CUSTOMIZABLE FITTED APPARATUS

Abstract

A customizable fitted device for immobilizing injuries and a method for constructing the fitted device is provided. The fitted device can be used to stabilize an arm, wrist, hand, leg, knee, ankle, foot or other body parts through custom formation. The device can be formed by a sidewall having one or more sidewall sections that can be secured together using retaining clips positioned within retaining clip slots on the device. The device can further include one or more openings defined in the sidewall of each device section while maintaining rigidity in the sidewall. The device can be constructed by of creating a 3D image scan of the particular body part on which the device will be applied, creating a design of the device to precisely match the contours of the 3D image scan, and using a 3D printer to construct the device according to the design.

Claims

1. A method of manufacturing a customized removable body part immobilization device, the method comprising: collecting information about a body portion of a user from one or more 3D scanning devices to precisely identify a shape and one or more contours of the user's body portion; creating a 3D image model of the user's body portion from the collected information; generating a 3D model of the device by drawing a shape of the device onto the 3D image model of the user's body portion; the 3D model of the device including a first shell-section and a second shell-section that together form a sidewall, the first shell-section and the second shell-section being configured to be placed around the user's body portion and conform to each other along a first longitudinal seam and a second longitudinal seam; wherein the sidewall is configured to conform to the shape and the one or more contours of the body portion of the user as manufactured and prior to being applied to the body portion of the user, and the sidewall is substantially rigid without noticeable flexibility; manufacturing each of the first shell-section and the second shell-section using a 3D printer; and placing the first shell-section and the second shell-section around the user's body portion to immobilize the body portion.

2. The method of claim 1, further comprising reversibly attaching the first shell-section and the second shell-section to each other with one or more connectors.

3. The method of claim 1, wherein the step of generating a 3D model of the device further includes generating in the sidewall voids and corresponding structural ribs between the voids.

4. The method of claim 1, further comprising a step of combining the collected information about the user's body portion with additional design information that is non-specific to the user in order to generate the 3D model of the device.

5. The method of claim 1, wherein the device is 3D printed from a rigid plastic material.

6. The method of claim 1, wherein the step of generating a 3D model of the device includes using 3D CAD software to generate the 3D model of the device.

7. The method of claim 1, wherein each of the first shell-section and the second shell section include a first longitudinal edge and a second longitudinal edge; the first longitudinal edge of the first shell-section being configured to conform to the first longitudinal edge of the second shell-section to form the first longitudinal seam; the second longitudinal edge of the first shell-section being configured to conform to the second longitudinal edge of the second shell-section to form the second longitudinal seam; wherein the first longitudinal edge and the second longitudinal edge on each of the shell sections extend substantially perpendicular to an outer surface of the sidewall.

8. A method of manufacturing a customized removable body part immobilization device, the method comprising: collecting information about a body portion of a user from one or more 3D scanning devices to precisely identify a shape and one or more contours of the user's body portion; creating a 3D image model of the user's body portion from the collected information; combining the collected information about the user's body portion with additional design information that is non-specific to the user; generating a 3D model of the device by drawing a shape of the device onto the 3D image model of the user's body portion using the collection information and the additional design information, the device being made up of at least a first shell-section and a second shell-section that together form a sidewall; and manufacturing each of the first shell-section and the second shell-section using a 3D printer.

9. The method of claim 8, further comprising steps of placing the first shell-section and the second shell-section around the user's body portion to immobilize the body portion; and reversibly attaching the first shell-section and the second shell-section to each other with one or more connectors.

10. The method of claim 8, wherein the first shell-section and the second shell-section are configured to be placed around the user's body portion and conform to each other along a first longitudinal seam and a second longitudinal seam; and wherein the sidewall is configured to conform to the shape and the one or more contours of the body portion of the user as manufactured and prior to being applied to the body portion of the user, and the sidewall is substantially rigid without noticeable flexibility; wherein the step of generating a 3D model of the device further includes generating in the sidewall voids and corresponding structural ribs between the voids.

