Method of making hinged fasteners by three-dimensional printing
First Claim
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1. A method of making a fastener, the method comprising:
- (a) creating a first layer of material to define a first section of the fastener;
(b) emitting light onto the first layer after the prior step to cure, harden or bond the layer;
(c) creating a second layer of the material upon the first layer to define a second section of the fastener after the prior step;
(d) emitting light onto the second layer after the prior step to cure, harden or bond the second layer;
(e) creating at least a third layer of the material upon the second layer to define at least a third section of the fastener after the prior step;
(f) emitting light onto the third layer after the prior step to cure, harden or bond the third layer;
(g) creating a flexible rotatable hinge section from the material which is a printable polymeric material;
(h) depositing a second and different polymeric material integrally connected to the printable polymeric material during the same machine head pass above the fastener being created;
(i) removing the finished fastener from a machine which performs the creating and emitting steps, with the layers all being integrally connected to their adjacent layers; and
(j) the finished fastener being functional and made by the machine in less than ninety minutes.
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Abstract
A fastener is provided. In another aspect, a fastener is made of layers of material, a light curable material and/or multiple built-up materials. Another aspect uses a three-dimensional printing machine to emit material from an ink jet printing head to build up a fastener.
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Citations
70 Claims
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1. A method of making a fastener, the method comprising:
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(a) creating a first layer of material to define a first section of the fastener; (b) emitting light onto the first layer after the prior step to cure, harden or bond the layer; (c) creating a second layer of the material upon the first layer to define a second section of the fastener after the prior step; (d) emitting light onto the second layer after the prior step to cure, harden or bond the second layer; (e) creating at least a third layer of the material upon the second layer to define at least a third section of the fastener after the prior step; (f) emitting light onto the third layer after the prior step to cure, harden or bond the third layer; (g) creating a flexible rotatable hinge section from the material which is a printable polymeric material; (h) depositing a second and different polymeric material integrally connected to the printable polymeric material during the same machine head pass above the fastener being created; (i) removing the finished fastener from a machine which performs the creating and emitting steps, with the layers all being integrally connected to their adjacent layers; and (j) the finished fastener being functional and made by the machine in less than ninety minutes. - View Dependent Claims (2, 3, 4, 5, 25, 26, 28, 29)
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6. A method of making a fastener, the method comprising:
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(a) depositing a layer of material onto a support surface, the layer defining an outer surface of the fastener; (b) depositing subsequent layers of the material upon each prior layer until the fastener is completely created; (c) creating the fastener to comprise a body and a rotatable hinge coupled to the body made of the material, as part of the depositing steps; (d) surrounding at least a majority of the fastener with a gas during the depositing and creating steps; (e) curing the fastener so that the layers of the material bond together; (f) removing the completed fastener from the support surface; and (g) wherein the body includes a substantially circular receptacle adapted to retain an elongated workpiece. - View Dependent Claims (8, 11, 12, 13, 15, 16, 18, 19, 21, 24)
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7. A method of making a fastener, the method comprising:
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(a) depositing a layer of material onto a support surface, the layer defining an outer surface of the fastener; (b) depositing subsequent layers of the material upon each prior layer until the fastener is completely created; (c) creating the fastener to comprise a body and a rotatable hinge coupled to the body made of the material, as part of the depositing steps; (d) surrounding at least a majority of the fastener with a gas during the depositing and creating steps; (e) curing the fastener so that the layers of the material bond together; (f) removing the completed fastener from the support surface; and (g) wherein the body includes an elongated shaft and workpiece-engaging barbs, the shaft extends from the body and the barbs are flexible to allow easier workpiece-insertion by the fastener as compared to more difficult extraction. - View Dependent Claims (9, 23, 49, 50, 51)
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10. A method of making a fastener, the method comprising:
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(a) depositing a layer of material onto a support surface, the layer defining an outer surface of the fastener; (b) depositing subsequent layers of the material upon each prior layer until the fastener is completely created; (c) creating the fastener to comprise a body and a rotatable hinge coupled to the body made of the material, as part of the depositing steps; (d) surrounding at least a majority of the fastener with a gas during the depositing and creating steps; (e) curing the fastener so that the layers of the material bond together; and (f) removing the completed fastener from the support surface; (g) wherein the gas is air, and the fastener is a single piece. - View Dependent Claims (22, 52, 53)
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14. A method of making a fastener, the method comprising:
