Universal Mould for Flexible 3D Articles
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Solution Overview
Problem
Existing manufacturing processes for flexible three-dimensional items like footwear and clothing require a new mould for each design, making them expensive and limiting the use of leather or non-stretch materials, especially when trying to produce multiple models.
Innovation Solution
A mould and counter mould system without projections, allowing cut pieces to be arranged with touching edges and injected with plastic to form a seamless bond, enabling the production of various designs using the same mould by varying the cut pieces and using an adhesive for enhanced bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mould with projections and ridges is used to delimit channels for injecting plastic material, then the cut pieces can be bound together seamlessly, but a new mould is required for each footwear design, increasing production costs
Solution Approach 1:
The mould is designed without fixed projections or ridges, making it a universal tool that can accommodate various cut piece arrangements and footwear designs. The same mould can be used for different models by simply changing the cut pieces, eliminating the need to create new moulds for each design.
Solution Approach 2:
The bonding channels are formed dynamically by the arrangement of cut pieces themselves rather than being fixed in the mould. The cut pieces create the channel structure through their positioning and spacing, allowing the mould to be reused with different piece configurations.
2Manufacturing precision
If ridges are used to bind cut pieces together, then seamless bonding is achieved, but the process becomes more expensive and complex when producing multiple models
Solution Approach 1:
The mould design is simplified by removing fixed ridges and projections, making it universally applicable to multiple designs. The bonding function is achieved through the dynamic arrangement of cut pieces rather than through complex fixed structures.
3Ease of manufacture
If a prefabricated sock lining is used, then the manufacturing process is simplified, but the use of leather or non-stretch materials is limited and production costs increase
Solution Approach 1:
The lining is constructed from multiple cut pieces arranged on the counter mould, allowing the use of flexible materials like leather or non-stretch fabrics. This segmented approach provides the same manufacturing simplicity as prefabricated socks while enabling greater material versatility.
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 method reduces production costs by allowing multiple models to be produced with the same mould, facilitates the use of leather, and ensures a strong, breathable bond without visible seams, while allowing for flexible and elastic ridges for better fit and durability.
Implementation Method 1
A plastic material is injected into these channels. The plastic material is injected into the mould, which fills all the channels and spaces and comes into contact with the cut pieces which will form the upper in order to bind them together once it has cooled down.
Implementation Method 2
The plastic material is injected into the mould, which fills all the channels and spaces and comes into contact with the cut pieces which will form the upper in order to bind them together once it has cooled down.
Data Source
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AI summary
Manufacturing process for the production of flexible three-dimensional items which entails: cutting the pieces (4) which will form the outer material of the item to be produced and shearing the edges of these pieces, preparing a mould (1) and a counter mould (3) with smooth opposing surfaces onto which the cut pieces (4) which will form the outer material are placed, with the opposing sheared edges of the adjacent cut pieces touching or being very close together and injecting a liquid plastic material which will fill the volume delimited between the mould, counter mould and cut pieces which will form the outer material.