11. The method of claim 8, wherein each of the first shell-section and the second shell section include a first longitudinal edge and a second longitudinal edge; the first longitudinal edge of the first shell-section being configured to conform to the first longitudinal edge of the second shell-section to form the first longitudinal seam; the second longitudinal edge of the first shell-section being configured to conform to the second longitudinal edge of the second shell-section to form the second longitudinal seam; the conforming longitudinal edges thereby joining the first shell-section to the second shell-section when the shell-sections are placed around the user's body portion.

12. The method of claim 11, wherein the first longitudinal edge and the second longitudinal edge on each of the shell-sections extend substantially perpendicular to an outer surface of the sidewall; and the conforming longitudinal edges are contiguous to each other along a full length of each longitudinal edge from a first end of the device to a second end of the device.

13. The method of claim 8, wherein the device is 3D printed from a rigid plastic material.

14. The method of claim 8, wherein the step of generating a 3D model of the device includes using 3D CAD software to generate the 3D model of the device.

15. A customized removable fitted immobilization device for a body portion comprising: a sidewall formed by one or more shell-sections, the shell-sections each having a first longitudinal edge and a second longitudinal edge, wherein the first longitudinal edge and the second longitudinal edge of each shell-section collectively forms a plurality of longitudinal edges, and wherein the sidewall is configured to conform to a shape and one or more contours of the body portion of a specific user as manufactured and prior to being applied to the body portion of the specific user; at least one longitudinal sidewall seam extending longitudinally along the sidewall between an upper sidewall edge and a lower sidewall edge, wherein each longitudinal sidewall seam removably joins two longitudinal edges of the plurality of longitudinal edges such that the two longitudinal edges making up the longitudinal side wall seam are directly contiguous to each other; wherein the plurality of longitudinal edges of each of the one or more shell-sections are configured so as to conform to a corresponding longitudinal edge of another of the one or more shell-sections such that corresponding longitudinal edges conform to each other so as to join the shell-sections together when the shell-sections are placed around the body portion; wherein the sidewall is substantially rigid without noticeable flexibility.

16. The customized removable fitted immobilization device of claim 15, wherein the first longitudinal edge and the second longitudinal edge on each of the one or more shell-sections extend substantially perpendicular to an outer surface of the sidewall.

17. The customized removable fitted immobilization device of claim 15, wherein the corresponding longitudinal edges are contiguous to each other along a full length of each longitudinal edge from a first end of the device to a second end of the device.

18. The customized removable fitted immobilization device of claim 15, wherein . . . wherein the sidewall has a plurality of voids defined in the sidewall, and a configuration of the plurality of voids defines a plurality of structural ribs, each structural rib located between two or more voids of the plurality of voids, and the plurality of voids is arranged in a configuration that provides structural stability for the device.

19. The customized removable fitted immobilization device of claim 15, wherein the device includes a primary opening at each of the first end of the device and the second end of the device, and further includes at least one secondary opening.

20. The customized removable fitted immobilization device of claim 15, wherein the device includes two or more shell-sections, and the two or more shell-sections are reversibly attached to each other by one or more connectors.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The disclosure can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the disclosure. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views.

[0011] In the accompanying drawing, which forms a part of the specification and is to be read in conjunction therewith in which like reference numerals are used to indicate like or similar parts in the various views:

[0012] FIG. 1 is a front perspective view of a fitted device for immobilizing a lower arm of a user in accordance with one embodiment of the present invention;

[0013] FIG. 2 is a side perspective view of the fitted device of FIG. 1;

[0014] FIG. 3 is a rear perspective view of the fitted device of FIG. 1;

[0015] FIG. 4 is a side perspective view of the fitted device of FIG. 1;

[0016] FIG. 5 is an exploded perspective view of the fitted device of FIG. 1, illustrating a first section and a second section of the fitted device separated prior to being applied to a user's arm in accordance with one embodiment of the present invention;

