Unitary deflection member for making fibrous structures having increased surface area and process for making same

A method for making a unitary deflection member that is utilized for making fibrous webs, the method comprising the steps of:

• a. providing an additive manufacturing making apparatus;
• b. providing at least one material for the unitary deflection member that is utilized for making fibrous webs, the material being compatible for use with the additive manufacturing making apparatus;
• c. generating a 3-D digital image of objects in an element of the unitary deflection member, the objects including at least a reinforcing member comprising a first plurality MD-oriented elements along an MD axis and a second plurality of CD-oriented elements along a CD axis, the MD and CD-oriented elements being unitary with each other and also being unitary with a plurality of regularly spaced protuberances of the unitary deflection member, such that, in cross-section, the MD and CD-oriented elements and the plurality of protuberances are a single unit not formed from separate parts, wherein the regularly spaced tuberances extend from the reinforcing member in a Z-direction and at least two of said protuberances are similar in size and shape, each said protuberance having a transition portion having a transition portion width and a forming portion having a forming portion width, and wherein the transition portion width is less than the forming portion width;
• d. assembling the objects into a digitized file including the at least one protuberance being on said reinforcing member;
• e. importing the digitized file to make a numerical control file of the additive manufacturing making apparatus;
• and
• f. depositing the material using the additive manufacturing making apparatus to make the unitary deflection member that is utilized for making fibrous webs.

A method for making a unitary deflection member that is utilized for making fibrous webs, the method comprising the steps of:

• a. providing 3-D printer apparatus;
• b. providing at least one material for the unitary deflection member that is utilized for making fibrous webs, the material being compatible for use with the additive manufacturing making apparatus;
• c. generating a 3-D digital image of objects in an element of the unitary deflection member, the objects including at least a reinforcing member comprising a first plurality MD-oriented elements along an MD axis and a second plurality of CD-oriented elements along a CD axis, the MD and CD-oriented elements being unitary with each other and also being unitary with a plurality of regularly spaced protuberances, such that, in cross-section, the MD and CD-oriented elements and the plurality of protuberances are a single unit not formed from separate parts, wherein the regularly spaced tuberances extend from the reinforcing member in a Z direction and at least two of said protuberances are similar in size and shape;
• d. assembling the objects into a digitized file including the at least one protuberance being on said reinforcing member;
• e. importing the digitized file to make a numerical control file of the additive manufacturing making apparatus;
• and
• f. depositing the material using the additive manufacturing making apparatus to make the unitary deflection member that is utilized for making fibrous webs.