Examples include a process comprising forming a molded panel that includes a fluid ejection die molded in the molded panel. The molded panel is formed with a mold chase and a release liner. The mold chase has a fluid slot feature that aligns with fluid feed holes of the fluid ejection die. The mold chase and release liner is released from the molded panel such that the molded panel has a fluid slot formed therethrough corresponding to the fluid slot feature of the mold chase, and the fluid slot is fluidly connected to the fluid feed holes of the fluid ejection die.

Provided is a method of producing a skin-covered product in which a skin is bonded to a base material, the method capable of performing a roll treatment by a robot to improve work efficiency and quality, and reducing the number of production steps for producing the skin-covered product by immediately performing a rolling step after trimming the bonded skin by vacuum molding.

The method of producing a skin-covered product in which the skin is bonded to the base material according to the present invention includes (1) an integration step of integrating the base material and the skin by vacuum molding while drawing the skin to the base material such that the skin is rolled on a back surface side, (2) a skin trimming step of cutting an extra portion around the skin rolled on a back side in accordance with a form of the base material, and (3) a rolled portion welding step of moving the skin, rolled by a horn tip of an ultrasonic welding machine manually or by a robot, to a skin end portion while sliding the skin on the back surface side of the base material, and then ultrasonically welding the base material and the skin by ultrasonic welding.

In one aspect, there is a method of making a composite skin for a tiltrotor aircraft including providing a first skin in a mold, the first skin having a periphery defined by a forward edge, an aft edge, and outboard ends; providing a plurality of honeycomb panels having an array of large cells onto the first skin, each cell having a width of at least 1 cm; assembling the plurality of honeycomb panels along the longitudinal axis of the first skin to form a honeycomb core having an outer perimeter within the periphery of the first skin; positioning a second skin onto the honeycomb core, the second skin having an outer perimeter within the periphery of the first skin; and curing an adhesive to create a bond between the first skin, the honeycomb core, and the second skin to form a composite skin.

A system and process of printing a package of expanded material (e.g., expanded starch, foam or other expanded material). The expanded material can be heated and extruded, poured, sprayed, or otherwise applied in malleable form that sets up to become a porous protective covering for an item to be packaged. In an example, a layer of expanded material is laid down, and the item in a protective covering (e.g., a plastic bag, sleeve, coating, etc.) is positioned on the layer of expanded material. Additional layers or expanded material may be applied, thereby encasing the item. The top surface of the expanded material may be flattened, such as by operation of a roller, press, or cutter. The top surface may be sprayed with a shellac sealant, paint, or other coating, to allow printing of a label on the top surface.

A method for manufacturing a structural element for a fuselage of an aircraft. To improve the manufacture of structural elements, a method includes laying up textile material members on a mandrel to form a plurality of structural element preforms that are space apart along an extended direction of the mandrel. The structural element preforms form closed loops and are subsequently cured to obtain annular structural elements. The annular structural elements are used as basic building blocks for stiffening panel members or are directly used as structural frame elements reinforcing cut-outs in a fuselage for windows and/or doors.

A system includes a mandrel contoured to define a tapering tubular shape of a workpiece cured on the mandrel and a demolding tool. The demolding tool is configured to remove the workpiece from the mandrel after the workpiece is cured on the mandrel and cut longitudinally. The demolding tool is configured to remove the workpiece from the mandrel by deforming a first end of the workpiece to at least partially disengage the first end of the workpiece from a first end of the mandrel, and subsequently, deforming a second end of the workpiece to at least partially disengage the second end of the workpiece from a second end of the mandrel. The first end of the workpiece may have a first cross-sectional area that is smaller than a second cross-sectional area of the second end of the workpiece.

This document describes systems and processes for forming improved synthetic molded slabs suitable for use in living or working spaces (e.g., along a countertop, table, floor, or the like).

A fiber-reinforced polymer composite assembly, that includes a plurality of sheets, each formed from a composite mixture including a fibrous material and a resin, wherein each of the first plurality of sheets are cut to one or more predetermined dimensions. The plurality of sheets are configured to form a stack, and wherein the stack is shaped by positioning the stack on a mold and pressing and consolidating/curing the stack to form a doubly-curved geometric shape. An insert may be positioned between the plurality of sheets, prior to the pressing and consolidating/curing, wherein the fibrous material may in include paper, and wherein the resin includes one of a thermoset resin or a thermoplastic resin.

Disclosed is a rigid and monolithic composite under-vehicle protector containing phenolic felt and a polyurethane material applied by spraying on the phenolic felt. A production method for the under vehicle protector is also disclosed.

This document describes systems and processes for forming improved synthetic molded slabs suitable for use in living or working spaces (e.g., along a countertop, table, floor, or the like).