Razor Cartridge Rapid Prototyping with Metal Insert
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Solution Overview
Problem
Traditional methods for manufacturing razor cartridges are inefficient and inflexible, as they require significant time and cost for mold production, and materials used in rapid prototyping are not durable enough for actual shaving applications.
Innovation Solution
A method using rapid prototyping to create a functional razor cartridge with a housing made from UV-curable resin with aluminum oxide fillers and a metal insert, allowing for easy dimension adjustments and increased durability, combined with a metal insert formed by direct metal laser sintering for enhanced strength and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mold tools are used to form functional razor cartridges, then durability and dimensional accuracy are improved, but manufacturing cost and time increase significantly
Solution Approach 1:
The razor cartridge is divided into two main segments: a housing formed by rapid prototyping and a separate metal insert containing the blade assemblies. This segmentation allows each component to be optimized independently - the housing can be quickly prototyped with flexible materials while the metal insert provides the necessary durability and precision, resolving the contradiction between manufacturing flexibility and product reliability
Solution Approach 2:
The invention uses composite construction by combining the rapid prototyped housing with a metal insert. The metal insert is made from materials suitable for durability and precision, while the housing can be made from various materials including UV-curable resins with fillers. This composite approach allows the final product to achieve both the flexibility of rapid prototyping and the reliability of traditional molding
2Ease of manufacture
If rapid prototyping materials are used for razor cartridges, then manufacturing flexibility and cost are improved, but durability and hot water resistance deteriorate
Solution Approach 1:
The invention changes the material parameters of the rapid prototyped housing by incorporating fillers such as aluminum oxide, titanium dioxide, or silica into UV-curable resin. These filler materials improve the hot water resistance and durability of the housing while maintaining the manufacturing flexibility and geometric freedom of rapid prototyping, thus resolving the contradiction between manufacturing ease and product reliability
Solution Approach 2:
The housing is constructed as a composite material system combining UV-curable resin with inorganic fillers. This composite structure maintains the dimensional stability and hot water resistance required for functional razor cartridges while preserving the advantages of rapid prototyping such as design flexibility and cost-effectiveness
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
Enables the production of functional razor cartridges that are durable, flexible, and cost-effective, allowing for optimized dimensions and performance without the need for extensive mold production, while withstanding hot water exposure and repeated use.
Implementation Method 1
rapid prototyping a housing of said razor cartridge, wherein said housing comprises a front wall, a rear wall and opposing side walls disposed transverse to and between said front and rear walls
Implementation Method 2
a metal insert formed by direct metal laser sintering for enhanced strength and accuracy
Data Source
AI summary
A method of forming a functional razor cartridge for repeated shaving comprises rapid prototyping a housing of a razor cartridge. The housing has a front wall, a rear wall and opposing side walls disposed transverse to and between said front and rear walls. The method further comprises loading a metal insert with one or more elongate blade assemblies and disposing the metal insert in the housing such that the one or more blade assemblies extend between the opposing side walls of the housing.