Described herein are three-dimensional (3D) printer systems and methods, which may provide for “continuous pull” 3D printing. An illustrative 3D printer includes: a resin container, a base plate, a light source arranged below the resin container and operable to cure resin in the resin container; and a control system operable to: (a) receive model data specifying a 3D structure; (b) determine 2D images corresponding to layers of the 3D object; and (c) generate control signals to operate the light source and the base plate to sequentially form the layers of the 3D object onto the base plate, wherein the base plate moves a formed portion of the 3D object upward after formation of each layer, and wherein at least a surface of a formed portion of the 3D object remains in contact with the resin in the resin container throughout the formation of the layers of the 3D object.

A method of forming micro-channels in a plastic surface using a pressing device includes structuring a micro-channel forming tool for the pressing device to include a press end including a press surface that extends along a plane and a micro-channel detail positioned on the press end and extending beyond the plane of the press surface. The micro-channel detail includes a non-critical portion and a critical portion supported by the non-critical portion. The press end of the micro-channel forming tool is driven into the plastic surface at a predetermined force using a pressing device. Ultrasonic vibrations are applied to the micro-channel forming tool for a predetermined amount of time to melt portions of the plastic surface in contact with the pressing surface. The ultrasonic vibrations are removed after the predetermined amount of time has elapsed and the press end is retracted from the plastic surface.

Aspects disclosed herein relate to forming on a substrate fastener elements suitable for use in touch fastener by employing vibration forming methods. The processes described provide for a greater flexibility in manufacturing than prior methods and overcome certain limitations in prior forming techniques. Further, the product made can embody a variety of different configurations suitable for a given application. Employing vibration forming methods, such as ultrasonic forming methods, allows for the use of a wider variety of substrate material than materials used with convention methods of touch fastener formation.

In example implementations, a spreading blade is provided. The spreading blade includes a body portion, an ultrasonic vibration source, and a kicker. The ultrasonic vibration source is coupled to a top portion of the body portion to apply a vibration along a cross-sectional length of the body portion. The kicker is coupled to a side facing a process direction at a bottom end of the body portion. The kicker comprises a tip formed by a combination of two angled surfaces that extend from a lateral side of the body portion.

A method of manufacturing a fiber-reinforced composite material which is molded by impregnating a fiber-reinforced sheet with a resin and curing the resin includes: placing the fiber-reinforced sheet in a cavity of a mold; and molding the fiber-reinforced composite material, the molding including injecting the resin into the cavity of the mold, impregnating the fiber-reinforced sheet with the resin, and curing the resin. In the molding, after fine air bubbles contained in the resin are placed at a predetermined position of the cavity, the resin is cured.

A method of forming an oral care implement, a method of forming a head plate for an oral care implement, and an oral care implement or head plate formed therefrom. The head plate may have micro-sized or fine features. The method may include providing an amount of a first solid material upstream of a first mold cavity; prior to the first solid material entering the first mold cavity, applying ultrasonic energy to the first solid material to melt the first solid material into a first molten material; flowing the first molten material into the first mold cavity; allowing the first molten material to harden within the first mold cavity to form a head plate comprising micro-sized features; forming a body from a second material, the body including a handle portion and a head portion; and coupling the head plate to the head portion of the body.

Aspects disclosed herein relate to forming on a substrate fastener elements suitable for use in touch fastener by employing vibration forming methods. The processes described provide for a greater flexibility in manufacturing than prior methods and overcome certain limitations in prior forming techniques. Further, the product made can embody a variety of different configurations suitable for a given application. Employing vibration forming methods, such as ultrasonic forming methods, allows for the use of a wider variety of substrate material than materials used with convention methods of touch fastener formation.

An ultrasonic device comprising a fusion chamber (10) with an inlet bore (11) for a polymer in pellet, powder or tablet form, a plunger that modifies the volume of the fusion chamber, an outlet bore (12) that communicates with a mould (60), a sonotrode bore (13) through which a distal portion (21) of an ultrasonic head (20) is inserted into the fusion chamber, wherein the distal portion is separated from the rest of the ultrasonic head by a first nodal plane (PN1) in correspondence of a first surface (S1) in contact with a complementary surface of a ring seal (30) that closes the fusion chamber, the ultrasonic head including a second nodal plane (PN2) away from and parallel to the first nodal plane in correspondence of or adjacent to a second surface (S2) wherein an anchoring device (40) presses the ultrasonic head against the ring seal ensuring a tight closure.

The equipment for the production of slabs in mineral grits bound with resins, comprises: a support frame, at least one lower plate, locked together with the frame, comprising at least one positioning zone for at least one mold having at least one forming cavity, open at the top, to contain a mix comprising the materials necessary to obtain the slabs, at least one pressing assembly comprising an upper plate movable, with respect to the frame, from an upper position of loading/unloading the mold in/from the positioning zone, to a lower position of pressing the mix inside said forming cavity, vibrating means associated at least with the lower plate, and an airtight chamber, communicating with suction means, adapted to reduce the pressure to a value lower than the atmospheric pressure, containing the mold, where the chamber is interposed between the lower plate and an upper closing element opposite the lower plate.

An apparatus (10) for improving the flow properties of injection moulding material has a flow chamber (18) that is formed in an injection moulding assembly. The flow chamber includes an ultrasonic vibration device (22), and an outlet (20) through which injection moulding material can pass from the flow chamber towards a mould tool (14, 16). The ultrasonic vibration device is arranged in the flow chamber such that injection moulding material flows along an outer wall (41) of the ultrasonic vibration device, in use.