Unitary Deflection Member for Making Fibrous Structures Having Increased Surface Area and Process for Making Same

A method for making a unitary deflection member, the method comprising the steps of:

• a. providing an additive manufacturing making apparatus;
• b. providing at least one material for the unitary deflection member, 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 and at least one protuberance of the unitary deflection member;
• d. optionally, 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.

A method for making a unitary deflection member, the method comprising the steps of:

• a. providing 3-D printer apparatus;
• b. providing at least one material for the unitary deflection member, 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 and at least one protuberance having transition portions and forming portions;
• d. optionally, 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.