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US 8,834,666 B2Granted
Monolithic fabrication of three-dimensional structures
AssigneePresident and Fellow of Harvard College
InventorsPratheev Sabaratnam Sreetharan, John Peter Whitney, Robert J. Wood
Life of this patent
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Abstract
A multi-layer, super-planar structure can be formed from distinctly patterned layers. The layers in the structure can include at least one rigid layer and at least one flexible layer; the rigid layer includes a plurality of rigid segments, and the flexible layer can extend between the rigid segments to serve as a joint. The layers are then stacked and bonded at selected locations to form a laminate structure with inter-layer bonds, and the laminate structure is flexed at the flexible layer between rigid segments to produce an expanded three-dimensional structure, wherein the layers are joined at the selected bonding locations and separated at other locations.
Claims10
A method for fabricating a three-dimensional structure, comprising:
- producing a plurality of layers with distinct patterns, wherein the layers include at least one rigid layer, at least one flexible layer, and at least one adhesive layer that bonds the rigid layer to the flexible layer, wherein the rigid layer includes a plurality of rigid segments that are substantially more rigid than the flexible layer;
- then
- stacking the plurality of layers and bonding the plurality of layers at selected locations to form a laminate structure with inter-layer bonds;
- and
- flexing the laminate structure at joints between the rigid segments to produce an expanded three-dimensional structure, wherein the layers are joined at the selected bonding locations and separated at other locations.
2 more elements
A method for fabricating a three-dimensional structure, comprising:
- producing a plurality of layers with distinct patterns, wherein the layers include at least one rigid layer and at least one flexible layer, wherein the rigid layer includes a plurality of rigid segments that are substantially more rigid than the flexible layer;
- then
- stacking the plurality of layers by passing dowel pins through aligned orifices in the layers and bonding the plurality of layers by a press at selected locations to form a laminate structure with inter-layer bonds;
- and
- flexing the laminate structure at joints between the rigid segments to produce an expanded three-dimensional structure, wherein the layers are joined at the selected bonding locations and separated at other locations.
2 more elements
A method for fabricating a three-dimensional structure, comprising:
- producing a plurality of layers with distinct patterns, wherein the layers include at least one rigid layer and at least one flexible layer, wherein the rigid layer includes a plurality of rigid segments that are substantially more rigid than the flexible layer;
- then
- stacking the plurality of layers and bonding the plurality of layers at selected locations to form a laminate structure with inter-layer bonds;
- flexing the laminate structure at joints between the rigid segments to produce an expanded three-dimensional structure, wherein the layers are joined at the selected bonding locations and separated at other locations;
- and
- locking at least one of the joints in the structure after flexing to form the expanded three-dimensional structure.
3 more elements
A method for fabricating a three-dimensional structure, comprising:
- producing a plurality of layers with distinct patterns, wherein the layers include at least one rigid layer and at least one flexible layer, wherein the rigid layer includes a plurality of rigid segments that are substantially more rigid than the flexible layer, wherein at least one of the layers in the laminate structure includes a pre-strained flexure spring;
- then
- stacking the plurality of layers and bonding the plurality of layers at selected locations to form a laminate structure with inter-layer bonds;
- and
- flexing the laminate structure at joints between the rigid segments to produce an expanded three-dimensional structure, wherein the layers are joined at the selected bonding locations and separated at other locations.
2 more elements
A method for fabricating a three-dimensional structure, comprising:
- producing a plurality of layers with distinct patterns, wherein the layers include at least one rigid layer and at least one flexible layer, wherein the rigid layer includes a plurality of rigid segments that are substantially more rigid than the flexible layer;
- then
- stacking the plurality of layers and bonding the plurality of layers at selected locations to form a laminate structure with inter-layer bonds;
- and
- flexing the laminate structure at joints between the rigid segments to produce an expanded three-dimensional structure, wherein the layers are joined at the selected bonding locations and separated at other locations, wherein the laminate structure includes a frame and at least one structure that is flexed to produce a final product, and wherein the frame and the structure that is flexed to produce the final product are joined by at least one sacrificial bridge, the method further comprising severing the sacrificial bridge.
2 more elements
A method for fabricating a three-dimensional structure, comprising:
- producing a plurality of layers with distinct patterns, wherein the layers include at least one rigid layer and at least one flexible layer, wherein the rigid layer includes a plurality of rigid segments that are substantially more rigid than the flexible layer;
- then
- stacking the plurality of layers and bonding the plurality of layers at selected locations to form a laminate structure with inter-layer bonds;
- flexing the laminate structure at joints between the rigid segments to produce an expanded three-dimensional structure, wherein the layers are joined at the selected bonding locations and separated at other locations;
- and
- providing a scaffold, wherein the layers of the laminate structure form a plurality of inter-connected faces mounted for expansion and rotation in the scaffold, and wherein the method further comprises:
- expanding the scaffold;
- lifting at least one of the faces with the scaffold expansion;
- rotating at least some of the faces with the scaffold expansion;
- and
- locking the raised and rotated faces in the resulting three-dimensional structure.
8 more elements
Dependencies are inferred from the claim text.