A method of forming a fibre article, comprising: providing a former having a contoured forming surface; locating a fibre preform between a first diaphragm and a second diaphragm, the second diaphragm being offset from the forming surface; drawing a vacuum between the first and second diaphragms so as to hold the preform captive between the diaphragms; displacing the second diaphragm towards the former so as to bring the second diaphragm into partial contact with the former; drawing a vacuum between the second diaphragm and the former so as to bring at least a part of the second diaphragm adjoining the preform into conformity with the forming surface; and setting the preform in its configuration; wherein: the fibre preform comprises one or more substantially inextensible fibres extending linearly in a first direction; the forming surface comprises a concavity and prominences on either side of the concavity; and the step of bringing the second diaphragm into partial contact with the former comprises bringing the second diaphragm into contact with the prominences whilst the second diaphragm does not fully contact the concavity and with the substantially inextensible fibres extending from one of the prominences to the other.

A method of forming a fibre article, comprising: providing a former having a contoured forming surface; locating a fibre preform between a first diaphragm and a second diaphragm, the second diaphragm being offset from the forming surface; drawing a vacuum between the first and second diaphragms so as to hold the preform captive between the diaphragms; displacing the second diaphragm towards the former so as to bring the second diaphragm into partial contact with the former; drawing a vacuum between the second diaphragm and the former so as to bring at least a part of the second diaphragm adjoining the preform into conformity with the forming surface; and setting the preform in its configuration; wherein: the fibre preform comprises one or more substantially inextensible fibres extending linearly in a first direction; the forming surface comprises a concavity and prominences on either side of the concavity; and the step of bringing the second diaphragm into partial contact with the former comprises bringing the second diaphragm into contact with the prominences whilst the second diaphragm does not fully contact the concavity and with the substantially inextensible fibres extending from one of the prominences to the other.

A system for forming material includes a housing including at least one wall defining an interior space. The housing is configured to contain a pressurized fluid in the interior space. The system also includes at least one tool configured to shape the material. The at least one tool is movable along a path from a first position external to the housing to a second position at least partially within the interior space. The system further includes a membrane extending at least partially in the path of the at least one tool.

A method of forming a castless orthotic for a patient's foot in need thereof. The method comprises preparing an orthotic template for the foot wherein the template extends between a heel end and a toe end. In preparing the template the steps of attaching a three-quarter length or full length upper thermoplastic material to a or three-quarter length lower thermoplastic material, or providing a thermoplastic material having a variable thickness such that said thickness decreases from said heel end to said toe end is provided. Then attaching an outer lower layer to the lower thermoplastic material and attaching an outer upper layer to the upper thermoplastic material, or attaching an outer layer to each face of the variable thickness thermoplastic material and heating the prepared orthotic template for a predetermined period of time at a predetermined temperature to soften the orthotic template. A wrap is then placed on top of the foot foam and the foot of the patient is placed on top of the wrap and foot foam. The patient's foot is lifted and the heated orthotic template is placed on top of the the wrap and then placing the patient's foot on top of the heated orthotic template. The wrap is placed about the longitudinal axis of the foot to retain the heated orthotic template intermediate the sole of the foot and the foot foam whereby the sides of the orthotic template are particularly supported by the wrap. The method further includes ensuring the foot is positioned over a cuboid support and a medial longitudinal arch support wherein the cuboid support is disposed on the outside of the bottom of the foot and the cuboid support is moved to push the foot upwardly until a resistance is felt, and where the foot is also positioned over the medial longitudinal arch support which is then pushed and pulled upwardly until the foot is moved into a neutral position or if it is unable to be translated or rotated due to until it reaches its end range of motion. At this time, the heel of the patient's foot is lifted to place their weight substantially on the front of their foot and a coolant is applied to at least the heel end of the orthotic template.

Systems and methods are provided for enhancement of vacuum bagging processes for a composite part. One system includes dispensers configured to dispense materials onto a forming tool for a composite part, and a controller. The controller is able to identify a location for placing the composite part on the tool, and to direct the dispensers to lay up a laminate of constituent material for the composite part at the location. The controller is also able to direct the dispensers to spray vacuum bag material atop the laminate to form a vacuum bag that covers the laminate.

Articles of footwear including a thermo-molded upper having a skin composed of one or more low melting point thermoplastic polymers. The skin may include at least one of: a base layer composed of a low melting point thermoplastic polymer and a grid layer including a yarn composed of a low melting point thermoplastic polymer. The uppers may be formed by placing a skin and an inflatable bladder into a mold cavity and heating the mold to a predetermined temperature. The inflatable bladder may be inflated such that the skin is pressed against an interior surface of the heated mold cavity to cause the skin to take on the shape of the internal surface of the mold cavity, thereby forming an upper for an article of footwear.

Articles of footwear including a thermo-molded upper having a skin composed of one or more low melting point thermoplastic polymers. The skin may include at least one of: a base layer composed of a low melting point thermoplastic polymer and a grid layer including a yarn composed of a low melting point thermoplastic polymer. The uppers may be formed by placing a skin and an inflatable bladder into a mold cavity and heating the mold to a predetermined temperature. The inflatable bladder may be inflated such that the skin is pressed against an interior surface of the heated mold cavity to cause the skin to take on the shape of the internal surface of the mold cavity, thereby forming an upper for an article of footwear.

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 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.

Articles of footwear including a thermo-molded upper having a skin composed of one or more low melting point thermoplastic polymers. The skin may include at least one of: a base layer composed of a low melting point thermoplastic polymer and a grid layer including a yarn composed of a low melting point thermoplastic polymer. The uppers may be formed by placing a skin and an inflatable bladder into a mold cavity and heating the mold to a predetermined temperature. The inflatable bladder may be inflated such that the skin is pressed against an interior surface of the heated mold cavity to cause the skin to take on the shape of the internal surface of the mold cavity, thereby forming an upper for an article of footwear.