer may be fabricated from a mixture including wood product and a binder. The first layer and/or the additional layer may be cured.

Methods of in-situ additively manufacturing (AM) a part include placing a blank of a decorative material onto a platform and applying an AM material onto the blank such that the blank and the AM material simultaneously contour to a shape of the platform to form the part. The AM material may be applied onto the part by an extrusion process. The blank and the AM material may be under vacuum. The blank and/or the AM material may be directly or indirectly heated while the AM material is applied onto the blank.

A forming tool is used, which has a tool trough arranged in a stationary manner and a pressure bell, which can be lowered onto and lifted away from the tool trough. An arrangement is created in which a single- or multi-layer, initially flat, flexible laminate separates the trough interior from the pressure-bell interior in a pressure tight manner. A table, on which the 3-D substrate to be coated is located, assumes a lowered position within the trough interior; there is a considerable, free intermediate space (between the laminate and the 3-D substrate. A radiant-heater assembly is inserted into said intermediate space. The radiant-heater assembly has a carrier, on the top side of which radiant heaters that can be activated are attached and on the bottom side of which radiant heaters that can be activated are attached.