Digital Retention Mesh Morphable Regions Undercut Removal
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Solution Overview
Problem
Conventional negative molds and appliances face challenges in accurately designing retention features to securely hold objects while allowing for easy insertion and removal, particularly due to the presence of undercut regions which can lead to excessive force requirements and potential damage.
Innovation Solution
A computer-implemented method and system for generating a digital retention mesh with morphable regions, corresponding to removed undercut regions, allowing for customizable retention features by modifying the shape of these regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If undercut regions are removed from the mold design, then the formed object can be easily removed from the mold, but the formed object loses retention and can be removed by gravity or other forces
Solution Approach 1:
The patent divides the mold surface into distinct regions: undercut regions that are removed for easy removal, and non-undercut regions that provide retention. This segmentation allows different parts of the mold to serve different functions - the removed undercut regions facilitate extraction while the retained non-undercut regions provide holding force through gravity and interference fit.
Solution Approach 2:
The patent applies different surface characteristics to different locations on the mold. Specifically, undercut regions are digitally removed to create smooth extraction surfaces, while non-undercut regions are preserved to provide retention through interference fit and gravitational force. This local differentiation of surface properties enables simultaneous achievement of easy removal and secure retention.
2Reliability
If undercut regions are kept in the mold design, then retention is improved, but excessive force is required for insertion and removal which can damage the mold, appliance, or object
Solution Approach 1:
The patent extracts or removes undercut regions from the digital mold model before manufacturing. By digitally eliminating these problematic undercut areas, the resulting mold lacks the geometric features that would cause excessive force requirements during insertion and removal, while still maintaining sufficient retention through the preserved non-undercut regions.
3Ease of manufacture
If conventional methods are used to design molds, then the design process is simple, but the ability to provide customizable retention in different areas and amounts is challenging
Solution Approach 1:
The patent introduces a dynamic, interactive digital design process where retention characteristics can be adjusted in real-time. Users can modify the digital mold model to add or remove undercut regions, adjust retention amounts, and customize retention distribution across different areas. This dynamic capability allows flexible adaptation to various retention requirements while maintaining digital workflow efficiency.
Solution Approach 2:
The patent enables customization of retention by allowing users to modify digital model parameters such as undercut region extent, non-undercut region distribution, and overall retention characteristics. These parameter changes in the digital domain directly translate to physical mold variations, providing adaptable retention design without complex manufacturing processes.
Data Source
AI summary
A computer-implemented system and method of generating a digital retention mesh with one or more morphable regions, the one or more morphable regions corresponding to one or more removed undercut regions,