SHAPE-ADJUSTABLE EYEWEAR TEMPLE AND/OR EAR TIP

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent No.62/232,458, filed September 25, 2015. The content of the provisional application is hereby incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

Field of the Invention

[0002] This application relates to eyewear. In particular, this application relates to eyewear frames having bendable temples and/or ear tips.

Description of the Related Technology

[0003] The temples of traditional eyewear, including their tips, can be adjusted to fit the head and ears of the wearer. These adjustments are typically made by heating the acetate temple piece and bending it to the desired shape and/or angle. When the acetate cools, the frame stiffens so that the temple piece remains in the adjusted position. In certain types of eyewear, such as 3D printed eyewear for example, the structural properties of the material used in the temple piece often causes the adjusted temple piece to revert to its original shape after it has been adjusted to fit the head of the wearer. Or, if the adjustment is too much, the structural integrity of the temple piece may suffer, and in some instance break. Accordingly, improvements are needed in the design and manufacture of eyewear temples to alleviate the problems identified above.

SUMMARY

[0004] One aspect of the present disclosure relates to an eyewear temple piece, comprising an ear tip; one or more cutouts located on a surface of the eyewear temple piece in or around the ear tip, the one or more cutouts being configured to alter a degree of flexibility of the ear tip in at least one direction; and a hollow interior portion configured to receive a support core, wherein the one or more cutouts and the hollow interior portion form a continuous cavity.

[0005] The one or more cutouts may be located on at least an inner surface of the eyewear temple piece and a bottom surface of the eyewear temple piece in relation to the head of a wearer of the eyewear temple piece when worn by the wearer. In some embodiments, each of the one or more cutouts has a shape that comprises an opening with a geometric shape, a notch, or an opening between beams of a lattice structure. In certain embodiments, all of the one or more cutouts have the same shape. At least one surface of the eyewear temple piece may be closed off with no cutouts.

[0006] In some embodiments, at least one direction comprises one or more of a downward direction and inward direction in relation to a head of a wearer of the eyewear temple piece when worn by the wearer.

[0007] In certain embodiments, the eyewear temple piece may comprise the support core received in the hollow interior portion. A material of the support core may comprise at least one of a metal and a plastic. The support core may comprise a first portion that is less flexible than a second portion of the support core. In some embodiments, the support core includes a hinge configured to connect the eyewear temple piece to a portion of the eyewear frame. The support core may comprise one or more screw holes configured to align with one or more screw holes in the eyewear temple piece.

[0008] The eyewear temple piece and a second eyewear temple piece may be coupled to a front portion of an eyewear frame.

[0009] In some embodiments, the one or more cutouts comprise a plurality of regularly- spaced cutouts on each surface of the eyewear temple piece in or around the ear tip, wherein the cutouts comprise openings with a geometric shape.

[0010] In certain embodiments, the one or more cutouts comprise a first plurality of regularly- spaced cutouts on an inner surface of the eyewear temple piece in or around the ear tip; and a second plurality of regularly-spaced cutouts on a bottom surface of the eyewear temple piece in or around the ear tip, wherein both the first and second plurality of regularly-spaced cutouts comprise notches that extend to the hollow inner portion.

[0011] In some embodiments, a portion of the eyewear temple piece in or around the ear tip comprises a lattice structure having intersecting beams, and the one or more cutouts comprise openings formed between the intersecting beams. A cross section through a portion of the eyewear temple piece in or around the ear tip may be a geometric shape, for example, the geometric shape may comprise a circle, an ellipse, a hexagon, a polyhedron, a square, or a triangle. [0012] A further aspect of the present disclosure relates to an eyewear frame comprising two eyewear temple pieces, each comprising one or more cutouts located on a surface of the eyewear temple piece in or around the ear tip, the one or more cutouts being configured to alter a degree of flexibility in the ear tip in at least one direction; and a hollow interior portion configured to receive a support core, wherein the one or more cutouts and the hollow interior portion form a continuous cavity; and a front portion of the eyewear frame configured to receive lenses.

[0013] Another aspect of the present disclosure relates to a method of manufacturing an eyewear temple piece, comprising receiving a design for an eyewear temple piece comprising one or more cutouts located on a surface of the eyewear temple piece in or around the ear tip, the one or more cutouts being configured to alter a degree of flexibility of ear tip in at least one direction; and a hollow interior portion configured to receive a support core, wherein the one or more cutouts and the hollow interior portion form a continuous cavity; manufacturing the eyewear temple piece using a powder-based additive manufacturing process; and removing powder via the one or more cutouts. In some embodiments, removing the powder comprises applying air pressure into the hollow interior portion.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1A is an example of a shape-adjustable eyewear temple piece for an eyewear frame according to one or more embodiments.

