The method of the present invention for producing a shaped film includes a step of arranging a thermoplastic resin film to divide a space into a first space located on one surface side of the film, and a second space located on the other surface side, a step of heating the thermoplastic resin film, a step of curving the thermoplastic resin film in one space by using a difference in pressure between the first space and the second space, a step of stopping the curving step of the thermoplastic resin film in a state where at least a convex curved surface of both surfaces of the film is exposed into the space, and a step of cooling the curved film.

A composite material 10 for forming custom fitted orthopedic and other products. The composite material is easily formable when heated to temperatures of about two hundred degrees Fahrenheit for a time of at least six to eight minutes and then is rigid at temperatures of about one hundred thirty degrees. The composite material can be sewn and formed in complex shapes when initially heated to about two hundred degrees. Closure attachments 60 can be secured to the composite material as needed on site rather than at the manufacturing facility. The composite material can be custom fitted to a patient in situ.

A material forming apparatus comprises: a support which is positioned at a side of a forming tool with respect to a material arranged on the forming tool to have a first part covered by the forming tool and a second part separated from the forming tool, and which supports the forming tool; a diaphragm which presses the second part of the material while the outer surface of the expanded diaphragm comes in close contact therewith, in a state in which the first part of the material is compressed by the forming tool and the outer surface of the diaphragm; and a volume-varying member which is disposed near the forming tool between the diaphragm and the support so that at least a portion thereof is positioned on the second part of the material.

An orthopaedic brace includes two rigid valves hinge-coupled to one another and each having a respective pelvic section and a respective supporting shell. The pelvic sections are rigidly coupled to the supporting shells of the respective valves and are made of a thermoformable polymeric material having a softening point between 45° C. and 80° C.

A film structure including at least a functional film, a carrier layer, and a counter-force liner, the functional film being in between the carrier layer and the counter-force liner. The carrier layer and the counter-force liner are larger than the receiving area, and the film structure includes a fastener adapted to fasten, directly or indirectly, the counter-force liner to the carrier layer at least on a portion of a zone outside the functional film. It is also proposed a corresponding machine, optical device and method for forming a functional film intended to be laminated on an optical article.

A material forming apparatus comprises: a support which is positioned at a side of a forming tool with respect to a material arranged on the forming tool to have a first part covered by the forming tool and a second part separated from the forming tool, and which supports the forming tool; a diaphragm which presses the second part of the material while the outer surface of the expanded diaphragm comes in close contact therewith, in a state in which the first part of the material is compressed by the forming tool and the outer surface of the diaphragm; and a volume-varying member which is disposed near the forming tool between the diaphragm and the support so that at least a portion thereof is positioned on the second part of the material.

A film structure comprising at least a functional film (212), a carrier layer (20), and a counter-force liner (22), said a functional film (212) being in between said carrier layer (20) and said counter-force liner (22). The carrier layer (20) and the counter-force liner (22) are larger than the receiving area, and the film structure comprises fastening means adapted to fasten, directly or indirectly, the counter-force liner (22) to the carrier layer (20) at least on a portion of a zone outside the functional film (212). It is also proposed a corresponding machine, optical device and method for forming a functional film intended to be laminated on an optical article.

A composite material 10 for forming custom fitted orthopedic and other products. The composite material is easily formable when heated to temperatures of about two hundred degrees Fahrenheit for a time of at least six to eight minutes and then is rigid at temperatures of about one hundred thirty degrees. The composite material can be sewn and formed in complex shapes when initially heated to about two hundred degrees. Closure attachments 60 can be secured to the composite material as needed on site rather than at the manufacturing facility. The composite material can be custom fitted to a patient in situ.

A method of forming a material using a supersonic fluidic oscillator in a superplastic forming process and a related system. Pressurized gas, at a baseline pressure, is applied to a surface of the material when the material is received within a cavity of a forming tool. Pressure fluctuations, relative to the baseline pressure within the tool cavity, are created with a supersonic fluidic oscillator. Each pressure fluctuation (i) deforms the material and (ii) subsequently allows for a partial stress relief of the material during the forming process.

A medical balloon is provided for which the working surface may be identified during an interventional procedure with enhanced precision. Related methods of manufacturing such a balloon are also disclosed.