Method of making 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 a 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 member from the material which is a printed polymeric material, the member being at least one of;
(i) an umbrella or (ii) a work-piece engaging leg; and
(h) 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;
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
32 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 a 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 member from the material which is a printed polymeric material, the member being at least one of;
(i) an umbrella or (ii) a work-piece engaging leg; and(h) 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; the finished fastener being functional and made by the machine in less than ninety minutes. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 24, 25, 26, 27)
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13. A method of using a three-dimensional printing machine, the method comprising:
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emitting material from an ink jet printing head of the three-dimensional printing machine, and building up a fastener by placing the material to create workpiece-retention legs laterally extending from a stem; and creating an enlarged fastener head with the building up step; wherein the workpiece-retention legs include at least one of;
(a) moveable legs adapted to expand on the opposite end of the fastener from the fastener head, or (b) moveable barbs which are tapered toward a longitudinal centerline opposite the fastener head. - View Dependent Claims (14, 15, 18, 19, 28, 29, 30, 31, 32)
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16. A method of using a three-dimensional printing machine, the method comprising:
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emitting material from an ink jet printing head of the three-dimensional printing machine, and building up a fastener by placing the material to create at least one of;
(i) a threaded receptacle, (ii) a resilient segment, or (iii) workpiece-retention legs laterally extending from a stem; andcreating a preassembled shaft located partially within a bore of the fastener during the building up step, the bore being located within a body, the body including workpiece-engaging surfaces, and the shaft being further insertable into the bore after the fastener is manufactured. - View Dependent Claims (17, 20, 21, 22, 23)
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Specification