Method of making a transaction instrument

• US 10,513,081 B1
• Filed: 12/09/2014
• Issued: 12/24/2019
• Est. Priority Date: 12/10/2013
• Status: Active Grant

• Current Assignee: Wells Fargo Bank NA (Wells Fargo & Company)
• Original Assignee: Wells Fargo Bank NA (Wells Fargo & Company)
• Inventors: Vittimberga, Paul, Ing, Kristine, Wright, John
• Primary Examiner(s): Labaze, Edwyn
• Application Number:
  US14/564,842
• Time in Patent Office: 1,841 Days
• Field of Search: 235492, 235380, 235488, 235487, 235451, 235375, 235792
• CPC Class Codes: B22F 10/12 by photopolymerisation, e.g. stereolithography [SLA] or digital light processing [DLP]
• CPC Class Codes: B22F 10/18 by mixing binder with metal in filament form, e.g. fused filament fabrication [FFF]
• CPC Class Codes: B22F 10/25 Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/39 Traceability, e.g. incorporating identifier into a workpiece or article
• CPC Class Codes: B22F 10/66 by mechanical means
• CPC Class Codes: B22F 2003/247 Removing material: carving, cleaning, grinding, hobbing, honing, lapping, polishing, milling, shaving, skiving, turning the surface
• CPC Class Codes: B22F 2998/10 Processes characterised by the sequence of their steps
• CPC Class Codes: B22F 3/02 Compacting only
• CPC Class Codes: B22F 5/00 Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
• CPC Class Codes: B22F 5/006 of flat products, e.g. sheets B22F3/1103 takes precedence; by using pressure rollers only see B22F3/18
• CPC Class Codes: B22F 5/106 Tube or ring forms
• CPC Class Codes: B22F 7/02 of composite layers B22F7/002 takes precedence
• CPC Class Codes: B22F 7/08 with one or more parts not made from powder B22F7/062 takes precedence
• CPC Class Codes: B23K 15/0086 welding for purposes other than joining, e.g. built-up welding
• CPC Class Codes: B23K 26/34 Laser welding for purposes other than joining
• CPC Class Codes: B28B 1/001 Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00
• CPC Class Codes: B29C 64/153 using layers of powder being selectively joined, e.g. by selective laser sintering or melting
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: G06K 19/02 : characterised by the selection of materials, e.g. to avoid wear during transport through the machine
• CPC Class Codes: G06K 19/041 : Constructional details G06K19/06 takes precedence
• CPC Class Codes: G06K 19/07716 : the record carrier comprising means for customization, e.g. being arranged for personalization in batch
• CPC Class Codes: G06K 19/0772 : Physical layout of the record carrier
• CPC Class Codes: Y02P 10/25 : Process efficiency

Abstract

A method of making a transaction instrument comprising making a transaction instrument by three-dimensional (3D) printing or additive manufacturing. The transaction instrument such as a transaction card may have many features or components made by or using three-dimensional (3D) printing or additive manufacturing.

Claims

1. A method of making a transaction instrument, the method comprising:

generating a series of virtual cross-sections based on a virtual blueprint from a digital computer model of the transaction instrument; and

additive manufacturing or three-dimensional printing the transaction instrument, wherein the transaction instrument is comprised of a plastic and metal blend, wherein the plastic and metal blend is a metal-filled plastic, and wherein additive manufacturing or three-dimensional printing the transaction instrument includes;

depositing successive layers of the metal-filled plastic corresponding to the series of virtual cross-sections, and

automatically fusing the successive layers of the metal-filled plastic to form the transaction instrument, wherein automatically fusing the successive layers comprises melting or sintering the metal-filed plastic.

2. The method according to claim 1, wherein the additive manufacturing or three dimensional printing is selected from the group consisting of selective laser sintering, selective heat sintering, plaster-based three-dimensional printing, selective fusing of materials in a granular bed, selective laser melting, direct metal laser sintering, fused deposition modeling, electron-beam melting, electron-beam freeform fabrication, photopolymerization, stereolithography, laminated object manufacturing, digital light processing, and other selective fusing or photopolymerization processes.

3. The method according to claim 1, further comprising finishing the transaction instrument by subtractive manufacturing.

4. The method according to claim 1, wherein the transaction instrument further comprises ceramic, carbon, or a combination thereof.