[0017] FIG. 6 is a front perspective view of the fitted device of FIG. 1, illustrating the fitted device applied to a user's arm in accordance with one embodiment of the present invention;

[0018] FIG. 7 is a front perspective view of a fitted device for immobilizing a hand of a user in accordance with one embodiment of the present invention;

[0019] FIG. 8 is a front perspective view of the fitted device of FIG. 7;

[0020] FIG. 9 is a rear perspective view of the fitted device of FIG. 7;

[0021] FIG. 10 is a side perspective view of the fitted device of FIG. 7;

[0022] FIG. 11 is an exploded perspective view of the fitted device of FIG. 7, illustrating a first section and a second section of the fitted device separated prior to being applied to a user's hand in accordance with one embodiment of the present invention;

[0023] FIG. 12 is a rear perspective view of the fitted device of FIG. 7, illustrating the fitted device applied to a user's hand in accordance with one embodiment of the present invention;

[0024] FIG. 13 is a top perspective view of a connector used to secure two sections of a fitted device in accordance with one embodiment of the present invention;

[0025] FIG. 14 is a perspective view of a connector and fitted device for immobilizing a user's hand in accordance with one embodiment of the present invention, illustrating the connector inserted into a receiver slot and holding two sections of the fitted device together;

[0026] FIG. 15 is a section plan view of the fitted device of FIG. 3, illustrating a connector inserted into a receiver slot for holding a first section and a second section of the fitted device together; and

[0027] FIG. 16 is a perspective view of a connector and fitted device fitted device for immobilizing a user's hand in accordance with one embodiment of the present invention, illustrating the connector inserted into a receiver slot and holding two end of the fitted device together.

DETAILED DESCRIPTION

[0028] The invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. For purposes of clarity in illustrating the characteristics of the present invention, proportional relationships of the elements have not necessarily been maintained in the drawing figures.

[0029] The following detailed description of the invention references specific embodiments in which the invention can be practiced. The embodiments are intended to describe aspects of the invention in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments can be utilized and changes can be made without departing from the scope of the present invention. The present invention is defined by the appended claims and the description is, therefore, not to be taken in a limiting sense and shall not limit the scope of equivalents to which such claims are entitled.

[0030] The present invention is directed toward a fitted device 10. FIG. 1 illustrates one embodiment of the present invention, where device 10 is configured for application to a user's arm. FIG. 7 illustrates another embodiment of the present invention where device 10 is configured for application to a user's hand. As illustrated in the various figures, device 10 can be configured for application to an arm or hand of a human user; however, device 10 can also be suitable for application to other limbs or body parts, such as a leg or foot. Additionally, device 10 as described herein may be used for animals of all types and sizes.

[0031] Device 10 can be used to support, stabilize and/or immobilize a limb or similar target area of a user by forming a partially enclosed structure around the target area. Device 10 can be formed as a substantially rigid structure without noticeable flexibility or device 10 can be formed with semi-flexible properties in all or some of device 10 depending on the particular intended application of device 10. Device 10 can also substantially conform to the shape and contours of the target area by forming device 10 in accordance with a method of construction as described in greater detail below. As also described below, device 10 can be comprised of one or more sections that can enable device 10 to be easily applied, removed and re-applied to a user without damage to device 10.

[0032] As shown throughout the various figures, device 10 can comprise a generally enclosed sidewall 12 having a plurality of voids 14 defined therein. Voids 14 can have any number of different sizes and shapes and can be configured into particular patterns or non-uniformly entangled formations across sidewall 12. As shown in FIG. 1, and in accordance with one embodiment of the present invention, voids 14 can be positioned in a certain configuration within sidewall 12 so as to form a plurality of structural ribs 16 between voids 14. This configuration of voids 14 and ribs 16 can reduce the amount of material necessary to form device 10 and maintain rigidity of device 10 while providing the device with lightweight properties and enabling ventilation and breathability of device 10 with regard to the user's limb or other target area where device 10 is applied while conforming to manufacturing requirements.

