Advanced Molding Tech for Medical & Aerospace Inserts

Publication ID: 24-11857025_0007_PTD

Published: October 27, 2025

Category:New Applications & Use Cases

Legal Citation

pr1or.art Inc., “Advanced Molding Tech for Medical & Aerospace Inserts,” Published Technical Disclosure No. 24-11857025_0007_PTD, Published October 27, 2025, available at https://archive.pr1or.art/24-11857025_0007_PTD

This technical disclosure describes improvements that would be readily apparent to a Person Having Ordinary Skill In The Art (PHOSITA) when considered in combination with the foundational architecture disclosed in U.S. Patent No. 11,857,025.

Background and Problem Solved

The original patent disclosed a system and method for forming molded components with inserts, primarily focused on articles of footwear. However, this invention recognizes the limitations of the original patent in addressing the specific challenges of medical devices and aerospace applications, where critical features of the insert require protection during the molding process. This new invention addresses these limitations by adapting the core technology to these new fields.

Novelty and Inventive Step

The new claims introduce the application of the core technology to medical devices and aerospace applications, which is a non-obvious extension of the original patent. The use of a removable plugging material to protect critical features of the insert during the molding process is a novel solution to the specific challenges of these fields.

Alternative Embodiments and Variations

Alternative embodiments may include using different types of molding materials, such as biocompatible materials for medical devices or high-temperature materials for aerospace applications. Variations may also include modifying the design of the insert or the molding machine to accommodate specific requirements of different industries.

Potential Commercial Applications and Market

This invention has significant commercial potential in the medical device and aerospace industries, where custom implants and lightweight structural components are in high demand. The ability to protect critical features of the insert during the molding process enables the creation of complex components with high precision and accuracy, opening up new opportunities for innovation and growth in these industries.

CPC Classifications

Section	Class	Group
A	A43	A43B13/04
B	B29	B29D35/0018
B	B29	B29D35/122
B	B29	B29D35/14
B	B29	B29D35/142

Section 103 Obviousness Analysis (PHOSITA)

▼

Field of Art

Molding and manufacturing technologies, specifically insert molding techniques for complex components across multiple industries including footwear, medical devices, and aerospace structural components

Person of Ordinary Skill (PHOSITA) Profile

A manufacturing engineer with expertise in injection molding, materials science, and design for manufacturability, possessing knowledge of insert molding techniques and material compatibility across different industrial applications

Obviousness Rationale

A PHOSITA would recognize that the core molding technique disclosed in the source patent can be readily adapted to different industrial contexts by selecting appropriate materials and modifying insert designs. The fundamental principles of protecting critical insert features during molding remain consistent across various applications. The variations presented represent predictable extensions of the original patent's core technological concept.

Obvious Combinations & Variations

Source Patent Element

Method of disposing a plug within a receptacle of an insert with an engagement feature

PTD Variation

Applying the molding technique to medical device implant manufacturing with patient-specific designs

Obviousness Reasoning

Adapting insert molding to medical devices is a known technique involving material selection and design modification, representing a predictable application of an existing manufacturing process

Source Patent Element

Using elastomeric materials for molding a plug within an insert

PTD Variation

Selecting biocompatible materials for medical device and aerospace applications

Obviousness Reasoning

Material substitution for specific industrial requirements is a standard design choice for a PHOSITA familiar with material science and manufacturing techniques

Source Patent Element

Molding process involving heat and pressure to form a component with an insert

PTD Variation

Modifying molding parameters for high-temperature aerospace structural components

Obviousness Reasoning

Adjusting molding parameters for different material properties is a routine engineering task within the skill set of a person experienced in manufacturing technologies

Source Patent Element

Insert with engagement features and bushing design

PTD Variation

Customizing insert geometry for specific medical or aerospace applications

Obviousness Reasoning

Geometric modifications to standard insert designs represent an obvious design optimization approach for addressing specific functional requirements

Source Patent Element

Method of protecting insert features during molding process

PTD Variation

Using removable plugging material to preserve critical insert features across different manufacturing contexts

Obviousness Reasoning

Developing protective strategies for maintaining insert integrity is a predictable solution that would be obvious to a skilled practitioner familiar with complex molding techniques

35 U.S.C. § 103 Summary: Based on the teachings of US Patent 11857025, a person having ordinary skill in the art would find the variations disclosed herein to be obvious extensions of the fundamental insert molding technique. The application of the core molding methodology to medical device and aerospace manufacturing represents a predictable adaptation of known technological principles, thereby rendering potential claims to such variations unpatentable under 35 U.S.C. Section 103.

Original Patent Information

Patent Number	US 11,857,025
Title	System and method for forming a molded component with an insert
Assignee(s)	NIKE, Inc.