A process and assembly for producing a structural article, as well as an article produced according to any process and assembly. A mold has a base and a hinged lid, either or both of which include a cavity interior which defines a negative of the structural article to be produced. A structural insert placed within the mold, prior or subsequent to a plasticized and structural forming foam material also being placed within the mold. The foam cures and sets in encapsulating fashion around the insert so that, upon removal, the insert is coated within the formed material.

A multilayer hollow massage auxiliary tool and a manufacturing method thereof are disclosed. The manufacturing method includes steps of: disposing a first plastic material in a mold cavity; allowing the first plastic material to be melted and expanded for forming as a first gel layer; allowing a second plastic material to be disposed in the mold cavity; allowing the second plastic material to be disposed in the first gel layer and melted and expanded for forming as a second gel layer; allowing the first gel layer and the second gel layer to be gelled as one piece; and allowing the first gel layer to be solidified to form as an outer body and allowing the second gel layer to be solidified to form as an inner body.

A process and assembly for producing a structural article, as well as an article produced according to any process and assembly. A mold has a base and a hinged lid, either or both of which include a cavity interior which defines a negative of the structural article to be produced. A structural insert placed within the mold, prior or subsequent to a plasticized and structural forming foam material also being placed within the mold. The foam cures and sets in encapsulating fashion around the insert so that, upon removal, the insert is coated within the formed material.

A device for molding a plastic component having at least one undercut is disclosed herein. The device including; a fixed block and a mobile block, the fixed block and the mobile block joining along a joining plane and defining first and second cavities defining a molding cavity to receive the plastic, the molding cavity having a first volume and a main direction of demolding; means of separating the mobile block from the fixed block; at least one mobile insert placed in the fixed block; thrusting means urging the mobile insert toward the mobile block; means for moving the at least one mobile element in a secondary direction not parallel to the main direction of demolding.

A method of making at least partially foam-filled sandwich panels includes providing a panel shell, moving at least one of a portion of a first and/or second panel facer or a side member away from the panel volume, thereby defining an opening between the volume and an exterior area. A dispenser proximate the opening moves across at least a portion of the opening while dispensing an amount of a foam agent into the volume through the opening. A press has three platens, a third platen of which is secured to at least one of a portion of the first and/or second facer and the at least one side member and is moveable with respect to the first platen and the second platen in response to a control system.

A method of making at least partially foam-filled sandwich panels includes providing a panel shell, moving at least one of a portion of a first and/or second panel facer or a side member away from the panel volume, thereby defining an opening between the volume and an exterior area. A dispenser proximate the opening moves across at least a portion of the opening while dispensing an amount of a foam agent into the volume through the opening. A press has three platens, a third platen of which is secured to at least one of a portion of the first and/or second facer and the at least one side member and is moveable with respect to the first platen and the second platen in response to a control system.

Device for moulding a plastic component having at least one undercut. The device (100) for moulding a plastic component (15) from a plastic comprising a dissolved gas comprises:a fixed block (1) comprising a first half-cavity (2) and a mobile block (3) comprising a second half-cavity (4), the fixed block (1) and the mobile block (3) joining along a joining plane (5) and the first and second cavities (2, 4) delimiting a moulding cavity (6) designed to receive the plastic, having a first volume (7) and having a main direction of demoulding (8),means (28) of separating the mobile block (3) from the fixed block (1), allowing the moulding cavity (6) to be changed from the first volume (7) to a second volume (9);at least one mobile insert (11) placed in the fixed block (1) bearing at least one mobile element (16, 25), thrusting means (24) urging the mobile insert (11) toward the mobile block (3), the thrusting means being configured so that the mobile insert (11) accompanies the separation of the mobile block (3) between the first (volume (7) and the second volume (9), keeping the separation between the second half-cavity (4) formed in the mobile block (3) and the mobile element or elements (16, 25) borne by the mobile insert (11) constant,means of moving the mobile element or elements (16, 25) in a secondary direction not parallel to the main direction of demoulding during complete opening.