Nested Array Data for Concurrent Cranial Orthosis Manufacturing

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Solution Overview

Problem

Current additive manufacturing methods for custom cranial remodeling orthosis devices are inefficient, as they require a long time to manufacture each device individually, limiting throughput and making it costly to produce large quantities.

Innovation Solution

The method involves combining multiple cranial remodeling orthosis device data files into a nested array, allowing an additive manufacturing apparatus to concurrently manufacture multiple device portions, which are then assembled into complete devices, increasing production efficiency and reducing manufacturing time.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If additive manufacturing is used to manufacture custom cranial remodeling orthosis devices, then manufacturing precision and customization are improved, but manufacturing time increases excessively

Engineering Contradiction:

Improvecustomization precisionVSAvoidmanufacturing time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent divides a single cranial remodeling orthosis device into multiple separate portions (e.g., anterior portion, posterior portions, lateral portions). Each portion can be manufactured independently or in parallel batches, reducing the overall manufacturing time while maintaining customization precision through additive manufacturing processes.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent combines data files for multiple different cranial remodeling orthosis devices into a single nested array data file. This allows the additive manufacturing apparatus to manufacture multiple customized devices concurrently in one production run, significantly improving throughput while maintaining the customization precision of individual devices.

Inventive Principle:

Principle #5Merging (Combining)

2Manufacturing precision

If single device manufacturing is used in additive manufacture, then manufacturing precision is maintained, but productivity decreases

Engineering Contradiction:

Improvedevice accuracyVSAvoidmanufacturing throughput

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent merges multiple individual device data files into a single nested array data file that contains information for manufacturing multiple different customized cranial remodeling orthosis devices. This allows the additive manufacturing apparatus to produce multiple devices in parallel, dramatically increasing productivity while each device maintains its customization accuracy.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent segments the manufacturing process into multiple independent device portions that can be produced simultaneously within the same build chamber. Each portion maintains its design precision while the overall system throughput increases due to parallel production capability.

Inventive Principle:

Principle #1Segmentation

3Productivity

If multiple devices are manufactured concurrently, then productivity increases, but device complexity increases

Engineering Contradiction:

Improvemanufacturing throughputVSAvoiddata file structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent implements a nested array data file structure where individual device data files are organized within a hierarchical nested array format. This structured approach allows multiple device specifications to be contained within a single file while maintaining clear organization and relationships, enabling the manufacturing system to process multiple devices efficiently despite the increased data complexity.

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentUS20250022242A1Concurrent additive manufacture of a plurality of custom cranial remodeling orthosis devices

Publication Date: 2025.01.16 CRANIAL TECHNOLOGIES INC

AI summary

A method for concurrent additive manufacture of a plurality of custom cranial remodeling orthosis devices for a corresponding plurality of subjects is provided. Each cranial remodeling orthosis device is customized for a different subject and each cranial remodeling device orthosis is represented by a corresponding device data file. The method comprises partitioning each corresponding device data file into a plurality of device portion data files. Each device portion data file corresponds to a device portion of a corresponding one cranial remodeling orthosis device. The method further comprises processing each of the plurality of device portion data files into a nested data array corresponding to a nested array of device portions of all of the plurality of cranial remodeling orthosis devices. The nested data array is concurrently manufactured in a production or build chamber of additive manufacture apparatus.