A method of manufacturing a structural member includes preheating a plurality of fibers to a first temperature, moving the preheated fibers along an assembly line, applying a binder having a viscosity lower than 25 centipoise to at least one of the preheated fibers, providing a die shaped to receive the preheated fibers, wherein the die moves together with the preheated fibers along at least a portion of the assembly line, maintaining a temperature of the plurality of fibers at a temperature substantially similar to the first temperature, and compressing the plurality of fibers within the die while maintaining a temperature.

A simple, cost effective Precision Shaped Tow Manufacturing system can produce high tolerance, dimensionally accurate, ready to use, Unidirectional Resin Impregnated Fiber Tow, Shaped Tow, in one procedure by a single machine that is precise enough to support Automatic Fiber Placement, AFP and Automatic Tape Laying specifications, ATL. The tow shaping system may include a Rotating Forming System, a Static Forming System, or both. A flash cooling chiller is provided to instantaneously set the tow to lock in the shape with a high tolerance.

The invention relates to a method for producing a fiber-reinforced, polymeric continuous profiled element (1), wherein the continuous profiled element (1), having preferably at least one hollow chamber (2, 2), comprises a core profile (10) which can be produced by means of a pultrusion process, and wherein during the pultrusion process at least one continuous strand having reinforcement fibers (5) is integrated into the polymer matrix (4) of the core profile (10). According to the invention, the curing of the core profile (10) is carried out by means of a dual-cure method.

A method and an extrusion- or pultrusion device (1) for forming a profile product (2) made from a material in a production direction (Y), said device comprising: a rotating die (3), extending in a radial (R) direction and a width direction (X), having two opposite first and second side walls (5, 6) and an outer circumferential surface (4) extending in the width direction (X) there between, wherein the rotating die (3) comprises a first side portion (23) in connection to the first side wall (5) and a second side portion (25) in connection to the second side wall (6) and a mid-portion (22) extending between the first and second side portions (23, 25), and a profile definition zone (7) having a longitudinal direction (Y) coinciding with the production direction (Y), a height direction (Z) and a width direction (X) being perpendicular to the height direction (Z), comprising a through channel (8) comprising a first channel section (9) followed by a second channel section (10) downstream the first channel section (9) with reference to the production direction,
wherein the rotating die (3) is rotatable about an axis extending across the production direction (Y) and arranged to allow the outer circumferential surface (4) to, while the rotating die (3) rotates, exert a pressure onto a surface of the material when fed through the profile definition zone (7).

A system for pultruding a beam, such as a pultruded beam of natural fibers, comprises a pulling mechanism continuously pulling on a preform of yarns including a thermoplastic matrix and fibers, the pulling mechanism being downstream of the system. A sequence is provided in the system and has a pre-heating module to pre-heat the preform. A first die has a tapering channel portion heated such that the preform reaches a desired low viscosity temperature for resin in the thermoplastic matrix to impregnate the fibers. A vacuum module has a vacuum cavity to remove air from the preform exiting the first die. A second die has a tapering channel portion heated such that the preform is at the desired low viscosity temperature for resin in the thermoplastic matrix to further impregnate the fibers. A cooling module to cool the beam before the beam reaches the pulling mechanism. A system for pultruding beams is also provided.

A method and apparatus for resistive heating usable in composite-based additive manufacturing is disclosed. The method includes providing a prepared stack of substrate sheets, placing the stack between electrode assemblies of a compression device, applying a current to thereby heat the stack to a final temperature to liquefy applied powder, compressing the stack to a final height, cooling the stack, and removing the cooled, compressed stack from the compression device. The apparatus comprises at least two plates, a power supply for providing current, a first electrode assembly and a second electrode assembly.

According to one implementation, a preform shaping method for producing a preform having a web, a flange, and a chamfered portion includes: pressing a first portion of a laminated body of fiber sheets by sandwiching the first portion between a first mold and a second mold; and pressing a second portion of the laminated body of the fiber sheets after pressing the first portion. The first portion corresponds to the web. The second portion corresponds to the flange. The first mold fits a surface in one side of the web, an inner surface of the chamfered portion and a surface in one side of the flange. The second mold fits a surface in the other side of the web. The second portion is pressed by sandwiching the second portion between the first mold and a third mold.

A die or die assembly for forming a bundle of fibres into a rod or tube includes a body defining a passage for conducting the bundle fibres through the die from an inlet to an outlet, a constriction in the passage having an entrance shaped to form the fibres of the bundle into a desired configuration as the bundle passes through the die, and one or more conduits through which a treatment fluid e.g. steam, for curing the bundle of fibres may be introduced into the passage, and wherein at last one conduit is arranged to discharge fluid in the immediate vicinity of the entrance to the constriction to facilitate passage of the fibres through the die and reduce the risk of blockage.

A process unit and methods are disclosed. One process unit including a pultrusion unit having a pultrusion channel, with the pultrusion channel being limited by at least one shaping wall. The process unit further includes an extrusion unit having an extrusion channel and an opening for removing the extrudate out of the extrusion channel, a cutting unit having a moving cutting element for cutting off the extrudate with the moving cutting element, and a conveying device for conveying a raw extrudate from the pultrusion unit into the extrusion unit. The cutting unit comprises a component that can be caused to move in a rotational manner and the component is mechanically coupled to the cutting element by a mechanical coupling device, such that the rotational movement of the component determines the movement of the cutting element.

One example provides a process unit including a conveying device to convey a hybrid yarn comprising a plurality of fibers and a matrix through a channel bounded by a base body, and a cutting unit having a component configured as a sleeve mounted about the base body, the sleeve rotatable about the base body and including a circular recess at an axial end region which is eccentrically aligned with an axis of rotation of the sleeve, and a cutting element on a slide slidably mounted to the base body and disposed within the circular recess, wherein the slide rests on a support surface of the sleeve bounding the circular recess so that, due to the circular recess being eccentrically aligned with the axis of rotation, a rotational movement of the sleeve causes translational movement of the slide and the cutting element across the channel to cut the hybrid yarn.