A method, system, and apparatus are provided for creating complex-geometry composite parts with dissolvable internal support structures. Methods include: forming a core from a dissolvable material; layering composite material layers over the core; curing the composite material layers; and dissolving the core to leave cured composite layers of the composite part. Forming the core from the dissolvable material may include using three-dimensional printing to form the core. The dissolvable material may include polyvinyl alcohol. The core can include a channel formed therein, where layering composite material layers includes layering composite material layers within the channel of the core.

A support material formulation for use in additive manufacturing of a three-dimensional object, which, when hardened, is soluble upon immersion in water, is provided. The formulation includes a hydrophilic curable mono-functional material; a polyol (e.g., a branched polyol) having a molecular weight lower than 1,000, or lower than 800 grams/mol; and a polyester material having a molecular weight higher than 400, or higher than 500, grams/mol. Additive manufacturing using the disclosed formulation and objects made thereby are also provided.

Ophthalmic device molds made from at least one highly amorphous vinyl alcohol polymer, ophthalmic devices such as ocular inserts and contact lenses and including silicone hydrogel devices formed using these molds, and related methods are described. The methods of manufacturing ophthalmic devices can use dry or wet demolding processes, or dry or wet delensing processes.

A marker composition and a package using same. The marker composition can include retroreflective particles and a dispersion medium, the blending ratio of the retroreflective particles being from 50 to 90 mass % on the basis of the total marker composition.

In one embodiment, a method to form a downhole element is disclosed, including weaving a continuous glass filament and a continuous degradable thermoplastic filament to form a commingled glass fiber. In another embodiment, a commingled glass fiber is disclosed, including a continuous glass filament, and a continuous degradable thermoplastic filament interwoven with the continuous glass filament. In another embodiment, a downhole element is disclosed, including a commingled glass fiber. The commingled glass fiber includes a continuous glass filament, and a continuous degradable thermoplastic filament interwoven with the continuous glass filament.

A self-sealing shell useful as a component of a soft fluid-filled prosthetic implant is provided. The shell is at least partly constructed of a wall made of a colloid of an elastomeric polymer matrix and particles of a water-swellable material distributed therein.

Ophthalmic device molds made from at least one vinyl alcohol copolymer and having a static sessile drop contact angle of less than 70 degrees, ophthalmic devices such as ocular inserts and contact lenses and including silicone hydrogel devices formed using these molds, and related methods are described. The methods of manufacturing ophthalmic devices can use dry or wet demolding processes, or dry or wet delensing processes.

A method for making a thermoplastic composite structure includes the steps of: (1) placing, in situ, fiber-reinforced thermoplastic material around a mandrel, wherein the mandrel includes a soluble material, (2) consolidating, in situ, the fiber-reinforced thermoplastic material to form a thermoplastic composite structure, and (3) at least partially solubilizing the mandrel from within the thermoplastic composite structure to remove the mandrel and provide the thermoplastic composite structure including a material thickness of the fiber-reinforced thermoplastic material, a structure shape, and a hollow interior.

Systems and methods for making a custom sleep apnea mask or other wearable article are disclosed. The sleep apnea system comprises a face mask, a headband integrally connected to the face mask, and at least one air duct configured to direct air from the CPAP machine to nasal tubes. The face mask preferably comprises: an inner surface having the same shape as the user's face; an upper surface configured to sit at a first predetermined distance between the user's nose and eyes; and an outer surface configured to extend a second predetermined distance from the inner surface. Nearly shape and position of substantially all the surfaces of the mask are configured based on the shape and or location of facial features, resulting in a highly customized mask optimized for each individual patient.

A method of making a blind hole in a wall of a multi-section tank during manufacture includes inserting a thin, flexible composite spacer ring in a hole in a composite material between mating parts of a soluble tool. The composite spacer ring is cured to the composite material during curing and maintains the hole between sections of the tank once completed.