3D-Printed Deformable Input Structures Without Assembly
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Solution Overview
Problem
Conventional input devices such as keyboards and switches require multiple manufacturing processes and assembly steps, increasing time, cost, and complexity in prototyping and production.
Innovation Solution
The use of multi-material 3D-printing to integrate non-conductive and conductive material portions within a single print process, enabling the creation of durable, deformable input devices like switches and keyboards without post-processing or assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional manufacturing processes are used to produce input devices, then each component can be manufactured with standard techniques, but multiple separate manufacturing processes and assembly steps are required, increasing time, cost, and complexity
Solution Approach 1:
The patent combines multiple separate components (keycaps, PCB, mechanical springs, switches, and shell) into a single integrated structure that is 3D printed as one piece. This merging eliminates the need for separate manufacturing processes and assembly steps, directly resolving the contradiction between manufacturing simplicity and device complexity
Solution Approach 2:
The 3D printed input device performs multiple functions within a single component: structural support, electrical conduction, mechanical spring action, and keycap functionality. This multi-functionality reduces the number of separate components needed, addressing the contradiction by consolidating diverse functions into one manufacturable unit
2Productivity
If multiple components are manufactured separately and assembled, then each component can be optimized independently, but the assembly process increases manufacturing time and cost
Solution Approach 1:
By merging all components into a single 3D printed unit, the patent eliminates the assembly process entirely. The single-print approach produces the complete input device without requiring separate manufacturing and assembly operations, directly improving productivity and eliminating assembly time loss
3Ease of manufacture
If conventional manufacturing and assembly are used, then standard production techniques can be applied, but post-processing and assembly are required after 3D-printing components
Solution Approach 1:
The patent merges mechanical and electrical systems into a single integrated 3D printed component, achieving both ease of manufacture (single process) and manufacturing precision (integrated design). The conductive pathways and mechanical structures are co-designed and co-manufactured, eliminating integration errors from assembly
Solution Approach 2:
The patent uses composite materials that combine conductive and non-conductive properties within the same 3D printed component. This allows electrical pathways and mechanical structures to be integrated in a single material system, resolving the contradiction between manufacturing integration and precision
Data Source
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AI summary
Electrical input devices can be produced using a multi-material 3D-printing process. The electrical input devices can include a non-conductive material portion and a conductive material portion. The non-conductive and conductive material portions are integrally formed during a single 3D-printing process. Deformation of the electrical input devices cause an electrical variance of the conductive material portion that is responsive to the deformation. Some electrical input devices described provide digital responses, and some electrical input devices described provide analog responses. The described techniques can be used to manufacture complex finished devices in a single 3D-print run, and, in some examples, without the need for post-processing or assembly.