There is provided a polymer fabrication method for forming 3-dimensional shapes from a sheet polymer blank (10) by machining at least one re-entrant, elongate groove forming a reduced thickness portion (25) permitting the blank to be folded and having opposed edges (12) at the surface, folding the blank about the groove to form at least a portion of the 3-dimensional shape, the re-entrant of the groove forming an elongate chamber (21) adjacent the reduced thickness portion and opening through an elongate gap (20) between the opposed edges, hot air welding the opposed edges across the gap with filler rod (22), and heating the reduced thickness portion to a selected thermo-reforming temperature via the chamber.

Disclosed embodiments provide automated fiber placement techniques for fabrication of parts made from composite materials. A peening system with multiple pins provides compaction over irregular surfaces, providing superior performance as compared with traditional compaction rollers. The apparatus that carries out the techniques include a tape dispensing system, a heating system, a peening system, a processor and a memory coupled to the processor. The memory contains instructions that when executed by the processor perform the steps of: dispensing a first ply of thermoplastic composite tape over a mandrel; dispensing a second ply of thermoplastic composite tape on the first ply; and peening the second ply onto the first ply, such that the second ply is bonded to the first ply.

A novel spring-loaded device utilizes a linear or rotary measuring sensor to measure distance and control heat using a PID loop or other type of control loop feedback program. The power of the heating element is controlled by a program, which takes distance from the target into consideration when determining output power. For example, if the target distance is 10 mm away the algorithm will apply 100% power until reaching 9 mm, at which point it will lower power to 90%. When the distance is 5 mm from the target, the power level will be 50%, and so on and so forth. The closed loop nature of the system will reduce power automatically using pulse width modulation (PWM) of the input power. This will allow modulation of the power to the heating element on the fly.

A methods of executing start, run, and stop sequences on a machine for converting a web of preformed pouches into inflated dunnage units. The pouches are defined by transverse seals extending from a remote edge to within a predetermined distance from an inflation edge.

A methods of executing start, run, and stop sequences on a machine for converting a web of preformed pouches into inflated dunnage units. The pouches are defined by transverse seals extending from a remote edge to within a predetermined distance from an inflation edge.

In order to provide a method for heating an object (102) that is simple to perform and makes it possible to heat an object (102) efficiently and reliably, it is proposed that the method should include the following: providing an object (102) to be heated; applying at least one energy beam (108, 109) to the object (102) to be heated, wherein at least one energy beam (108) is guided over the object (102) to be heated multiple times, along a predetermined intended heating path (114), and this heats the object (102) along the intended heating path (114); determining a temperature distribution over the intended heating path (114), for identifying one or more deviation points (120) at which an actual local temperature differs from an expected and/or calculated temperature; changing and/or supplementing the application of at least one energy beam (108, 109) in order to compensate for the temperature difference at one or more deviation points (120).

An automated fiber placement (AFP) system includes a tool head with a compaction roller and a first variable heat source. The compaction roller is configured to receive at least one of a fiber and a plurality of fibers formed as a laydown tape, and is controlled to apply the laydown tape to a workpiece at a predetermined speed and direction. The first variable heat source is configured to apply a first amount of heat to the laydown tape. The first amount of heat applied is related to the predetermined speed. The AFP system further includes a second variable heat source configured to apply a second amount of heat to the workpiece. The second amount of heat applied is related to at least one of: a position on the workpiece, a thickness of the workpiece at that position, and a separation distance between the second variable heat source and the workpiece.

A laser welding apparatus is provides that includes: a support member including a heat generation portion which has a size that is limited to correspond to a size of a welding area of a plurality of plastic components and is made from a material that absorbs a laser beam and generates heat, and which generates heat of a temperature that is equal to or greater than a melting temperature of the plastic components; a laser beam irradiation unit for converging a laser beam to be transmitted through the plurality of plastic components, and irradiating the laser beam toward the heat generation portion through the plurality of plastic components; and a welding controller for causing a laser beam to be irradiated at the heat generation portion using the laser beam irradiation unit to thereby cause the heat generation portion to generate heat, and welding abutting faces of a welding area of the plurality of plastic components with heat that is generated.

A machine and method for converting film into bags or other articles includes a web traveling from an input section to a rotary drum, to an output section. The rotary drum includes at least one seal bar with a sealing zone and a weakening zone, or it can include or at least one sealing die that extends in the machine direction. The single sealing zone or sealing die may be a heated perforator, and may include a heating wire. The heating wire may be an NiCr wire stitched into the heater, and be disposed on a cap or on the seal bar. The weakening zone may create a line of weakness that is uniform or varies in intensity. The sealing zone may include temperature zones, cartridge heaters, cooling air, or heated air, or a source of ultrasonic, microwave or radiative energy.

An exemplary air cushion inflation machine includes: a first terminal connected to a direct current input; a second terminal; a reference resistor powered by the direct current input; an op-amp; and a transistor. The first terminal of the op-amp is connected to a variable voltage source and the second terminal of the op-amp is connected to the reference resistor. The transistor has a base connected to an output of the op-amp, an emitter connected to the reference resistor, and a collector connected to a first terminal of a sealing band apparatus having first and second terminals. A meltable material placed between the first and second terminals is melted by resistance of current flowing between the first and second terminals. The variable voltage source changes voltage based on a voltage drop measured across the first and second terminals by a voltage measurement device and the constant current.