[0015] Figure IB is an example of another shape-adjustable eyewear temple piece for an eyewear frame according to one or more embodiments.

[0016] Figures 2A-2C provide an illustration of another shape-adjustable eyewear frame temple piece according to one or more embodiments.

[0017] Figure 3 is an illustration of an shape-adjustable eyewear frame temple piece with an aesthetic feature according to one or more embodiments.

[0018] Figure 4 provides an example of a metal core which can be inserted into the temple pieces shown in Figures 1-3 to provide stability and maintain an adjusted shape.

[0019] Figure 5 illustrates one example of a system for designing and manufacturing one or more embodiments of the eyewear temple pieces and support cores shown in Figures 1-4.

[0020] Figure 6 provides a more detailed view of a computer of the system of Figure 5. [0021] Figure 7 is an illustration of a general process for manufacturing one or more embodiments of the eyewear frame disclosed herein using an additive manufacturing apparatus of Figure 5.

[0022] Figure 8 is an example of an additive manufacturing apparatus that may be used to manufacture the eyewear frame temple pieces disclosed herein.

[0023] Figure 9 is a flow diagram illustrating a process for creating a three dimensional design for an eyewear frame temple piece according to one or more embodiments.

[0024] Figure 10 is a flow diagram illustrating a process for manufacturing and finishing a shape-adjustable eyewear temple piece according to one or more embodiments.

[0025] Figure 11A provides an illustration of a side view of another shape-adjustable eyewear frame temple piece according to one or more embodiments.

[0026] Figure 11B provides an illustration of a bottom-up view of the other shape- adjustable eyewear frame temple piece of Figure 11 A according to one or more embodiments.

[0027] Figure 12A provides an illustration of a top-down view of an ear tip of an eyewear temple piece according to one or more embodiments.

[0028] Figure 12B provides an illustration of a side view of the ear tip of the eyewear temple piece of Figure 12A according to one or more embodiments.

[0029] Figure 13A-13E provide illustrations of exemplary cross sectional shapes of the eyewear temple pieces.

[0030] Figures 14A-14D provide illustrations of another shape-adjustable eyewear frame temple piece according to one or more embodiments.

DETAILED DESCRIPTION OF CERTAIN INVENTIVE EMBODIMENTS

[0031] Embodiments of the inventions disclosed herein relate to eyewear temple pieces which can be adjusted by bending in order to better fit the head of the wearer. The eyewear temple pieces may be 3D printed eyewear temple pieces, produced using powder-based additive manufacturing technologies such as selective laser sintering, for example. The eyewear temple pieces disclosed herein may be part of a larger 3D printed eyewear frame. The 3D printed eyewear frame may be designed to conform to the facial features of the wearer. For example, the front portion of the eyewear frame may be sized and dimensioned using 3D scan data of the wearer's face. Thus, the front portion of the eyewear frame may be 3D printed to provide an optimal fit and look for the wearer. The eyewear frame may include the front portion and two eyewear temple pieces, as described herein, coupled to the front portion of the eyewear frame. The front portion of the eyewear frame may be configured to hold or secure optical lenses.

[0032] While the front portion of the eyewear frame can be customized based on scanning data of the wearer's face, in most scenarios it is only the face of the wearer that is scanned. The sides and the back of the head of the wearer are not scanned. Thus, while the specific facial features of the wearer may be taken into consideration when creating the eyewear design, the regions of the wearer behind the face and in particular behind the ear may not be available to the designer. Although the front portion of the eyewear frame may be optimized and designed to specifically fit the face of the wearer, the lack of scanned data for the side of the head and behind the ear results in eyewear frame temple pieces which may require adjustment for an optimal fit.

