A reinforced hydroform member having an outer structural member reinforced by a structural foam supported by the outer structural member. The structural foam extends along at least a portion of the length of the outer structural member. The structural foam is a heat-activated epoxy-based resin. As the foam is heated, it expands and adheres to adjacent surfaces. The preferred structural foam material is commercially available from L&L Products of Romeo, Mich. under the designation L5206, L5207, L5208, or L5209.

An activatable material and articles incorporating the same is disclosed. The activatable material includes at least three of an epoxy resin; a thermoplastic polyether; a blowing agent; a curing agent; and a filler. The activatable material is preferably used for sealing, baffling or reinforcing an article of manufacture such as an automotive vehicle.

A structural reinforcement member include a carrier member and a reinforcement material disposed upon the carrier member. The reinforcement member also includes at least one locating member. The reinforcement member has been found particularly useful for forming a structural system for articles of manufacture such as automotive vehicles.

Methods and apparatuses are disclosed for applying melt flowable materials to components of articles of manufacture. The methods and apparatuses disclosed herein are concerned with formation of appropriate flowable materials, control over the manner in which the flowable materials are applied, treatment of the components prior to application of the flowable materials and the like. Moreover, the apparatuses and methods may be particularly suited for applying flowable materials to surfaces and components found in automotive, aerospace, and marine vehicles.