Systems and Methods for 3D Printing Customized Non-Medical Devices

Publication ID: 24-11857735_0007_PTD
Published: October 28, 2025
Category:New Applications & Use Cases

Legal Citation

pr1or.art Inc., “Systems and Methods for 3D Printing Customized Non-Medical Devices,” Published Technical Disclosure No. 24-11857735_0007_PTD, Published October 28, 2025, available at https://archive.pr1or.art/24-11857735_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. 11,857,735.

Summary of the Inventive Concept

This inventive concept leverages the core technology of the original patent to create customized 3D-printed devices for various non-medical industries, such as architecture, furniture, music, sports, and aerospace.

Background and Problem Solved

The original patent focused on additive manufacturing of medical devices, but its core technology has broader applicability. Current methods for creating customized devices in non-medical industries often involve labor-intensive and expensive processes, resulting in limited design flexibility and high production costs. This inventive concept addresses these limitations by applying the original patent's technology to create customized devices with unique properties for various non-medical applications.

Detailed Description of the Inventive Concept

The new inventive concept involves adapting the original patent's additive manufacturing system to deposit a variety of materials with distinct properties, enabling the creation of customized devices with unique combinations of properties. For example, in architecture, this could involve depositing materials with varying thermal insulation properties to create energy-efficient buildings. In furniture, it could involve combining materials with different textures and colors to produce bespoke pieces. Similarly, in music, aerospace, and sports, the inventive concept enables the creation of customized devices with unique properties, such as varying flex modulus or catheter handling properties.

Novelty and Inventive Step

The new claims introduce novel applications of the original patent's technology, expanding its scope to non-medical industries. The inventive step lies in recognizing the potential of the original technology to solve problems in these new domains and adapting it to create customized devices with unique properties.

Alternative Embodiments and Variations

Alternative embodiments of the inventive concept could involve using different types of materials, such as metals, ceramics, or polymers, or incorporating additional features, such as sensors or actuators, to further customize the devices. Variations could include adapting the system for use in other industries, such as automotive or consumer electronics.

Potential Commercial Applications and Market

The inventive concept has significant commercial potential, as it enables the creation of customized devices with unique properties for various non-medical industries. This could lead to new business opportunities, partnerships, and revenue streams for companies operating in these industries.

CPC Classifications

SectionClassGroup
A A61 A61M25/0012
B B29 B29C64/118
B B29 B29C64/209
B B29 B29C64/295
B B29 B29C64/336
B B29 B29C64/393
B B33 B33Y10/00
B B33 B33Y30/00
B B33 B33Y40/00
B B33 B33Y50/02
B B33 B33Y80/00
A A61 A61N1/05
B B29 B29K2995/007
B B29 B29L2031/7542

Field of Art

Additive manufacturing and 3D printing technologies, with expertise in material deposition systems, multi-material printing techniques, and manufacturing process optimization across medical, industrial, and consumer domains

Person of Ordinary Skill (PHOSITA) Profile

A skilled practitioner with advanced engineering degree, experience in materials science, 3D printing technologies, and cross-domain manufacturing techniques, capable of adapting manufacturing processes between different technical domains

Obviousness Rationale

A person of ordinary skill would recognize the fundamental transferability of the source patent's 3D printing methodology across different technical domains. The core technological principles of precise material deposition, temperature control, and multi-material integration are universally applicable beyond medical devices. The PTD demonstrates predictable extensions of the original patent's core technological framework by applying identical additive manufacturing principles to alternative industries with minor contextual adaptations.

Obvious Combinations & Variations

Source Patent Element
Heating cartridge with substrate inlet and outlet ports for controlled material deposition
PTD Variation
Adapting heating cartridge for multi-material deposition in architectural, furniture, and aerospace components
Obviousness Reasoning
Predictable modification using known multi-material printing techniques, representing a standard design adaptation within additive manufacturing domain
Source Patent Element
Rotational and longitudinal movement parameters for precise substrate manufacturing
PTD Variation
Applying identical movement parameters to create customized components in sports equipment and musical instruments
Obviousness Reasoning
Routine engineering translation of precise manufacturing parameters across similar technological domains with predictable results
Source Patent Element
Filament deposition with specific durometer properties
PTD Variation
Extending material property selection to create components with unique mechanical characteristics in non-medical applications
Obviousness Reasoning
Obvious extension of material science principles, representing a standard design choice in engineering problem-solving
Source Patent Element
Substrate channel and interior volume configuration for controlled material flow
PTD Variation
Repurposing channel design for creating complex multi-material architectural and aerospace components
Obviousness Reasoning
Predictable technological transfer using established additive manufacturing principles
Source Patent Element
Particulate integration near outer surface of manufactured component
PTD Variation
Applying surface modification techniques to create unique textural properties in furniture and sports equipment
Obviousness Reasoning
Routine materials engineering adaptation representing a known technique for enhancing component characteristics
35 U.S.C. § 103 Summary: Based on US Patent 11857735, the present disclosure demonstrates that the claimed innovations in customized 3D-printed devices across multiple domains would have been obvious to a person having ordinary skill in additive manufacturing technologies. The fundamental principles of material deposition, precise movement control, and multi-material integration are directly transferable, rendering the proposed variations predictable extensions of existing technological frameworks.

Original Patent Information

Patent NumberUS 11,857,735
TitleSystems and methods for manufacturing 3D printed medical devices
Assignee(s)Medtronic, Inc.