[0033] In many applications, 3D printed eyewear temple pieces are made using a powder-based 3D printing technology. The inventors have recognized that the materials used to produce eyewear temple pieces using 3D printing technology (also referred to as additive manufacturing technology) may have a certain degree of flexibility, but also a high degree of resilience. As a result, to the extent a 3D printed eyewear temple piece can be bent to better fit to the head of the wearer, it generally reverts back to its original shape. To overcome these problems, the inventors have found that by changing the wall thickness of the 3D printed eyewear temple piece, and by removing material at certain locations in the design, the eyewear temple piece may be given a high degree of flexibility in certain areas. The material may be removed from the eyewear temple piece design using one or more cutouts which are located in the area in and around the ear tip of the eyewear temple piece. The position and shape of the cutouts influence the direction in which and the ease with which the ear tip can bend in a certain direction. For example, placing cutouts on the lower surface of the eyewear temple piece, while leaving the top portion fully enclosed, results in an ear tip which tends downward with relative ease. It should be noted, though the use of cutouts as described herein is mostly described with respect to cutouts in or around an eartip of the eyewear temple piece, in some aspects, the cutouts may be made additionally or alternatively in other sections of the eyewear temple piece. For example, the cutouts may be made near a front portion of an eyewear temple piece, such as to create a flexible hinge like structure between the eyewear temple piece and a front portion (e.g., including one or more lenses) of an eyewear frame.

[0034] 3D printed eyewear temple pieces may be printed as hollow tubes. The hollow tube design may be used in order to utilize less material, and also to reduce the weight of the eyewear frame as a whole. The inventors have recognized, however, that when creating hollow tubes using powder-based 3D printing technology, it can be very difficult to remove the powder inside the tube after the item has been manufactured. This is especially the case where the tube diameter is relatively small, and there are few openings in the hollow tube from which powder may escape. In these situations, a manual process may be needed to remove the powder. Powder removal may be achieved by utilizing a wire brush which is inserted into the chamber and used to loosen the powder debris and remove it from the chamber. By including cutouts in the eyewear temple piece design, the difficulty of removing powder from inside the temple piece is meaningfully reduced. Moreover, the use of cutouts in the eyewear temple piece design allows for powder removal to be effectively achieved using air pressure, making the labor-intensive process of brushing the inside no longer necessary. For example, in some aspects, the cutouts and the hollowed interior portion of the eyewear temple pieces may form a continuous cavity to allow for powder removal.

[0035] As noted above, many of the materials used to create eyewear temple pieces using additive manufacturing technologies tend to return to their original shape after they have been bent in a certain direction. This problem does not arise in the context of traditional eyewear frames, because those temple pieces are typically made from acetate and will hold their shape after they have been heated and bent. In order to ensure that the eyewear temple pieces disclosed herein maintain their shape after having been bent in a specific direction, the inventors have added a support core inside the temple which helps to ensure that it keeps its shape after it has been bent to fit to the wearer's head. The support core may be made of metal, and it can be integrated with a hinge that is used to connect the temple piece with the front portion of the eyewear frame.

[0036] Figure 1A is an example of a shape-adjustable eyewear temple piece 100 for an eyewear frame according to one or more embodiments. As noted above, the shape-adjustable eyewear temple piece 100 may be created using additive manufacturing technologies such as, for example, selective laser sintering. Various types of additive manufacturing devices may be used to manufacture the eyewear temple pieces described herein. For example, additive manufacturing devices from suppliers such as EOS (P100, P300, P 700, P800 type platforms), 3D Systems (SPro and Spro X types), Farsoon (platform types 400, 250, Syntratec) may all be used. The eyewear temple piece 100 may be made from various types of powder-based materials. These materials may include polyamide powders such as PA 12, PA 11, PA 6, polyarylketones such as PEEK, PEKK and PAEK, thermoplastic polyurethane (TPU), polycarbonate, polystyrene, polyesters, polypropylene, polyethylene, polyetherimides, polysulfon ethers, and sulfon polymers in general.

[0037] As shown, the eyewear temple piece 100 includes a front portion 102 and a rear portion 104, which may also be referred to herein as an ear tip portion. Included in the front portion 102 is an opening 106, which may take the form of an annulus. The opening 106 leads to a hollowed interior portion of the eyewear temple piece 100. The hollow portion may extend throughout the eyewear temple piece to its distal end 114. In some aspects, the hollow portion may extend through only a portion of the eyewear temple piece 100. The front portion 102 may also include a screw hole 108, which as will be explained below, may be used to the secure a support core and a hinge within the hollow center of the eyewear temple piece.

[0038] The ear tip portion 104 may include various cutouts such as cutouts 110 (located on the bottom surface) and cutouts 112 (located on the inner surface). As shown, the cutouts 110 create flexibility in the downward direction, as indicated by the black arrows in the downward direction. Similarly, the cutouts 112, which are positioned on the inner surface of the eyewear temple piece 100, create flexibility in an inward direction, typically toward the head of the wearer. In this example, the top surface of the ear tip portion 104 is closed off, with no cutouts. As a result, there is a relatively small degree of flexibility in an upward direction in this particular design. In some aspects, the cutouts 110 and/or 112 may form a continuous cavity with the hollowed interior portion. In certain aspects, directions (e.g., downward, inward, upward, etc.) and locations (e.g., bottom, top, side, etc.), as described herein, may be in relation to a head of a wearer of eyewear including embodiments of the eyewear temple piece when worn by the wearer.