[0033] Device 10 can further comprise one or more shell-sections 18, which can be joined together to form the enclosed sidewall 12. As shown in FIG. 16, device 10 comprises a shell-section 18, which can be joined at its ends 26 and 28 to form the enclosed sidewall 12. As shown in FIGS. 5 and 11, device 10 can comprise a shell-section 18 and a shell-section 20, which can be joined together to form the enclosed sidewall 12. Device 10 can also comprise more than two sidewall sections in alternative embodiments of the present invention (this alternative embodiment is not shown in the figures).

[0034] In an embodiment where device 10 includes one shell-section 18, sidewall 12 can include a sidewall seam 22 defined longitudinally through sidewall 12. Sidewall seam 22 can define a first and a second longitudinal ends 26 and 28 of shell-section 18, which join together to form sidewall seam 22. Sidewall seam 22 can be configured in a general wave-like configuration or a generally straight configuration. Alternative configurations can also be used, especially configurations that further the structural stability of the device 10. A wave-like configuration can also be configured to provide structural stability of the device 10.

[0035] As best illustrated in FIGS. 1 and 3, in an embodiment where device 10 includes shell-sections 18 and 20, shell-sections 18 and 20 can be defined by sidewall seams 22 and 24 defined longitudinally through sidewall 12 and thereby separating sidewall 12 into shell-sections 18 and 20. As shown in FIGS. 1 and 3, when both shell-sections 18 and 20 form sidewall 12, shell-section 18 has first and second longitudinal edges 26 and 28 that correspond to first and second longitudinal edges 30 and 32 of shell-section 20. Longitudinal edges 26 and 30 combine to form first seam 22 while longitudinal edges 28 and 32 combine to form second seam 24. As shown in FIG. 3, seams 22 and 24 (along with corresponding longitudinal ridges 26-32) can be configured in a general wave-like pattern, as shown in FIG. 3, or can have a straighter configuration as shown in FIG. 7. Other configurations or orientations can also be used for seams 22 and 24 so long as seams 22 and 24 are suitable for joining shell-sections 18 and 20 together. Seams 22 and 24 can be formed (and correspondingly, enclosed sidewall 12) when first longitudinal edge 26 of shell-section 18 is joined to conforming first longitudinal edge 30 of shell-section 20 and second longitudinal edge 28 of shell-section 18 is joined to conforming second longitudinal edge 32 of shell-section 20. When shell-sections 18 and 20 are joined together at seams 22 and 24 to form enclosed sidewall 12, adjacent longitudinal edges 26 and 30 and 28 and 32 can be positioned with minimal space defined between.

[0036] Enclosed sidewall 12 can also define primary end openings 34 and 36 of device 10 at sidewall's 12 terminal or axial ends, as best illustrated in FIGS. 4 and 14. Primary end openings 34 and 36 can accommodate a user's arm, hand, fingers, leg, foot, etc. extending away from device 10 in either direction. Depending on the particular application or use, device 10 can also include secondary openings 38 for thumbs, fingers or similar extremities. As shown in FIG. 2, device 10 can include a secondary opening 38 for receiving a user's thumb, according to one embodiment of the present invention.

[0037] Device 10 can also include one or more connector receiver pairs 40 located on seams 22 and/or 24 and comprising two connector receivers 42. As described below, each connector pair 40 can be separable into two portions to allow shell-section 18 to be separated at its ends 26 and 28 or to be separated from shell-section 20. FIG. 2 illustrates one embodiment of device 10 having two receiver pairs 40 along each seam 22 and 24 while FIGS. 9 and 10 illustrate another embodiment of device 10 having only one receiver pair 40 along each seam 22 and 24. FIG. 16 illustrates yet another embodiment of device 10 having only one receiver pair along seam 22, which connects the first and second longitudinal ends 26 and 28 of shell-section 18 together. Any number of additional combinations of receiver pairs 40 may be suitable depending on the particular configuration and shape of device 10. Receiver pairs 40 can be used in conjunction with connectors 44 to secure and hold shell-sections 18 and 20 together along seams 22 and 24, as best shown in FIG. 14, or to secure shell-section 18 together at its ends 26 and 28, as best shown in FIG. 16.

