A cushion includes a cover and a cushioning element having a top surface heat-fused to the cover. The cushioning element comprises an elastomeric material having a plurality of voids formed therein. At least 60% of a bottom surface of the cushioning element is exposed such that when the cushion is disposed over a surface at least 60% of the bottom surface of the cushioning element is in direct contact with the surface. Methods of forming the cushion include disposing a cover adjacent a mold, conforming the cover to a selected shape of the mold, injecting molten elastomeric material into the mold, bonding the molten elastomeric material to the cover, solidifying the molten elastomeric material to form the cushioning element, and separating the mold from the cover. The cushioning element maintains the cover in the selected shape.

A ceramic and plastic composite includes a ceramic matrix and a plastic layer. Plastics are injected onto the surface of the baked ceramic matrix to form a plastic layer. The plastic layer more deeply fills nanoholes distributed on the surface of the ceramic matrix to have higher adhesion. Thus, the higher combined strength and air tightness exist between the ceramic matrix and the plastic layer to improve the reliability and the using performance of the ceramic and plastic composite.

The invention relates to a process for manufacturing a plastic-metal hybrid part by plastic overmolding on a metal surface via nano-molding technology (NMT), wherein the moldable plastic material is a polymer composition comprising thermoplastic polyamide, or a thermoplastic polyester, or a blend thereof, and boron silicon glass fibers. The invention also relates to a plastic-metal hybrid part, obtainable by said process, wherein a metal part is overmolded by a polymer composition comprising thermoplastic polyamide, or a thermoplastic polyester, or a blend thereof, and boron silicon glass fibers.

A composite object with more complete and stronger adhesion between the constituent parts includes a substrate and a plastic member formed on a surface of the substrate. The substrate can be made of memory metal. Nano-holes are formed on the surface of the substrate. The composite further includes a combining layer. The combining layer is positioned between the substrate and the plastic member. The nano-holes are at least partially filled with the combining layer, unfilled holes being filled with the plastic constituent in the molten state. The disclosure further provides a method for manufacturing the composite.

The disclosure provides a method of fabricating an applicator member for applying a liquid cosmetic, the method comprising a step of making a porous core out of sintered material and a step of overmolding a shell on the porous core, the shell including at least one inlet orifice for admitting liquid cosmetic into the core and at least one dispenser orifice for dispensing liquid cosmetic by means of the core. The disclosure also provides an applicator member obtained by the method and an applicator comprising such an applicator member and a reservoir.

A method for producing a foam body (10) having an internal structure (100, 200, 300), comprising the steps: I) selecting an internal structure (100, 200, 300) to be formed in the foam body (10), the structure comprising a first polymer material; II) providing a foam body (10), the foam body (10) comprising a second polymer material which is different to the first polymer material; III) injecting, by means of an injection means (20), a predefined amount of a melt of the first polymer material or a predefined amount of a reaction mixture (30, 31, 32) which reacts to form the first polymer material at a predefined location inside the foam body (10), corresponding to a volume element of the internal structure (100, 200, 300); IV) repeating step III) for further predefined locations inside the foam body (10), corresponding to further volume elements of the internal structure (10), until the internal structure (10) is formed. The invention also relates to a foam body (10) which has an internal structure (100, 200, 300) and is obtainable by the method according to the invention.

A method for manufacturing a composite molded body in which a metallic molded body and a resin molded body are joined, includes a step of irradiating laser light onto a joining surface of the metallic molded body with the resin molded body in an energy density of 1 MW/cm2 or more and at an irradiation rate of 2000 mm/sec or more to roughen the surface, and a step of placing, in a mold, a portion of the metallic molded body containing the joining surface roughened in the preceding step and injection-molding a resin to obtain a composite molded body. The roughened joining surface of the metallic molded body has a porous structure containing a hole having a maximum depth from a surface exceeding 500 m, and a joining strength between the metallic molded body and the resin molded body is 60 MPa or more.

An exemplary process includes determining a desired pore size, selecting an initial pore size greater than the target pore size, manufacturing a porous structure with the initial pore size, forging the porous structure to form a forged part having the desired pore size, and forming an orthopedic device from the forged part.

Embodiments of the present technology include molding processes for metallic foams, apparatuses, and products. An example method includes placing an uncompressed charge of conductive metal foam into a cavity disposed on a first tool, wherein the first tool is located on a first portion of a compression mold apparatus, translating the first portion of the compression mold apparatus towards a second portion of the compression mold apparatus so as to compress the uncompressed charge of conductive metal foam, creating a compressed charge of conductive metal foam, and overmolding around and through the compressed charge of conductive metal foam with an overmolding material.

An exemplary process includes determining a desired pore size, selecting an initial pore size greater than the target pore size, manufacturing a porous structure with the initial pore size, forging the porous structure to form a forged part having the desired pore size, and forming an orthopedic device from the forged part.