5. The method according to claim 1, wherein the plastic is selected from the group consisting of polyvinyl chloride (PVC), polyvinyl chloride acetate (PVCA), polyester, polyethylene, polyethylene terephthalate, polycarbonate, polyethylene glycol (PET-G), acrylonitrile butadiene styrene (ABS), polypropylene, or a combination thereof.

6. The method according to claim 1, wherein some or all of the plastic is optically transparent.

7. The method according to claim 6, wherein the optically transparent plastic is opaque to some or all light outside of the visible spectrum.

8. The method according to claim 6, wherein the optically transparent plastic is opaque to ultraviolet light.

9. The method according to claim 1, wherein the transaction instrument is in a form of a card, fob, ring, watch, wrist band, bracelet, other electronic jewelry or other hand-held device.

10. The method according to claim 9, wherein the card includes a machine readable indicium.

11. The method according to claim 10, wherein the transaction card comprises a recess to accommodate the machine readable indicium.

12. The method according to claim 11, wherein the recess is made by leaving a void during the three-dimensional printing or additive manufacturing process or by using subtractive manufacturing after additive manufacturing or three-dimensional printing.

13. The method according to claim 11, wherein additive manufacturing or three dimensional printing inclusive of the recess is done onto or around the machine readable indicium.

14. The method according to claim 10, wherein the machine readable indicium is printed directly onto the transaction card inclusive of the recess during three-dimensional printing.

15. The method according to claim 9, further comprising forming one or more recesses in the transaction instrument.

16. The method according to claim 15, wherein the one or more recesses comprise one or more inset devices including one or more of an integrated circuit, conducting contact pads, an EMV chip, or an antenna.

17. The method according to claim 15, wherein three-dimensional printing inclusive of the recess is done onto or around the inset device.

18. The method according to claim 1, wherein the transaction instrument comprises a hole, decorative relief, image, personalization, decorative inset, decorative color variance, transparent portion or layer, inlay, recessed area, or a combination thereof.

19. The method according to claim 1, further comprising three-dimensionally printing a personalization on the transaction instrument.

20. The method according to claim 19, wherein the personalization comprises an indicium indicative of an account associated with the transaction instrument.

21. The method according to claim 20, wherein the indicium is raised with respect to a surface of the instrument.

22. The method according to claim 19, wherein the personalization comprises a name of an individual or a company associated with the transaction instrument.

23. The method according to claim 20, wherein the indicium is of a different color than a surface of the instrument.

24. The method according to claim 19, wherein the transaction instrument is a card.

25. The method according to claim 1, wherein the transaction instrument is printed in a shape other than a transaction card.

26. A method of making a transaction instrument, the method comprising:

generating a series of virtual cross-sections based on a virtual blueprint from a digital computer model of a three-dimensional object, and

printing the three-dimensional object from the digital computer model, wherein the object is a financial transaction instrument, wherein the financial transaction instrument is comprised of a plastic and metal blend, wherein the plastic and metal blend is a metal-filled plastic, and wherein printing the financial transaction instrument includes;

depositing successive layers of the metal-filled plastic corresponding to the series of virtual cross-sections,

forming one or more recesses in the financial transaction instrument corresponding to the series of virtual cross-sections, wherein the one or more recesses are configured to hold at least one financial transaction component, and

automatically fusing the successive layers of the metal-filled plastic to form the financial transaction instrument, wherein automatically fusing the successive layers comprises melting or sintering the metal-filed plastic.

27. A kit comprising:

a financial transaction instrument made by;

generating a series of virtual cross-sections based on a virtual blueprint from a digital computer model of a three-dimensional object; and

printing the three-dimensional object from the digital computer model, wherein the object is a financial transaction instrument, wherein the financial transaction instrument is comprised of a plastic and metal blend, wherein the plastic and metal blend is a metal-filled plastic, and wherein printing the financial transaction instrument includes;

depositing successive layers of the metal-filled plastic corresponding to the series of virtual cross-sections,

forming one or more recesses in the financial transaction instrument corresponding to the series of virtual cross-sections, and

automatically fusing the successive layers of the metal-filled plastic to form the financial transaction instrument, wherein automatically fusing the successive layers comprises melting or sintering the metal-filed plastic; and

at least one financial transaction component, wherein the at least one financial transaction component comprises one or more of a machine readable indicium, an integrated circuit, an antenna, or a combination thereof, each configured for insertion into one of the one or more recesses.