A process for injection molded microcellular foaming various flexible foam compositions from biodegradable and industrially compostable bio-derived thermoplastic resins for use in, for example, footwear components, seating components, protective gear components, and watersport accessories wherein a process of manufacturing includes the steps of: producing a suitable thermoplastic biopolymer or biopolymer blend; injection molding the thermoplastic biopolymer or biopolymer blend into a suitable mold shape with inert nitrogen gas; controlling the polymer melt, pressure, temperature, and time such that a desirable flexible foam is formed; and utilizing gas counterpressure in the injection molding process to ensure the optimal foam structure with the least amount of cosmetic defects and little to no plastic skin on the outside of the foamed structure.

A purpose of the present disclosure is to provide a fine pattern transfer mold and a fine pattern molding method that allow high-resolution transfer of a fine pattern to the interior of a hollow product by integral molding. In a product formation chamber that is formed between a cavity and a core pin member having a predetermined portion at which a fine pattern original plate is fixed by closing of a mold body, a gate into which a molten resin material flows from a hot runner member has an opening that is located outside an end of a fixed surface of the fine pattern original plate in a horizontal direction of the fixed surface and that faces the end of the fixed surface, an injection nozzle of the hot runner member and the gate are directly coupled together, and the hollow product is integrally molded by the resin material flowing from the gate.

A vertical injection molding machine has a rotary table rotatably in an axial direction as a vertical direction, lower molds on an upper surface of the rotary table, and an upper mold for opening and closing the lower molds, and opening and closing mold in a vertical direction. The vertical injection molding machine has a robot mounted on the lower molds on the plane surface part of the fiber resin base material and a heater for heating the fiber resin base material mounted on the lower molds, and when the plane surface part of the fiber resin base material facing the lower molds is defined as a lower surface, and an opposite surface being defined as an upper surface, an upper and a lower directions of the fiber resin base material is matched to a mold opening and closing direction of the upper mold and the lower molds.

A process for injection molded microcellular foaming various flexible foam compositions from biodegradable and industrially compostable bio-derived thermoplastic resins for use in, for example, footwear components, seating components, protective gear components, and watersport accessories wherein a process of manufacturing includes the steps of: producing a suitable thermoplastic biopolymer or biopolymer blend; injection molding the thermoplastic biopolymer or biopolymer blend into a suitable mold shape with inert nitrogen gas; controlling the polymer melt, pressure, temperature, and time such that a desirable flexible foam is formed; and utilizing gas counterpressure in the injection molding process to ensure the optimal foam structure with the least amount of cosmetic defects and little to no plastic skin on the outside of the foamed structure.

A purpose of the present disclosure is to provide a fine pattern transfer mold and a fine pattern molding method that allow high-resolution transfer of a fine pattern to the interior of a hollow product by integral molding.

In a product formation chamber that is formed between a cavity and a core pin member having a predetermined portion at which a fine pattern original plate is fixed by closing of a mold body, a gate into which a molten resin material flows from a hot runner member has an opening that is located outside an end of a fixed surface of the fine pattern original plate in a horizontal direction of the fixed surface and that faces the end of the fixed surface, an injection nozzle of the hot runner member and the gate are directly coupled together, and the hollow product is integrally molded by the resin material flowing from the gate.

A molding system is provided, which includes at least one mold part and a heating and cooling module. The at least one mold part defines a mold cavity having an opening. The heating and cooling module is inserted into the opening to close the mold cavity. The heating and cooling module includes a die insert defining a mold surface, a layered heater for heating the mold surface, and a cooling unit for cooling the mold surface. The layered heater is disposed between the die insert and the cooling unit and includes functional layers formed directly on a surface of the cooling unit or a surface of the die insert opposite to the mold surface by using layered or layering processes selected from a group consisting of thick film, thin film, thermal spray and sol-gel processes.

Thermoplastic forming tools and assemblages are provided for forming thermoplastic components. In particular, thermoplastic forming tools and assemblages are provided for forming thermoplastic components having precision micro-scale features and reproducible macro-scale dimensions. The thermoplastic forming assemblages can include at least a bottom tool and a top tool having a rigid tool body and an elastomer layer conformally coating at least a portion of both rigid tool bodies. The bottom and top tool can be so dimensioned that, when in the closed position, they define a cavity forming the thermoplastic component. The rigid tool bodies provide the reproducible macro-scale dimensions in the thermoplastic component, while the elastomer layers form and release the precision micro-scale features in the thermoplastic component when formed. Tool-forming structures are also provided for making thermoplastic forming tools and assemblages, as well as methods of making the thermoplastic forming tools, and methods of use for forming thermoplastic components.

A process for injection molded microcellular foaming various flexible foam compositions from biodegradable and industrially compostable bio-derived thermoplastic resins for use in, for example, footwear components, seating components, protective gear components, and watersport accessories wherein a process of manufacturing includes the steps of: producing a suitable thermoplastic biopolymer or biopolymer blend; injection molding the thermoplastic biopolymer or biopolymer blend into a suitable mold shape with inert nitrogen gas; controlling the polymer melt, pressure, temperature, and time such that a desirable flexible foam is formed; and utilizing gas counterpressure in the injection molding process to ensure the optimal foam structure with the least amount of cosmetic defects and little to no plastic skin on the outside of the foamed structure.

A process for injection molded microcellular foaming various flexible foam compositions from biodegradable and industrially compostable bio-derived thermoplastic resins for use in, for example, footwear components, seating components, protective gear components, and watersport accessories wherein a process of manufacturing includes the steps of: producing a suitable thermoplastic biopolymer or biopolymer blend; injection molding the thermoplastic biopolymer or biopolymer blend into a suitable mold shape with inert nitrogen gas; controlling the polymer melt, pressure, temperature, and time such that a desirable flexible foam is formed; and utilizing gas counterpressure in the injection molding process to ensure the optimal foam structure with the least amount of cosmetic defects and little to no plastic skin on the outside of the foamed structure.

A casting mould comprising: an inorganic or refractory mould, wherein the mould is configured to receive feedstock; wherein the feedstock is configured to be heated in situ. A reusable mould, reusable susceptor, and/or release agent may be incorporated. Method of manufacturing a mould, and casting a part employing 5 in situ heating, are also provided.