Right-sized thermoformed cavities for packaging items

A method comprising:

• determining, by a computer device, at least a first dimension and a second dimension of an item, wherein the computer device is in communication with a first plurality of actuators arranged within an array, and wherein contact points of each of the first plurality of actuators are aligned in a common plane with each of the first plurality of actuators in a neutral position;
• selecting, by the computer device, a second plurality of actuators based at least in part on the first dimension of the item, wherein each of the second plurality of actuators is one of the first plurality of actuators;
• selecting, by the computer device, distances by which each of the second plurality of actuators is to be extended with respect to the common plane based at least in part on the second dimension of the item;
• providing a thermoplastic material adjacent to the common plane;
• extending each of the second plurality of actuators into the thermoplastic material by the distances selected for the respective ones of the second plurality of actuators;
• and
• retracting each of the second plurality of actuators by at least the distances selected for the respective ones of the second plurality of actuators, wherein a cavity for accommodating at least the item is formed in the thermoplastic material upon retracting each of the second plurality of actuators by at least the distances selected for the respective ones of the second plurality of actuators.

A method for forming a cavity for an item by an actuator system comprising:

• a housing;
• a plurality of motors disposed within the housing, wherein each of the plurality of motors is in communication with a computer system;
• and
• a first plurality of actuators aligned in parallel in an array, wherein each of the actuators is coupled at a proximal end to one of the plurality of motors by a shaft and comprises a contact point at a distal end, wherein at least some of the contact points are in a common plane when each of the first plurality of actuators is in a neutral position,
• wherein the method comprises:
• capturing at least one image of the item by at least one imaging device;
• determining at least a first dimension and a second dimension of the item based at least in part on the at least one image;
• selecting a second plurality of actuators based at least in part on the first dimension of the item, wherein each of the second plurality of the actuators is one of the first plurality of actuators;
• selecting a distance by which each of the second plurality of actuators is to be respectively extended beyond the common plane based at least in part on the second dimension of the item;
• providing a thermoplastic material adjacent to the common plane;
• and
• extending each of the second plurality of actuators into the thermoplastic material by the selected distances to form the cavity.