Athletic gear or other devices comprising post-molded expandable components

Abstract

A device (e.g., an article of athletic gear) comprising a post-molded expandable component, which is a part of the device that is configured to be expanded or has been expanded after being molded. This may allow the post-molded expandable component to have enhanced characteristics (e.g., be more shock-absorbent, lighter, etc.), to be cost-effectively manufactured (e.g., by using less material and/or making it in various sizes), and/or to be customized for a user (e.g., by custom-fitting it to the user).

1 .- 228 . (canceled) 
     
     
         229 . A method of making a component, the method comprising:
 forming expandable material into an initial three-dimensional configuration at a first location such that the expandable material formed into the initial three-dimensional configuration is a precursor of the component; and   causing the precursor of the component to be moved to a second location remote from the first location for expansion of the expandable material from the initial three-dimensional configuration to an expanded three-dimensional configuration that is a scaled-up version of the initial three-dimensional configuration at the second location such that the component has the expanded three-dimensional configuration.   
     
     
         230 . The method of  claim 229 , wherein the first location is a manufacturing site and the second location is a place of business different from the manufacturing site. 
     
     
         231 . The method of  claim 230 , wherein the place of business is a store. 
     
     
         232 . The method of  claim 229 , wherein the forming is performed by a first entity and the expansion is performed by a second entity different from the first entity. 
     
     
         233 . The method of  claim 232 , wherein the first entity is a manufacturer and the second entity is a seller. 
     
     
         234 . The method of  claim 233 , wherein the seller is a retailer. 
     
     
         235 . The method of  claim 232 , wherein the first entity is a manufacturer and the second entity is a user. 
     
     
         236 . The method of  claim 229 , comprising providing an instruction for the expansion of the expandable material from the initial three-dimensional configuration to the expanded three-dimensional configuration at the second location. 
     
     
         237 . The method of  claim 236 , wherein the instruction includes at least one of an expansion temperature and an expansion time for the expansion of the expandable material from the initial three-dimensional configuration to the expanded three-dimensional configuration at the second location. 
     
     
         238 . The method of  claim 237 , wherein the instruction correlates the at least one of the expansion temperature and the expansion time to a dimension of the expanded three-dimensional configuration. 
     
     
         239 . The method of  claim 229 , comprising expanding the expandable material from the initial three-dimensional configuration to the expanded three-dimensional configuration at the second location. 
     
     
         240 . The method of  claim 229 , wherein the expansion of the expandable material from the initial three-dimensional configuration to the expanded three-dimensional configuration at the second location is performed by heating the expandable material in an oven at the second location. 
     
     
         241 . The method of  claim 239 , wherein the expanding comprises heating the expandable material in an oven at the second location. 
     
     
         242 . The method of  claim 229 , wherein the forming comprises using 3D printing. 
     
     
         243 . The method of  claim 242 , wherein the using 3D printing comprises using selective laser sintering (SLS). 
     
     
         244 . The method of  claim 242 , wherein the using 3D printing comprises using stereolithography (SLA). 
     
     
         245 . The method of  claim 242 , wherein the using 3D printing comprises 3D printing a mold and molding the expandable material in the mold. 
     
     
         246 . The method of  claim 229 , wherein the forming comprises molding the expandable material in a mold. 
     
     
         247 . The method of  claim 246 , wherein the molding comprises injection molding. 
     
     
         248 . The method of  claim 229 , wherein the expandable material comprises a polymeric substance and an expansion agent mixed with the polymeric substance. 
     
     
         249 . The method of  claim 248 , wherein the expansion agent constitutes at least 40% of the expandable material by weight. 
     
     
         250 . The method of  claim 248 , wherein the expansion agent constitutes a majority of the expandable material by weight. 
     
     
         251 . The method of  claim 248 , wherein the expansion agent comprises expandable microspheres. 
     
     
         252 . The method of  claim 248 , wherein the polymeric substance is elastomeric. 
     
     
         253 . The method of  claim 229 , wherein an expansion ratio of the expandable material is at least three. 
     
     
         254 . The method of  claim 229 , wherein an expansion ratio of the expandable material is at least five. 
     
     
         255 . The method of  claim 229 , wherein the component comprises a plurality of regions that differ in stiffness and are made of the expandable material. 
     
     
         256 . The method of  claim 255 , wherein: a first one of the regions of the component is configured to be disposed closer to a user during use of the component than a second one of the regions of the component; and the second one of the regions of the component is stiffer than the first one of the regions of the component. 
     
     
         257 . The method of  claim 229 , wherein the component comprises a plurality of portions that are at least one of curved and angular and are present in the initial three-dimensional configuration and in the expanded three-dimensional configuration. 
     
     
         258 . The method of  claim 229 , wherein the component comprises a predetermined arrangement of shaped elements that are made of the expandable material, intersect one another, and are present in the initial three-dimensional configuration and in the expanded three-dimensional configuration. 
     
     
         259 . The method of  claim 258 , wherein the shaped elements are relief elements of a texture of the component. 
     
     
         260 . The method of  claim 229 , wherein the component is configured to be part of an article wearable by a user. 
     
     
         261 . The method of  claim 260 , wherein: the article is a protective article configured to protect the user; the protective article comprises a pad; and the pad comprises the component. 
     
     
         262 . The method of  claim 261 , wherein: the protective article is a helmet configured to protect a head of the user; the helmet comprises an outer shell and a liner disposed within the outer shell; and the liner comprises the pad comprising the component. 
     
     
         263 . The method of  claim 229 , wherein the component is a pad. 
     
     
         264 . The method of  claim 229 , wherein the component is a cushion. 
     
     
         265 . A device comprising the component made by the method of  claim 229 . 
     
     
         266 . A method of making a component, the method comprising:
 forming expandable material into an initial three-dimensional configuration using 3D printing at a first location such that the expandable material formed into the initial three-dimensional configuration is a precursor of the component; and   causing the precursor of the component to be moved to a second location remote from the first location for expansion of the expandable material from the initial three-dimensional configuration to an expanded three-dimensional configuration that is a scaled-up version of the initial three-dimensional configuration at the second location such that the component has the expanded three-dimensional configuration.   
     
     
         267 . A method of making a component, the method comprising:
 forming expandable material into an initial three-dimensional configuration at a first location such that the expandable material formed into the initial three-dimensional configuration is a precursor of the component;   causing the precursor of the component to be moved to a second location remote from the first location; and   expanding the expandable material from the initial three-dimensional configuration to an expanded three-dimensional configuration that is a scaled-up version of the initial three-dimensional configuration at the second location such that the component has the expanded three-dimensional configuration.