Three dimensional variable forming apparatus and methods of use thereof

US8956145B2 · kind B2 · utility

Assignee

• Iterations Inc. · US

Inventors

• Brent A. Johnson · Ladera Ranch, US
• Ken Hardman · Clarkston, US
• Leslie Johnson · New York, US
• Caleb Waugh · Grand Junction, US
• Jonathan Woahn · Pleasant Grove, US
• Tyson Triplett · Provo, US
• Eric Radford · Kyle, US
• Dean Stolworthy · Henderson, US
• Karl M. Taylor · Tualatin, US
• Brad Hyatt · Rochester, US
• Jeffrey C. Webster · Pleasant Grove, US
• James Kearl · Greensboro, US
• David Matsumura · Chicago, US

Key dates

• Filing date: Mar 27, 2009
• Grant date: Feb 17, 2015
• Expiry date: Feb 23, 2031

Classification

• Technology area (CPC B): Performing Operations; Transporting
• CPC primary: B29L2031/50
• WIPO field: Other special machines
• WIPO sector: Mechanical engineering

Abstract

The disclosed systems and methods include a mold assembly having a malleable mold (4), a moldable blank (2) and a bladder (1) positioned about the moldable blank (2) to transmit an external force applied to the mold assembly uniformly to the moldable blank (2) and hence to the malleable mold (4). The invention further includes a method of replicating a surface by use of the mold assembly. The method may include manipulating the malleable mold (4) to record the image to be replicated. This manipulation may include a physical engagement of the mold with a physical surface to be replicated. Alternatively, an image, e.g., photograph or laser scan of the surface may be transmitted to a computer numerically controlled (“CNC”) system. The CNC system then manipulates the malleable mold (4) to reflect the surface to be replicated. An activated moldable blank, e.g., a blank (2) fabricated from a thermo-forming material, is then positioned over the malleable mold. The bladder (1) is then secured about the moldable blank (2). An external force, such as that induced by placing the mold assembly in a vacuum chamber, is then applied to the mold assembly.