Shape forming process and application thereof for creating structural elements and designed objects

Abstract

A tool provided that individually creates three-dimensional structural elements which are sequentially positioned into formation of a shaped object.

What is claimed is: 
     
         1 . A structural element that is uniformly integrated with other structures to form a designed structure, the structural element comprising a material having a rigid and stable three-dimensional shape that is formed by a) coating a liquid resin onto a fiber, and b) curing the liquid resin and fiber from a liquid state to a solid state. 
     
     
         2 . The structural element of  claim 1 , wherein the structural element is formed by inserting the fiber into the resin, and then shaping the fiber and resin before curing the resin and fiber. 
     
     
         3 . The structural element of  claim 1 , wherein the structural element is formed by depositing the liquid resin onto the fiber, and shaping the liquid resin and fiber by manipulating the fiber into a desired shape. 
     
     
         4 . The structural element of  claim 1 , wherein the structural element is formed by shaping the liquid resin and the fiber. 
     
     
         5 . The structural element of  claim 1 , wherein the structural element is uniformly integrated with other structures by being formed in sequence in relation to other. 
     
     
         6 . The structural element of  claim 1 , wherein the material is formed from resin and fiber. 
     
     
         7 . The structural element of  claim 3 , wherein the resin is a monomer with one or more of acrylate, epoxide, or a vinyl reactive group. 
     
     
         8 . The structural element of  claim 7 , wherein the resin include one of a free-radical ultraviolet photoinitiator formulation, or a cationic ultraviolet photoinitiator formulation. 
     
     
         9 . The structural element of  claim 1 , wherein the material is formed from a fiber or bundle of fibers. 
     
     
         10 . The structural element of  claim 9 , wherein the fiber is a glass fiber, carbon fiber, natural fiber, conductive wire, or bundle of fibers. 
     
     
         11 . The structural element of  claim 1 , wherein the structural element is in the form of a strand. 
     
     
         12 . A designed structure comprising:
 a plurality of structural elements that are unitarily formed into a body, each structural element comprising a material having a rigid and stable three-dimensional shape that is formed into the body by curing the material from a liquid state, each of the structural elements being sequentially formed at a corresponding location of the body.   
     
     
         13 . The designed structure of  claim 12 , wherein each of the structural elements are formed from resin and fiber. 
     
     
         14 . The designed structure of  claim 13 , wherein the resin is a monomer with one or more of acrylate, epoxide, isocyanate, or a vinyl reactive group. 
     
     
         15 . The designed structure of  claim 14 , wherein the resin include one of a free-radical ultraviolet photoinitiator formulation, or a cationic ultraviolet photoinitiator formulation. 
     
     
         16 . The designed structure of  claim 12 , wherein the designed structure is a three dimensional circuit board. 
     
     
         17 . The designed structure of  claim 12 , wherein each structural element includes a material formed from resin and a conductive material. 
     
     
         18 . The designed structure of  claim 17 , wherein the body includes a network of electrical traces formed from the conductive material, the electrical traces providing electrical functionality through the conductive material. 
     
     
         19 . The designed structure of  claim 12 , wherein the structural element is in the form of a shaped strand, and wherein the designed structure is formed by combining a series of shaped strands. 
     
     
         20 . A device comprising:
 a resin delivery mechanism positioned to deposit liquefied resin to a given target location;   a fiber source to supply a fiber to the given target location;   an energy source positioned to provide energy to resin deposited and cured at the target location, sufficient to liquefy a tip portion; and   a controller to position curation of the deposited resin at the target location, so that with manipulation of the fiber at the given location, the resin is structured into a three-dimensional structural element of a larger body.