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(a) depositing a layer of material onto a support surface, the layer defining an outer surface of the fastener; (b) depositing subsequent layers of the material upon each prior layer until the fastener is completely created; (C) creating the fastener to comprise a body and a rotatable hinge coupled to the body made of the material, as part of the depositing steps; (d) surrounding at least a majority of the fastener with a gas during the depositing and creating steps; (e) curing the fastener so that the layers of the material bond together; and (f) removing the completed fastener from the support surface; (g) wherein the depositing is part of direct metal laser sintering, and the curing includes laser fusing of the layers. - View Dependent Claims (54, 55, 56, 57)
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17. A method of making a fastener, the method comprising:
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(a) depositing a layer of material onto a support surface, the layer defining an outer surface of the fastener; (b) depositing subsequent layers of the material upon each prior layer until the fastener is completely created; (c) creating the fastener to comprise a body and a rotatable hinge coupled to the body made of the material, as part of the depositing steps; (d) simultaneously creating a resilient segment integral with the body of the fastener by depositing a layer of a second and more flexible material adjacent the more rigid material defining the body, within the same machine cycle; (e) surrounding at least a majority of the fastener with a gas during the depositing and creating steps; (f) curing the fastener so that the layers of the material bond together; and (g) removing the completed fastener from the support surface. - View Dependent Claims (58, 59, 60, 61)
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20. A method of making a fastener, the method comprising:
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(a) depositing a layer of material onto a support surface, the layer defining an outer surface of the fastener; (b) depositing subsequent layers of the material upon each prior layer until the fastener is completely created; (c) creating the fastener to comprise a body and a rotatable hinge coupled to the body made of the material, as part of the depositing steps; (d) creating the hinge to have a curved shape when in a closed position; (e) surrounding at least a majority of the fastener with a gas during the depositing and creating steps; (f) curing the fastener so that the layers of the material bond together; and (g) removing the completed fastener from the support surface. - View Dependent Claims (62, 63)
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27. A method of making a fastener, the method comprising:
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(a) creating a first layer of material to define a first section of the fastener; (b) emitting light onto the first layer after the prior step to cure, harden or bond the layer; (c) creating a second layer of the material upon the first layer to define a second section of the fastener after the prior step; (d) emitting light onto the second layer after the prior step to cure, harden or bond the second layer; (e) creating at least a third layer of the material upon the second layer to define at least a third section of the fastener after the prior step; (f) emitting light onto the third layer after the prior step to cure, harden or bond the third layer; (g) creating a flexible rotatable hinge section from the material which is a printable polymeric material; (h) creating the fastener in an additive manner as a hose or wire clamp including an internal and hollow hose or wire receptacle; (i) removing the finished fastener from a machine which performs the creating and emitting steps, with the layers all being integrally connected to their adjacent layers; and (j) the finished fastener being functional and made by the machine in less than ninety minutes. - View Dependent Claims (64, 65, 66)
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30. A method of making a fastener, the method comprising:
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(a) three dimensionally printing layers of at least one material to create a base of the fastener; (b) three dimensionally printing layers of the at least one material to create a lid of the fastener; (c) three dimensionally printing layers of the at least one material to create a hinge of the fastener which rotatably couples the lid to the base; and (d) three dimensionally printing a barbed snap fit to secure together the base and the lid. - View Dependent Claims (31, 32, 34, 35, 36, 37)
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33. A method of making a fastener, the method comprising:
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(a) three dimensionally printing layers of at least one material to create a base of the fastener; (b) three dimensionally printing layers of the at least one material to create a lid of the fastener; (c) three dimensionally printing layers of the at least one material to create a hinge of the fastener which rotatably couples the lid to the base; and (d) making an elongated shaft extending from the base, a flexible workpiece-securing leg projecting from the shaft, and a hose or wire clamping receptacle. - View Dependent Claims (67, 68)
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38. A method of making a fastener, the method comprising:
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(a) three dimensionally printing layers of at least one material to create a base of the fastener; (b) three dimensionally printing layers of the at least one material to create a lid of the fastener; (c) three dimensionally printing layers of the at least one material to create a hinge of the fastener which rotatably couples the lid to the base; and (d) three dimensionally printing a resilient seal integral with the base. - View Dependent Claims (39, 69, 70)
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40. A method of making a fastener, the method comprising:
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(a) additively depositing base layers to create a rigid base including a side wall and a bottom wall; (b) additively depositing lid layers to create a lid including a side wall and a top wall; (c) creating a barbed snap fit extending from at least one of the base and the lid layers; (d) additively depositing receptacle layers to create a curved hose or wire clamping receptacle within a cavity between the base and the lid layers; and (e) creating a hinge coupling the side wall of the base to the side wall of the lid. - View Dependent Claims (41, 42, 43, 44, 45, 46, 47, 48)
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Specification