Molding.

BrettNortje · Aug 14, 2016

https://en.wikipedia.org/wiki/Molding_(process) said:
Molding or moulding (see spelling differences) is the process of manufacturing by shaping liquid or pliable raw material using a rigid frame called a mold or matrix.[1] This itself may have been made using a pattern or model of the final object.

A mold or mould is a hollowed-out block that is filled with a liquid or pliable material like plastic, glass, metal, or ceramic raw materials.[2] The liquid hardens or sets inside the mold, adopting its shape. A mold is the counterpart to a cast. The very common bi-valve molding process uses two molds, one for each half of the object. Piece-molding uses a number of different molds, each creating a section of a complicated object. This is generally only used for larger and more valuable objects.

The manufacturer who makes the molds is called the moldmaker. A release agent is typically used to make removal of the hardened/set substance from the mold easier. Typical uses for molded plastics include molded furniture, molded household goods, molded cases, and structural materials.

Types of molding include:

Blow molding
Powder metallurgy plus sintering
Compression molding
Extrusion molding
Injection molding
Laminating
Reaction injection molding
Matrix molding
Rotational molding (or Rotomolding)
Spin casting
Transfer molding
Thermoforming
Vacuum forming, a simplified version of thermoforming

Now that we understand what molding is, we can try to improve the functions of this type of thing.

BrettNortje · Aug 14, 2016

https://en.wikipedia.org/wiki/Blow_molding said:
Advantages: Highly suitable for low volumes and short runs. As the preform is not released during the entire process the preform wall thickness can be shaped to allow even wall thickness when blowing rectangular and non-round shapes.

Disadvantages: Restrictions on bottle design. Only a champagne base can be made for carbonated bottles.

To get more design out of the inside, we could observe the blowing of the inside of the 'bottle' or other materials to make it more easily shaped, by, instead of just blowing the inside, inserting a 'scalpel' to shape the inside of 'the thing.' that said, it will need one side open, so as to allow the 'shaping thing' inside the mold.

Or, we could try to close it once the object has been shaped, by allowing more mold material onto the outside of the materials to 'close the mold.'

BrettNortje · Aug 14, 2016

Then, we could also try to shape the inside by using an expanding cylinder. this will make the 'shaping device' expand inside the object, and, then retract to the inside of the object again. this can be likened to a little camera that people swallow, except instead of taking pictures, it could disperse materials like a dandy lion or other plant, or 'retract the rods' to the center of the inserted device.

BrettNortje · Aug 14, 2016

https://en.wikipedia.org/wiki/Powder_metallurgy said:
Powder metallurgy (PM) is a term covering a wide range of ways in which materials or components are made from metal powders. PM processes can avoid, or greatly reduce, the need to use metal removal processes, thereby drastically reducing yield losses in manufacture and often resulting in lower costs.

Powder metallurgy is also used to make unique materials impossible to melt or form in other ways. A very important product of this type is tungsten carbide (WC). WC is used to cut and form other metals and is made from WC particles bonded with cobalt. It is very widely used in industry for tools of many types and globally ~50,000t/yr is made by PM. Other products include sintered filters, porous oil-impregnated bearings, electrical contacts and diamond tools.

This obviously goes to liquid form before it gets hard. this means, of course, if you were to want it to 'dry quickly' you might want to 'flash treat' it with nitrogen to bond it quickly. or, we could use wax? these might be able to put the powder together quickly, then flash treat it with some heat, and the materials will be sewn together with the nitrogen in place or the wax melting off.

BrettNortje · Aug 14, 2016

https://en.wikipedia.org/wiki/Compression_molding said:
Compression molding is a method of molding in which the molding material, generally preheated, is first placed in an open, heated mold cavity. The mold is closed with a top force or plug member, pressure is applied to force the material into contact with all mold areas, while heat and pressure are maintained until the molding material has cured. The process employs thermosetting resins in a partially cured stage, either in the form of granules, putty-like masses, or preforms.

Compression molding is a high-volume, high-pressure method suitable for molding complex, high-strength fiberglass reinforcements. Advanced composite thermoplastics can also be compression molded with unidirectional tapes, woven fabrics, randomly oriented fiber mat or chopped strand. The advantage of compression molding is its ability to mold large, fairly intricate parts. Also, it is one of the lowest cost molding methods compared with other methods such as transfer molding and injection molding; moreover it wastes relatively little material, giving it an advantage when working with expensive compounds.

However, compression molding often provides poor product consistency and difficulty in controlling flashing, and it is not suitable for some types of parts. Fewer knit lines are produced and a smaller amount of fiber-length degradation is noticeable when compared to injection molding. Compression-molding is also suitable for ultra-large basic shape production in sizes beyond the capacity of extrusion techniques. Materials that are typically manufactured through compression molding include: Polyester fiberglass resin systems (SMC/BMC), Torlon, Vespel, Poly(p-phenylene sulfide) (PPS), and many grades of PEEK.[1]

Compression molding was first developed to manufacture composite parts for metal replacement applications, compression molding is typically used to make larger flat or moderately curved parts. This method of molding is greatly used in manufacturing automotive parts such as hoods, fenders, scoops, spoilers, as well as smaller more intricate parts. The material to be molded is positioned in the mold cavity and the heated platens are closed by a hydraulic ram. Bulk molding compound (BMC) or sheet molding compound (SMC), are conformed to the mold form by the applied pressure and heated until the curing reaction occurs. SMC feed material usually is cut to conform to the surface area of the mold. The mold is then cooled and the part removed.