[0039] Turning now to Figure IB, another example of a shape-adjustable eyewear temple piece 120 is provided. This particular design is similar to that shown in Figure 1 A, but includes additional cutouts which will now be described. The eyewear temple piece 120 includes a front portion 122 and an ear tip portion 124. As with the design shown in Figure 1 A, the front portion 122 includes an opening 126 into the hollow interior portion of the eyewear temple piece 120. It also includes a screw hole 128 which may be used to affix a hinge piece or support core (or both) within a hollowed interior portion which may extend to the distal end 136 of the eyewear temple piece 100. In some aspects, the hollow portion may extend through only a portion of the eyewear temple piece 100.

[0040] The bottom surface of the ear tip portion 124 includes several cutouts 130. These cutouts 130 create downward flexibility as indicated by the arrows below. In some aspects, the cutouts 130, 132, and/or 134 may form a continuous cavity with the hollowed interior portion. The embodiment shown in Figure IB also includes cutouts 132 on the inner surface, similar to that of the design shown in Figure 1A. (Not all of the inner surface cutouts 132 are specifically called out in this example). In addition, a series of cutouts 134 are provided on the top surface of the ear tip portion 124 of the eyewear temple piece 120. As indicated by the upward pointing arrows, these cutouts provide a degree of flexibility in an upward direction.

[0041] Figures 2A-2C provide an illustration of another eyewear frame temple piece according to one or more embodiments. In this particular example, cutouts are placed in the lower surface and inner surface of the eyewear frame temple piece. However, the cutouts are more significant than those shown in Figures 1A and IB, making the eyewear frame temple piece 200 more flexible in those directions.

[0042] Turning to Figure 2A, a side view of an eyewear temple piece 200 is shown. The eyewear temple piece 200 includes a front portion 202 and an ear tip portion 204. The front portion, as was the case with prior embodiments, includes an opening 206 into the hollowed out interior of the eyewear frame temple piece 200. The front portion 202 also includes a screw hole 208 which may be used to secure the eyewear frame temple piece 202 a hinge or a support core positioned within the hollowed temple piece 200. The hollowed out area may extend through the entire eyewear temple piece 200 to its distal end 214. In some aspects, the hollow portion may extend through only a portion of the eyewear temple piece 200. As shown, the ear tip portion 204 includes cutouts 210 which have been positioned in and around the lower surface of the ear tip portion 204. In this embodiment, the cutouts are larger and take up more surface area on the outer surface of the ear tip portion 204 than the cutouts shown in Figures 1 A and IB. The ear tip portion 200 also includes cutouts 212 across the inner surface (the surface closest to the wearer's head). These cutouts will allow for movement toward the ear and head of the wearer. In some aspects, the cutouts 210 and/or 212 may form a continuous cavity with the hollowed interior portion.

[0043] Figure 2B is a top-down view of the eyewear temple piece 200 shown in Figure 2A. In this top-down view, the apertures 212 which are on the inner surface of the ear tip portion are visible, while the cutouts 210 which are positioned on the lower surface of the ear tip portion are not, as they are hidden from view. Figure 2C is a cross-section of the side view from Figure 2A. This cross section view shows the hollowed out portion 220 which extends through the entire eyewear temple piece 200 until it reaches the distal portion 214.

[0044] Figures 12A and 12B are an illustration of an ear tip portion 1204, which is similar to ear tip portion 204. As in Figures 2A and 2B, cutouts are placed in the lower surface and inner surface of the eyewear frame temple piece. However, the cross-sectional shape of the ear tip in Figure 12A and 12B is a square, while the cross-sectional shape of the ear tip in Figures 2 A and 2B is a circle.

[0045] Figure 12A is a top-down view of the ear tip portion 1204. In this top-down view, the apertures 1212 which are on the inner surface of the ear tip portion are visible, while the cutouts 1210 which are positioned on the lower surface of the ear tip portion are not, as they are hidden from view.

