Forming features in the surface of a bicycle component involves depositing a substance onto a substrate in a geometric pattern to form a transfer medium. Forming features may also involve positioning the transfer medium relative to an unformed bicycle component, and forming a negative of the geometric pattern in the bicycle component through the application of heat and/or pressure to the transfer medium and the unformed bicycle component. The transfer medium may be configured for use in the molding of carbon fiber reinforced plastic (“CFRP”) bicycle components and may include a substrate formed of a flexible material, and a geometric pattern formed of a hard material, the hard material different than the flexible material.

Forming features in the surface of a bicycle component involves depositing a substance onto a substrate in a geometric pattern to form a transfer medium. Forming features may also involve positioning the transfer medium relative to an unformed bicycle component, and forming a negative of the geometric pattern in the bicycle component through the application of heat and/or pressure to the transfer medium and the unformed bicycle component. The transfer medium may be configured for use in the molding of carbon fiber reinforced plastic (“CFRP”) bicycle components and may include a substrate formed of a flexible material, and a geometric pattern formed of a hard material, the hard material different than the flexible material.

A system for manufacturing a panel includes a forming assembly having opposing press plates and at least one platen assembly arranged between the opposing press plates. The platen assembly includes first and second platens connected together via at least one elastic deformable member. Further, the forming assembly is operable in a heating mode and a cooling mode. Moreover, the first platen is maintained at a predetermined temperature range during each of the heating and cooling modes. During the heating mode, the elastic deformable member(s) is compressed such that the first and second platens contact each other. As such, one or more layers of material to be consolidated are held by the forming assembly as the forming assembly applies heat and pressure to the layer(s), thereby consolidating the panel.

A system for manufacturing a panel includes a forming assembly having opposing press plates and at least one platen assembly arranged between the opposing press plates. The platen assembly includes first and second platens connected together via at least one elastic deformable member. Further, the forming assembly is operable in a heating mode and a cooling mode. Moreover, the first platen is maintained at a predetermined temperature range during each of the heating and cooling modes. During the heating mode, the elastic deformable member(s) is compressed such that the first and second platens contact each other. As such, one or more layers of material to be consolidated are held by the forming assembly as the forming assembly applies heat and pressure to the layer(s), thereby consolidating the panel.

Tooling for manufacture of an apertured element made of a composite material includes first and second sole plates and tooling elements. Each sole plate is configured to be placed on either side of the apertured element to be manufactured. The tooling elements are placed between the first and second sole plates. The tooling elements include at least one core and peripheral bars. The core is configured to delimit a cell of the apertured element to be manufactured. The core is movable in translation along the first and second sole plates. The peripheral bars are placed on a periphery of the core and configured to delimit the apertured element to be manufactured. At least one peripheral bar is movable in translation along the first and second sole plates.

Tooling for manufacture of an apertured element made of a composite material includes first and second sole plates and tooling elements. Each sole plate is configured to be placed on either side of the apertured element to be manufactured. The tooling elements are placed between the first and second sole plates. The tooling elements include at least one core and peripheral bars. The core is configured to delimit a cell of the apertured element to be manufactured. The core is movable in translation along the first and second sole plates. The peripheral bars are placed on a periphery of the core and configured to delimit the apertured element to be manufactured. At least one peripheral bar is movable in translation along the first and second sole plates.

The invention includes a surface material (21) layered on both surfaces of a honeycomb core (11). The surface material (21) comprises a surface material member (27), which is a porous sheet (25) layered on a carbon fiber body (23), impregnated with a thermosetting resin which is then cured. Thermosetting resin that has exuded from the porous sheet (25) due to the honeycomb core (11) biting into the resin porous sheet (25) is cured at the position where the porous sheet (25) abuts the honeycomb core (11).

A system and method for designing and manufacturing free-form objects made of composite material and optimised in their weight ratio and load capacity; a system for the design and manufacture of said objects, and the objects resulting from said method. Using three-dimensional (3D) design computer programs and computer calculation programs, the design of a composite material object is obtained, with a specific shape and orientation of its component fragments, optimised to be light and at the same time to meet a required specific mechanical and/or structural performance. Subsequently, a mould of at least two parts is obtained from this design and the parameters of said design are transformed into instructions so that one or more automated manufacturing machines deposit fragments of wood or another material onto the lower part of the mould in specific orientations, calculated to minimise the weight of the object and optimise its load capacity. Then, with the addition of one or more binders, the object is pressed between the parts of said mould. Finally, the new manufactured object is obtained by removing it from the mould.

Systems and techniques to provide a flexible, lightweight material that is also effective at protecting a body from ballistic threats are described. An example composite material described herein is fiber-based, and it includes one or more first regions where the fiber composite material is consolidated, and one or more second regions where the fiber composite material is unconsolidated. Example methods of manufacturing the composite material disclosed herein include using a specialized tool with a heated platen press or an autoclave. The tool may include one or more protrusions and/or cavities that contact a precursor composite material to transform the precursor material into a partially consolidated fiber composite material, which is suitable for use as body armor, among other potential applications for the manufactured composite material.

A thermoplastic composite structure is produced by consolidating and forming a composite preform to a desired shape. The preform comprises plies of a high melt temperature thermoplastic prepreg that are tacked together by a low melt temperature thermoplastic adhering the plies together in fixed registration.