Additive Manufacturing Surface Feature Arrays for Grip
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Solution Overview
Problem
Existing methods for manufacturing objects with functional surfaces, such as gripping surfaces, face challenges like complex and costly processes, adhesion issues, and limited mechanical properties when using different materials, particularly in additive manufacturing.
Innovation Solution
The development of a polymer object with a single-piece construction featuring arrays of deformable and collapsible feature elements on its surface, produced through additive manufacturing processes like stereolithography or selective laser sintering, using a single material to achieve varying stiffness and elasticity across different regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If adhesive attachment or overmolding is used to create functional surfaces, then different functional characteristics can be achieved, but the process becomes complex and requires expensive tooling
Solution Approach 1:
The patent merges multiple manufacturing steps into a single additive manufacturing process. The body portion and surface features are created as one integrated component, eliminating the need for separate adhesive attachment or overmolding operations. This combining of operations reduces process complexity while maintaining the ability to create different functional characteristics on different surfaces.
Solution Approach 2:
The patent applies local quality by creating surface features with specific geometries (protrusions, recesses, textures) only in specific locations on the body portion. The additive manufacturing process allows different regions of the object to have different surface characteristics tailored to their functional requirements, while the rest of the body maintains its base material properties.
2Adaptability or versatility
If adhesive attachment or overmolding is used to create functional surfaces, then different functional characteristics can be achieved, but adhesion problems occur during extended field use
Solution Approach 1:
The patent eliminates adhesion interfaces by merging the body portion and surface features into a single monolithic structure created by additive manufacturing. Without separate materials being bonded together, there are no adhesion problems during extended field use, while still achieving different functional characteristics through geometric variation.
3Adaptability or versatility
If different grades of materials are used in additive manufacturing, then functional characteristics can be varied, but the process slows down and mechanical properties are limited
Solution Approach 1:
The patent achieves material property variation through geometric design rather than material composition. By varying the geometry of surface features (size, shape, distribution, depth) in different regions, the patent creates different functional characteristics (grip, texture, flexibility) while using a single material throughout, maintaining fast additive manufacturing speeds.
Solution Approach 2:
The patent changes geometric parameters (feature size, shape, spacing, depth) rather than material parameters to achieve functional differentiation. This allows a single material to exhibit different effective properties in different regions, avoiding the need to change materials during manufacturing and maintaining high productivity.
4Adaptability or versatility
If different grades of materials are used in additive manufacturing, then functional characteristics can be varied, but adhesion issues occur between different materials
Solution Approach 1:
The patent achieves functional differentiation through geometric variation of surface features rather than material composition changes. This eliminates inter-material adhesion interfaces entirely, as a single material is used throughout the body portion, while still providing different functional characteristics through the varying geometry of the additive-manufactured features.
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
This approach allows for the creation of objects with customizable, functional surfaces that can deform under pressure and return to their original configuration, providing improved grip and vibration isolation without the need for multiple materials or complex tooling, enhancing both performance and manufacturing efficiency.
Implementation Method 1
the feature elements are configured to deform or collapse by bending and/or buckling upon application of pressure thereto (e.g., constant pressure such as by grasping, vibratory pressure, etc.) and return to their previous configuration upon removal of such pressure
Implementation Method 2
the feature elements are configured to deform or collapse by bending and/or buckling upon application of pressure thereto
Implementation Method 3
produced as a single piece object by an additive manufacturing process... produced through additive manufacturing processes like stereolithography or selective laser sintering
Implementation Method 4
produced through additive manufacturing processes like stereolithography or selective laser sintering
Data Source
AI summary
A polymer object includes (a) a body portion having a surface portion thereon; (b) at least a first array of feature elements formed on said surface portion, each of said feature elements comprising: (i) a support structure connected to said surface portion and extending upward therefrom; and (ii) a top segment connected to said support structure, said top structure and said support structure together defining an internal cavity formed therein; (c) said polymer object produced as a single piece object by an additive manufacturing process.