David K Matsumura

US Patent:

20090273109, Nov 5, 2009

Filed:

Mar 27, 2009

Appl. No.:

12/383822

Inventors:

Brent Johnson - Elk Ridge UT, US
Ken Hardman - Pleasant Grove UT, US
Leslie Johnson - Elk Ridge UT, US
Caleb Waugh - Grand Junction CO, US
Jonathan Woahn - Pleasant Grove UT, US
Tyson Triplett - Provo UT, US
Eric Radford - Woodlands TX, US
Dean Keith Stolworthy - Henderson NV, US
Karl M. Taylor - Tualatin OR, US
Brad Hyatt - Rochester NY, US
Jeffrey Webster - Pleasant Grove UT, US
James Kearl - Greensboro NC, US
David Matsumura - Chicago IL, US

Assignee:

Iterations, Inc. - Elk Ridge UT

International Classification:

B29C 43/56

US Classification:

264 405, 425394

Abstract:

The disclosed systems and methods include a mold assembly having a malleable mold (), a moldable blank () and a bladder () positioned about the moldable blank () to transmit an external force applied to the mold assembly uniformly to the moldable blank () and hence to the malleable mold (). The invention further includes a method of replicating a surface by use of the mold assembly. The method may include manipulating the malleable mold () 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 () to reflect the surface to be replicated. An activated moldable blank, e.g., a blank () fabricated from a thermo-forming material, is then positioned over the malleable mold. The bladder () is then secured about the moldable blank (). An external force, such as that induced by placing the mold assembly in a vacuum chamber, is then applied to the mold assembly.