Materials may be loaded into the mold either in the form of pellets or sheet, or the mold may be loaded from a plasticating extruder. Materials are heated above their melting points, formed and cooled. The more evenly the feed material is distributed over the mold surface, the less flow orientation occurs during the compression stage.[citation needed]

Thermoplastic matrices are commonplace in mass production industries. One significant example are automotive applications where the leading technologies are long fibre reinforced thermoplastics (LFT) and glass fiber mat reinforced thermoplastics (GMT).

In compression molding there are six important considerations that an engineer should bear in mind[citation needed]:
Determining the proper amount of material.
Determining the minimum amount of energy required to heat the material.
Determining the minimum time required to heat the material.
Determining the appropriate heating technique.
Predicting the required force, to ensure that shot attains the proper shape.
Designing the mold for rapid cooling after the material has been compressed into the mold.

So, the main problem is; "Fewer knit lines are produced and a smaller amount of fiber-length degradation is noticeable when compared to injection molding." this means we need to make it more interwoven. this would mean that we need to simply turn it, like a steak? this would see the whole product have a once or twice over as if mixing batter, yes?

To do this, we need to only rotate the setting materials. this can be done by flipping the cast side ways or upside down and over. this will see the materials mix slightly in either direction, taking [a] materials over to materials territory, and materials over to [c] materials territory. in short, they will overlap like runners at the olympics holding hands.

BrettNortje · Aug 14, 2016

https://en.wikipedia.org/wiki/Extrusion said:
Extrusion is a process used to create objects of a fixed cross-sectional profile. A material is pushed through a die of the desired cross-section. The two main advantages of this process over other manufacturing processes are its ability to create very complex cross-sections, and to work materials that are brittle, because the material only encounters compressive and shear stresses. It also forms parts with an excellent surface finish.[1]

Drawing is a similar process, which uses the tensile strength of the material to pull it through the die. This limits the amount of change which can be performed in one step, so it is limited to simpler shapes, and multiple stages are usually needed. Drawing is the main way to produce wire. Metal bar and tube are also often drawn.

Extrusion may be continuous (theoretically producing indefinitely long material) or semi-continuous (producing many pieces). The extrusion process can be done with the material hot or cold. Commonly extruded materials include metals, polymers, ceramics, concrete, play dough, and foodstuffs. The products of extrusion are generally called "extrudates".

Hollow cavities within extruded material cannot be produced using a simple flat extrusion die, because there would be no way to support the centre barrier of the die. Instead, the die assumes the shape of a block with depth, beginning first with a shape profile that supports the center section. The die shape then internally changes along its length into the final shape, with the suspended center pieces supported from the back of the die. The material flows around the supports and fuses together to create the desired closed shape.

The extrusion process in metals may also increase the strength of the material.

The main problem here seems to be 'supporting the center barrier of the die.' this would allow for hollowed out things in this type of molding, of course. then, if we could support a 'center barrier,' we could shape the inside of the mold.

This means we need to simply have supports for it enveloped into it. this would see the hollowed out area supported, then the supports themselves become part of the design, allowing for much greater hollowed out potential.

BrettNortje · Aug 14, 2016

https://en.wikipedia.org/wiki/Reaction_injection_molding said:
The disadvantages are slow cycle times, compared to injection molding, and expensive raw materials.

So, while i cannot see a problem with injection molding, reaction injection molding seems to be slow? injection molding makes multiple injection points to fill the whole inside of the mold with materials, while reaction injection molding;

Thermosetting polymers are used, which requires a curing reaction to occur within the mold.

This can be made easier by using a quicker cooling technique, which i will soon explain to you. if the mold is 'cooled,' say by liquid helium being spilled inside the mold, it will quickly sizzle down to nothing, while the inside of the mold will require mere seconds to cool down as it absorbs the 'ice.'

I remember seeing a red hot nickel ball dropped into a huge piece of ice. the two temperatures quickly reduced each other to room temperature, and, we could do that with this type of problem in reaction injection molding.

zyzygy · Aug 14, 2016

Or we could just let people who do it and know something about it get on with the job.

BrettNortje · Aug 14, 2016

https://en.wikipedia.org/wiki/Transfer_molding said:
Transfer molding (BrE moulding) is a manufacturing process where casting material is forced into a mold. Transfer molding is different from compression molding in that the mold is enclosed [Hayward] rather than open to the fill plunger resulting in higher dimensional tolerances and less environmental impact.

This is where materials are encased inside a mold to get the desired product or parts. if we were to observe that this is mainly a transfer of shapes of the mold, then we would understand properly.

If we were to observe that the shape of the mold needs to be perfect, as there is no suction or pull, but merely a closed thing that rotates for it to 'set,' then there would be a new desire for 'perfect outcomes.' these can come from holding the cast flat, so that it is 'lying down,' and using electricity to make the insides form quickly. electrocuting the materials will provide better bonding, as they are mixing electrons all over the place, leading to better electron bonds.

zyzygy · Aug 14, 2016

BrettNortje said:
This is where materials are encased inside a mold to get the desired product or parts. if we were to observe that this is mainly a transfer of shapes of the mold, then we would understand properly.

If we were to observe that the shape of the mold needs to be perfect, as there is no suction or pull, but merely a closed thing that rotates for it to 'set,' then there would be a new desire for 'perfect outcomes.' these can come from holding the cast flat, so that it is 'lying down,' and using electricity to make the insides form quickly. electrocuting the materials will provide better bonding, as they are mixing electrons all over the place, leading to better electron bonds.

What did the materials do to deserve execution? It seems a little harsh.

Molding.

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