[0038] Each connector receiver 42 can extend axially away from sidewall 12 adjacent to seam 22 or 24 (and corresponding longitudinal edge 26-32) as best shown in FIG. 11. As also shown in FIG. 11, each connector receiver 42 can also have first and second raised sidewalls 46 and 48 and a top wall 50 extending therebetween and defining the upper boundary of the receiver 40. Defined within each connector receiver 40 can be a slot 52 extending from first raised sidewall 46 to second raised sidewall 48 for receiving a section of connector 44.

[0039] As shown in FIG. 11, second raised sidewall 48 of each receiver 42 can conform to the corresponding longitudinal edge 26-32 adjacent to the receiver 42 so that each receiver 42 does not extend beyond seam 22 or 24 and first and second shell-sections 18 and 22 can be joined at seams 22 and 24 with a conforming fit. As best shown in FIGS. 1 and 3, each connector receiver 42 on first longitudinal edge 26 of shell-section 18 corresponds to each connector receptacle 42 on first longitudinal edge 30 of shell-section 20 so that the receivers 42 align along seam 22 and form receiver pairs 40. Similarly, each connector receiver 42 on second longitudinal edge 28 of shell-section 18 can align with each connector receiver 42 on second longitudinal edge 32 of section-shell 18 to form receiver pairs 40. Alternatively, when sidewall 12 comprises only one shell-section 18, as shown in FIG. 16, each connector receiver 42 on first longitudinal edge 26 corresponds to a connector receiver 42 on second longitudinal edge 28 so that the receivers 42 align along seam 22 to form a receiver pair 40. Pursuant to this alignment, slots 52 of corresponding connector receivers 42 in a receiver pair 40 align to form a continuous slot or opening 52 through the receiver pair 40 when shell-sections 18 and 20 are joined together, as best shown in FIG. 8, or when ends 26 and 28 of shell-section 18 are joined together, as best shown in FIG. 16.

[0040] Connectors 44 can be used to lock receivers 42 in each connector receiver pair 40 together to join shell-section 18 at its ends as shown in FIG. 16, or to join shell-section 18 and 20 together as shown in FIG. 14. Connectors 44 can comprise many different types of fasteners depending on the particular embodiment of the present invention. FIG. 13 illustrates one specific embodiment of connector 44 in the form of a clip. As shown in FIG. 13, clip 44 can comprise an upper arm 54 and a lower arm 56 connected together by a resilient bridge 58 at one end of each arm. At its end opposing bridge 58, clip 44 can include a retaining rib 60 extending downward from upper arm 54 into a groove 62 defined in lower arm 56. Retaining rib 60 can include a lower edge 64 that has an inward-extending lip 66 as best shown in FIG. 13. Lip 16 facilitates securing connector pairs 42 together as described in greater detail below. Resilient bridge 58 allows upper arm 54 (and attached rib 60) to be flexed upward away from lower arm 56 by a user to fasten clip 44 to receptacle pair 40, as also described in greater detail below.

[0041] Lower arm 56 can be configured to be inserted into and through receiver slots 52 of a connector receiver pair 40 when joined together. According to this configuration, lower arm 56 preferably has a thickness Tc that is less than a height Tr of receiver slot 52 of receiver pair 40 as best shown in FIG. 15. Lower am1 56 also preferably has a width Yc that is less than a width Yr of receiver slot 52 as best shown in FIG. 14. As shown in FIG. 15, the distance between resilient bridge 58 and retaining rib 60 is preferably slightly greater than the length of receiver pair 40 so that clip 44 tightly joins receptacles 42 together.