[0046] Figure 12B is a side view of an ear tip portion 1204. The hollowed out area may extend through the entire ear tip portion 1204 to its distal end 1214. In some aspects, the hollowed interior portion may extend through only a portion of the eyewear temple piece. As shown, the ear tip portion 1204 includes cutouts 1210 which have been positioned in and around the lower surface of the ear tip portion 1204. In this embodiment, the cutouts are larger and take up more surface area on the outer surface of the ear tip portion 1204 than the cutouts shown in Figures 1A and IB. The ear tip portion 1200 also includes cutouts 1212 across the inner surface (the surface closest to the wearer's head). These cutouts will allow for movement toward the ear and head of the wearer. In some aspects, the cutouts 1210 and/or 1212 may form a continuous cavity with the hollowed interior portion.

[0047] Figure 3 is an illustration of an eyewear frame temple piece 300 with an aesthetic function according to one or more embodiments. As shown, the eyewear frame temple piece 300 also includes a front portion 302 which is near the face of the wearer, and an ear tip portion 304 which is located distally from the front portion. The eyewear frame temple piece 300 shown in Figure 3 also includes an opening 306 in the front of the temple piece 300 which allows for insertion of a support core and/or hinge which connects the eyewear temple piece to the front of the eyewear frame. The support core may extend to the distal portion 314 of the eyewear frame temple piece 300. The front portion 302 also includes a screw hole 308 which may receive a screw in order to fixate an object to the eyewear frame temple piece 300. In this particular example, the ear tip portion in includes anesthetic design way in which a pattern of cutouts 310 is symmetrically distributed throughout the design. In this embodiment, the ear tip portion 304 may be flexible in all directions, as the cutouts are positioned uniformly around the outer surface.

[0048] Figures 11A-11B provide an illustration of another eyewear frame temple piece according to one or more embodiments. In this particular example, cutouts are placed in the lower surface of the eyewear frame temple piece. The eyewear frame temple piece 1100 is more flexible because of the cutouts.

[0049] Turning to Figure 11 A, a side view of an eyewear temple piece 1100 is shown. The eyewear temple piece 1100 includes a front portion 1102 and an ear tip portion 1104. The front portion, as was the case with prior embodiments, includes an opening 1106 into the hollowed out interior of the eyewear frame temple piece 1100. The front portion 1102 also includes a screw hole 1108 which may be used to secure the eyewear frame temple piece 1102 a hinge or a support core positioned within the hollowed temple piece 1100. The hollowed out area may extend through the entire eyewear temple piece 1100 to its distal end 1114. In some aspects, the hollowed interior portion may extend through only a portion of the eyewear temple piece 1100. As shown, the ear tip portion 1104 includes cutouts 1110 which have been positioned in and around the lower surface of the ear tip portion 1104. These cutouts will allow for movement toward the ear the wearer. In some aspects, the cutouts 1110 may form a continuous cavity with the hollowed interior portion.

[0050] Figure 1 IB is a bottom-up view of the eyewear temple piece 1100 shown in Figure 11 A. In this bottom-up view, the cutouts 1110 which are on the lower surface of the ear tip portion are visible.

[0051] Figures 13A-13D are illustrations of different structures, from a side view. Each structure 1300 may be an eyewear temple piece, portion of an eyewear temple piece, or may be an ear tip portion. Each structure has a cross-section 1316, which is a geometrical shape and has a hollow portion represented by a circle. Figure 13 A has a circular cross section. Figure 13B has a square cross section. Figure 13C has a triangular cross section. Figure 13D has a hexagonal cross section. Figure 13E is a representative shape to illustrate that the cross section of the eyewear temple piece and/or the ear tip portion of the eyewear temple piece may be any geometrical shape.

[0052] Figures 14A-14D provide an illustration of another eyewear frame temple piece 1400 according to one or more embodiments. In this particular example, a cutout 1410 is placed in the distal end 1414 of the eyewear frame temple piece 1400. The eyewear frame temple piece 1400 is more flexible because of the cutouts

[0053] Figure 14A is a side view of the eyewear temple piece 1400. The eyewear temple piece 1400 includes a front portion 1402 and an ear tip portion 1404. Each of the front portion and the ear tip portion have an opening into the hollowed out interior 1420 of the eyewear frame temple piece 1400. The front portion 1402 may also include a screw hole, groove, and/or space which may be used to secure the eyewear frame temple piece to a hinge or a support core positioned within the hollowed temple piece 1400, for example, in a manner that accommodates the shape of the hinge. The hollowed out area extends through the entire eyewear temple piece 1400 to its distal end 1414. In some embodiments, the hollowed out area extends only in the front portion 1402 or only in the ear tip portion 1404. The ear tip portion 1404 includes a cutout 1410 which is positioned at the distal end of the eyewear temple piece, but is not visible in this view. The cutout 1410 is continuous with the hollowed out interior of the eyewear temple piece.

