A method of producing a custom medical device including a splint or brace for immobilization of a selected region of a patient's body part. The custom medical device is produced in accordance with the following operations: (a) production of a three-dimensional mold of a portion of the patient's body part including the selected region onto which the desired medical device is to be placed; (b) definition of a three-dimensional shape of the desired medical device covering the selected region; (c) generation of a two-dimensional template corresponding to the defined three-dimensional shape, and which corresponds to unfolding in a two-dimensional plane of the three-dimensional shape of the desired medical device; (d) production of at least one plate of moldable material in accordance with the two-dimensional template of the desired medical device; and (e) molding of the plate of moldable material onto the three-dimensional mold to shape the desired medical device.

A method of producing a custom medical device including a splint or brace for immobilization of a selected region of a patient's body part. The custom medical device is produced in accordance with the following operations: (a) production of a three-dimensional mold of a portion of the patient's body part including the selected region onto which the desired medical device is to be placed; (b) definition of a three-dimensional shape of the desired medical device covering the selected region; (c) generation of a two-dimensional template corresponding to the defined three-dimensional shape, and which corresponds to unfolding in a two-dimensional plane of the three-dimensional shape of the desired medical device; (d) production of at least one plate of moldable material in accordance with the two-dimensional template of the desired medical device; and (e) molding of the plate of moldable material onto the three-dimensional mold to shape the desired medical device.

The present invention provides a receptacle molding apparatus, a receptacle and a receptacle molding method. The receptacle molding apparatus, which is for molding a receptacle by means of heat molding, comprises: a first mold portion comprising a body molding part, which is for molding a body of a receptacle, a skirt molding part, which extends upward from the body molding part so as to mold a skirt of the receptacle, and a flange molding part which extends in the direction from the upper end of the skirt molding part toward the outside so as to mold the lower surface of a flange of the receptacle; and a second mold portion which is provided above the first mold portion, can move vertically and enable pressure-molding of the upper surface of the flange, and has a pressing surface for pressing a sheet which is to be molded into the flange from above at a position corresponding to the flange molding part. The pressing surface comprises an extension part which is a part extending further than the inner end part of the flange molding part in the direction toward the center of the body molding part.

The present invention provides a receptacle molding apparatus, a receptacle and a receptacle molding method. The receptacle molding apparatus, which is for molding a receptacle by means of heat molding, comprises: a first mold portion comprising a body molding part, which is for molding a body of a receptacle, a skirt molding part, which extends upward from the body molding part so as to mold a skirt of the receptacle, and a flange molding part which extends in the direction from the upper end of the skirt molding part toward the outside so as to mold the lower surface of a flange of the receptacle; and a second mold portion which is provided above the first mold portion, can move vertically and enable pressure-molding of the upper surface of the flange, and has a pressing surface for pressing a sheet which is to be molded into the flange from above at a position corresponding to the flange molding part. The pressing surface comprises an extension part which is a part extending further than the inner end part of the flange molding part in the direction toward the center of the body molding part.

A molding changing apparatus having a holder, a cooling plate, and a mold set coupled to the cooling plate is disclosed. The cooling plate has at least one connecting pin disposed on the surface which is reverse to the surface where the mold set is disposed, and the holder has at least one pneumatic pin receptacle disposed thereon. The connecting pin of the cooling plate can be inserted into the connecting hole of the pneumatic pin receptacle of the holder, and the connecting pin is fastened by the pneumatic pin receptacle, thereby connecting the mold set and the cooling plate to the holder. Through the use of the connecting pin and the pneumatic pin receptacle, the mold set and the cooling plate on the holder can be changed rapidly and the efficiency of the plastic vacuum forming with mold sets is enhanced.

A molding changing apparatus having a holder, a cooling plate, and a mold set coupled to the cooling plate is disclosed. The cooling plate has at least one connecting pin disposed on the surface which is reverse to the surface where the mold set is disposed, and the holder has at least one pneumatic pin receptacle disposed thereon. The connecting pin of the cooling plate can be inserted into the connecting hole of the pneumatic pin receptacle of the holder, and the connecting pin is fastened by the pneumatic pin receptacle, thereby connecting the mold set and the cooling plate to the holder. Through the use of the connecting pin and the pneumatic pin receptacle, the mold set and the cooling plate on the holder can be changed rapidly and the efficiency of the plastic vacuum forming with mold sets is enhanced.

A thermoforming mold device (1) providing a piece with a thin wall starting with a sheet of thermoplastic material is provided. At least one (3) of two parts of the mold (3, 3′) comprises at least one means (4) of local deformation of a sheet (2′) in the mold (3, 3′) in its closed state, the at least one means (4) comprises a piece of hollow molding with a peripheral edge, which can be connected selectively to a source of suction and can be displaced between a folded position, in which the molding piece is situated in close proximity with the wall of the thermoformed piece, and a deployed position, in which the molding piece is applied under pressure with its peripheral edge against the wall of the thermoformed piece upholding the other part of the mold.

A thermoforming mold device (1) providing a piece with a thin wall starting with a sheet of thermoplastic material is provided. At least one (3) of two parts of the mold (3, 3′) comprises at least one means (4) of local deformation of a sheet (2′) in the mold (3, 3′) in its closed state, the at least one means (4) comprises a piece of hollow molding with a peripheral edge, which can be connected selectively to a source of suction and can be displaced between a folded position, in which the molding piece is situated in close proximity with the wall of the thermoformed piece, and a deployed position, in which the molding piece is applied under pressure with its peripheral edge against the wall of the thermoformed piece upholding the other part of the mold.

Methods for fabricating three-dimensional microstructures are provided. The method includes disposing a reflow material on a mold, heating the reflow material, and creating a pressure gradient across the reflow material to reflow the material towards a bottom surface of the mold. The mold includes a molding region, a boundary region, and a thermal-isolating region disposed therebetween. The molding region includes a cavity and a projection projecting upwards from a bottom surface of the cavity. The thermal-isolating region includes at least one pocket formed adjacent to and along a perimeter of the cavity of the molding region. During heating, the temperature of the molding region is higher than that of the boundary region and the thermal-isolating region controls the thermal conductivity and mass therebetween. The material reflows towards the bottom surface of the cavity and the protrusion helps shapes the reflow material to form a substantially symmetrical three-dimensional microstructure.

Methods for fabricating three-dimensional microstructures are provided. The method includes disposing a reflow material on a mold, heating the reflow material, and creating a pressure gradient across the reflow material to reflow the material towards a bottom surface of the mold. The mold includes a molding region, a boundary region, and a thermal-isolating region disposed therebetween. The molding region includes a cavity and a projection projecting upwards from a bottom surface of the cavity. The thermal-isolating region includes at least one pocket formed adjacent to and along a perimeter of the cavity of the molding region. During heating, the temperature of the molding region is higher than that of the boundary region and the thermal-isolating region controls the thermal conductivity and mass therebetween. The material reflows towards the bottom surface of the cavity and the protrusion helps shapes the reflow material to form a substantially symmetrical three-dimensional microstructure.