[0042] Connectors 46 can also comprise any number of alternative embodiments that are suitable for maintaining a joined connected between first and second shell-halves 18 and 20. In an alternative embodiment (not shown), receiver slots 52 of each receiver pair 40 include a divider wall (not shown) that allows a cord, string, wire or similar tie to semi-permanently secure receivers 42 of each receiver pair 40 together.

[0043] As best shown in FIG. 5, prior to use, shell-sections 18 and 20 can be separated from one another. Device 10 can then be used by positioning shell-sections 18 and 20 around the user's target area (such as an arm or leg) and joining first longitudinal edges 26 and 30 to form seam 22 and joining second longitudinal edges 28 and 32 to form seam 24, as best illustrated in FIG. 6. When shell-sections 18 and 20 are joined together along seams 22 and 24, corresponding connector receivers 42 of each receiver pair 40 can be joined together. In an embodiment where sidewall 12 comprises only shell-section 18, the longitudinal ends 26 and 28 can be separated along seam 22 until device 10 can be applied to the target area of the user, where longitudinal seams 26 and 28 can be joined back together.

[0044] Connectors 44 can then be used to lock or secure shell-sections together as shown in FIGS. 14-16. When a clip 44 is used as shown in FIGS. 14-16, lower arm 56 of each clip 44 can be inserted into receiver slot 52 of the corresponding receiver pair 40 by raising upper arm 54 away from lower arm 56 until the distance between a lower edge 64 of retaining rib 60 and lower arm 56 is greater than the width top wall 50 of receivers 42. Once lower arm 56 of clip 44 is fully inserted through slot 52, retaining rib 60 snaps downward partially into groove 62 to lock clip 44 in place due to the resiliency of bridge 58. When fully inserted, clip 44 restricts receivers 42 in a receiver pair 40 from separating because top walls 50 of each receiver 42 enclosed by upper arm 54, lower arm 56, resilient bridge 58 and retaining rib 60 of clip 44. Lip 66 on retaining rib 64 can also be positioned partially within slot 52 and thereby prevent upper am1 54 and lower arm 56 from separating. After all clips 44 are inserted into each receiver pair 40 and enclosed around top walls 50, device 10 can be rigidly secured and sidewall 12 can form around the user's arm or other target area.

[0045] Device 10 can then be removed from the user by removing connectors 44 and separating first and second shell sections 18 and 20. Because lip 66 can be partially inserted into slot 52, a user can be required to push the resilient bridge laterally against the first sidewall 36 of connector receiver 42 in order to allow lip 66 to exit slot 52. Connectors 44 can then be removed by lifting upper arm 56 away from lower arm 58 and sliding lower arm 58 out of slot 52. Once all connectors 44 are removed from receiver pairs 40, shell-sections 18 and 20 can be removed from the user. Alternatively, when sidewall 12 includes one shell-section 18, longitudinal ends 26 and 28 can be separated in or to allow the device 10 to be removed from the user. Device 10 can then be reapplied in the manner described above.

[0046] Collectively, connectors 44 and receiver pairs 40 provide structural stability for the device 10. Each connector 44 can securely hold the connector receivers 44 within a connector receiver pair 40 together and restrict movement along several different directional axes. The sizing of the upper arm 54 and lower arm 56 thicknesses in relation to the top wall 50 thicknesses of the connector receivers 42 restricts movement of one longitudinal end 26-32 relative to another longitudinal end 26-32 along sidewall seam 22 or 24 in a first direction. Lip 66 on retaining rib 64 also assists in preventing this direction of movement by preventing upper and lower arms 54 and 56 from separating unless lip 66 is removed from slot 52. The length of clip 44 between resilient bridge 58 and retaining rib 60 relative to the length of a connector receiver pair 40 restricts movement of a paired longitudinal ends 26-32 relative to one another along seam 22 or 24 in a second direction. Resilient bridge 58 and retaining rib 60 also restrict movement of paired longitudinal ends 26-32 relative to one another along seam 22 or 24 in a third direction. As a result, device IO can maintain structural rigidity about sidewall 12 when connectors 44 are secured onto clip receiver pairs 40.

