System and method of manufacturing fiber based articles with steam molding

Abstract

In an example method, a NWM molding blank, including a non-woven material held in compression by a binder, is placed in a separable mold, and heated to a melting temperature of the binder. The molding blank expands, forming as an intermediate NWM object a NWM molded object with a 3D geometric form. The intermediate NWM object is cooled through a temperature band with an upper boundary and a lower boundary, and further cooled to a solidifying temperature of the binder. The upper boundary is above the solidifying temperature and the upper boundary is lower than the binder melting temperature. While in the temperature band, the mold is separated, rendering accessible an exposed surface of the intermediate NWM object. The object is then transported to a contoured forming surface of a forming base, by an actuatable arm having an end effector gripping the exposed surface via vacuum suction, lifting the object from the mold and placing the object on the contoured forming surface. Optionally, the end effector contact surface includes a final forming feature. The actuatable arm compresses the intermediate NWM object against the contoured forming surface, and the optional end effector final forming feature and continues compressing until cooling to the solidifying temperature.