Method of manufacturing contoured objects by radio frequency welding and tooling assembly for same

An assembly for radio frequency welding of a dielectric, contoured object, the assembly comprising:

• a first forming tool and a second forming tool at least one of which is configured to be movable toward and away from the other;
• at least one non-dielectric, elastically-deformable component supported on the second forming tool;
• a first wire mesh component positioned and supported on the non-dielectric, elastically-deformable component;
• a second wire mesh component separated from the first wire mesh component and positioned on the non-dielectric, elastically-deformable component independently of the first wire mesh component so that spacing between the first wire mesh component and the second wire mesh component is variable dependent upon the positioning of the second wire mesh component;
• wherein the first forming tool, the first wire mesh component, and the second wire mesh component are configured to transmit radio frequency energy to a dielectric, contoured object,
• wherein the dielectric, contoured object is compressed between the first forming tool and the first and second wire mesh components by:
• movement of said at least one of the forming tools toward the other forming tool;
• and
• the at least one non-dielectric, elastically-deformable component elastically deforming to distribute pressure of the first and second forming tools on the first wire mesh component and the second wire mesh component, the pressure flexing the first and second wire mesh components against the dielectric, contoured object to provide a first contoured weld of the dielectric, contoured object via the first wire mesh component and a second contoured weld of the dielectric, contoured object via the second wire mesh component.