[0047] Device 10 can be sized, constructed, and designed according to a number of different methods or processes. According to one process, different information can be collected about the intended user of the device. Such information can be collected by various types of equipment, such as scanners and other similar devices. Some or all of this information can also be collected manually. The collected information can then be used to design device 10 according to specific parameters. The information can be used in conjunction with one or more computer analysis programs or software, and other technology in order to develop the design of device 10. The information can also be in a human design process to develop device 10.

[0048] The design of device 10 can take into account several different parameters. For example, the design can be dependent on the user, the intended application of device 10, desired immobilization, desired stability, size, shape, temperature, conditions, etc., each of which can affect the material used, the type of scanning device or printer used, and the like. According to one process, the information collected is used to design a device 10 specifically customized to a user with lightweight, breathable, waterproof, and structural stability properties. Further, the process can incorporate additional factors, such as the degree of removability, degree of immobilization of the target area, among others. Based on the foregoing, the design process, according to one embodiment of the present invention, can collect different information specific to a user, combine the collected information with additional design information non-specific to the user, combine, manipulate, and factor the collected and additional information using computer implemented devices, a human design process or a combination of the two in order to develop the design of device 10 specifically adapted to the user in structure and functionality.

[0049] According to one method, device 10 can be formed using a 3D scanner to precisely identify the shape and contours of the user's target area. The 3D scanner can incorporate a hand-held, white-light reflective scanner that can be selectively positioned around the user's arm or other body part in which device 10 will be applied to create a 3D image of the target area. Additional information can be collected and incorporated in certain applications. 3D CAD software, along with other design software, can then be used to design the device 10 to precisely fit around 3D image by effectively drawing the shape of the device 10 onto the 3D image model. Voids 14 and corresponding structural ribs 16 can then be selectively designed into device 10. Seams 22 and/or 24 can then be provided onto the design of device 10 to form shell-section 18 and shell-section 20, if applicable. Connector receiver pairs 40 can then be provided onto device 10 along seams 22 and/or 24. Connectors 44 can also be designed to correspond to receiver pairs 40. Device 10 can then be constructed by printing each shell-section 18 and 20 (if applicable) using a 3D printer. Device 10 can be constructed from several different materials depending on the particular application of device 10. Device 10 can be constructed from a uniform material or a combination of materials. The specific material used can affect the flexibility, rigidity, structural stability, weight and other properties of the device. In one embodiment, device 10 is constructed from a rigid material such as rigid plastic. In an alternative embodiment, device 10 is constructed from a semi-rigid or semi-flexible material, such as flexible plastic or woven fabric material.

[0050] From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects hereinabove set forth together with other advantages which are inherent to the structure. It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims. Since many possible embodiments of the invention may be made without departing from the scope thereof, it is also to be understood that all matters herein set forth or shown in the accompanying drawings are to be interpreted as illustrative and not limiting.

[0051] The constructions described above and illustrated in the drawings are presented by way of example only and are not intended to limit the concepts and principles of the present invention. Thus, there has been shown and described several embodiments of a novel invention. As is evident from the foregoing description, certain aspects of the present invention are not limited by the particular details of the examples illustrated herein, and it is therefore contemplated that other modifications and applications, or equivalents thereof, will occur to those skilled in the art. The terms having and including and similar terms as used in the foregoing specification are used in the sense of optional or may include and not as required. Many changes, modifications, variations and other uses and applications of the present construction will, however, become apparent to those skilled in the art after considering the specification and the accompanying drawings. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention which is limited only by the claims which follow.