Cosmetic Applicator Additive Manufacturing Surface Control

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Solution Overview

Problem

Conventional methods for manufacturing cosmetic product applicators, such as those used for mascara, often result in roughness and particle detachment issues, particularly near the eyes, leading to potential irritation and are poorly adapted for mass production.

Innovation Solution

A method involving additive manufacturing by sintering of plastic powder followed by depowdering and post-treatment processes like sand-blasting and ionizing blowing to ensure desired surface roughness and the removal of irritant particles, using polyamide materials and optimized parameters for industrial-scale production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If additive manufacturing by sintering of plastic powder is used to manufacture cosmetic applicators, then mass production capability is improved, but surface roughness becomes uncontrolled and particles detach

Engineering Contradiction:

Improvemass production capabilityVSAvoidsurface roughness control

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by performing sand-blasting treatment on the applicator surface before final assembly. This pre-treatment removes loose particles and controls surface roughness in advance, preventing particle detachment during subsequent use while maintaining the benefits of additive manufacturing for mass production

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent changes physical parameters by controlling the sand-blasting process parameters (abrasive particle size, pressure, duration) to achieve the desired surface roughness profile. This parameter optimization allows the surface to retain sufficient texture for cosmetic product adhesion while eliminating harmful loose particles

Inventive Principle:

Principle #35Parameter changes

2Productivity

If additive manufacturing by sintering of plastic powder is used to manufacture cosmetic applicators, then mass production capability is improved, but particle detachment occurs causing eye irritation

Engineering Contradiction:

Improvemass production capabilityVSAvoidparticle detachment and eye irritation

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent converts the potentially harmful loose particles generated during additive manufacturing into a benefit by using sand-blasting to deliberately control particle removal. The process transforms uncontrolled particle detachment into a controlled surface treatment that eliminates harmful particles while maintaining structural integrity

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent replaces manual inspection and sorting methods with an automated sand-blasting process that mechanically removes particles. This substitution enables consistent particle elimination across mass production batches, ensuring safety without compromising productivity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If conventional additive manufacturing methods are used, then manufacturing flexibility is maintained, but surface roughness is badly controlled and irregular

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidsurface roughness uniformity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent segments the manufacturing process into distinct stages: additive manufacturing of the applicator body, depowdering to remove excess material, and sand-blasting for surface finishing. This segmentation allows each stage to be optimized independently, maintaining manufacturing flexibility while achieving uniform surface roughness control

Inventive Principle:

Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The method achieves controlled surface roughness and eliminates particles that could detach, ensuring safe and effective application of cosmetic products, particularly around the eyes, while enabling efficient mass production.

Implementation Method 1

additive manufacturing by sintering of a powder of plastic material

Methodology Applied

Scientific EffectSintering: Sintering

Implementation Method 2

The post-treatment comprises sand-blasting (S4)

Methodology Applied

Scientific EffectAbrasion: Abrasion

Implementation Method 3

ionizing blowing (S5)

Methodology Applied

Scientific EffectIonization: Ionisation

Data Source

PatentUS11267198B2Method for manufacturing a cosmetic product applicator by additive manufacturing

Publication Date: 2022.03.08 CHANEL PARFUMS BEAUTE SAS

AI summary

A method for manufacturing a cosmetic product applicator including a gripping part and an applicator part having bristles or teeth. The method includes additive manufacturing (S1) by sintering a powder of a plastics material followed by depowdering (S2) and post-treatment for the removal of particles that have become detached from the cosmetic product applicator or are partially sintered, the post-treatment including blasting (S4) and ionizing blowing (S5). This method allows the removal of particles likely to be irritating, for example with a size greater than 500 micrometers, while being suitable for industrial production. The invention also relates to an associated production method.