Method Of Making Winged 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) making a head, an elongated shaft and a flexible workpiece-engaging wing from the material which is a printable polymeric material, as part of at least some of the creating steps, the shaft extending from the head and the wing being flexibly attached to the shaft with an undercut and hollow cavity created between the shaft and an inwardly facing surface of the wing;
(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; and
(i) 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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34 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) making a head, an elongated shaft and a flexible workpiece-engaging wing from the material which is a printable polymeric material, as part of at least some of the creating steps, the shaft extending from the head and the wing being flexibly attached to the shaft with an undercut and hollow cavity created between the shaft and an inwardly facing surface of the wing; (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; and (i) the finished fastener being functional and made by the machine in less than ninety minutes. - View Dependent Claims (2, 3, 4, 5, 18, 19, 20, 21, 22, 23)
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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 head, a central shaft extending from the head and circumferentially arcuate wings flexibly attached to the shaft, with an undercut hollow cavity created between the shaft and an inwardly facing surface of each of the wings, 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. - View Dependent Claims (7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17)
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24. A method of making a fastener, the method comprising:
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(a) three dimensionally printing;
(i) a laterally enlarged head, (ii) a shaft longitudinally extending perpendicularly to the head, and (iii) wings each having a first longitudinally elongated edge attached to the shaft and a free opposite second elongated edge defining a slot;(b) an undercut hollow cavity being created between the shaft and an inwardly facing surface of each of the wings; (c) the wings and shaft joining together adjacent a tapered distal end opposite the head; and (d) light curing the head, shaft and wings to make the fastener. - View Dependent Claims (25, 26, 27, 28, 29, 30, 31, 32, 33, 34)
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Specification