[0054] Figure 14B is a top-down view of the eyewear temple piece 1400. In this top- down view, the cutout 1410 at the distal end of the ear tip portion 1404. Figure 14C is a cross section of the top-down view of the eyewear temple piece 1400. This cross section view shows the hollowed out portion 1420 which extends through the entire eyewear temple piece 1400 until it reaches the distal portion 1414. The end of the front portion 1402 is configured to receive a screw, hinge and/or a support core. Figure 14D shows the position of the cutout 1410 in the eyewear temple piece in the distal end of the ear tip portion.

[0055] Figure 4 is an example of a support core which can be inserted into the temple pieces shown in Figures 1-3 to provide stability and maintain an adjusted shape after the ear tip portion of the temple piece has been adjusted. As discussed above, certain materials used in selective laser sintering and other additive manufacturing technologies will revert to their original shape after they have been adjusted. The support core 400 shown in Figure 4 may be inserted into any one of the temple pieces shown in Figures 1 to 3 and Figures 11 to 14 in order to help the adjusted temple piece keep its modified shape. The support core may be made out of various materials, including various types of metal, plastics, or other materials that are able to bend and hold their shape. The support core 400 may be integrated with a hinge which connects the eyewear temple piece to the front portion of an eyewear frame. In the example shown in Figure 4 the support core includes a front portion 402 which is not flexible (or less flexible), and a flexible portion 404 (or more flexibile portion) located distally to the front portion. The flexible portion 404 may be configured to bend along with the eyewear frame temple piece in which it is inserted. Once the flexible portion of the support core 400 has been bent, it holds its shape, and in doing so prevents the eyewear frame temple piece from reverting to its original shape. In the front portion 402 there may be one or more screw holes such as screw holes 406 and 408 which allow the support core to be affixed to other parts of the eyewear frame. These parts may include the eyewear temple piece, a hinge, or even the front portion of the eyewear frame.

[0056] Embodiments of the invention may be practiced within a system for designing and manufacturing 3D objects. Turning to Figure 5, an example of a computer environment suitable for the implementation of 3D object design and manufacturing is shown. The environment includes a system 500. The system 500 includes one or more computers 502a-502d, which can be, for example, any workstation, server, or other computing device capable of processing information. In some aspects, each of the computers 502a-502d can be connected, by any suitable communications technology (e.g., an internet protocol), to a network 505 (e.g., the Internet). Accordingly, the computers 502a-502d may transmit and receive information (e.g., software, digital representations of 3D objects, commands or instructions to operate an additive manufacturing device, etc.) between each other via the network 505.

[0057] The system 500 further includes one or more additive manufacturing devices (e.g., 3D printers) 506a-506b. As shown the additive manufacturing device 506a is directly connected to a computer 502d (and through computer 502d connected to computers 502a-502c via the network 505) and additive manufacturing device 506b is connected to the computers 502a-502d via the network 505. Accordingly, one of skill in the art will understand that an additive manufacturing device 506 may be directly connected to a computer 502, connected to a computer 502 via a network 505, and/or connected to a computer 502 via another computer 502 and the network 505.

[0058] It should be noted that though the system 500 is described with respect to a network and one or more computers, the techniques described herein also apply to a single computer 502, which may be directly connected to an additive manufacturing device 506.

[0059] Figure 6 illustrates a functional block diagram of one example of a computer of Figure 5. The computer 502a includes a processor 610 in data communication with a memory 620, an input device 630, and an output device 640. In some embodiments, the processor is further in data communication with an optional network interface card 660. Although described separately, it is to be appreciated that functional blocks described with respect to the computer 502a need not be separate structural elements. For example, the processor 610 and memory 620 may be embodied in a single chip.

[0060] The processor 610 can be a general purpose processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any suitable combination thereof designed to perform the functions described herein. A processor may also be implemented as a combination of computing devices, e.g., a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration.

[0061] The processor 610 can be coupled, via one or more buses, to read information from or write information to memory 620. The processor may additionally, or in the alternative, contain memory, such as processor registers. The memory 620 can include processor cache, including a multi-level hierarchical cache in which different levels have different capacities and access speeds. The memory 620 can also include random access memory (RAM), other volatile storage devices, or non-volatile storage devices. The storage can include hard drives, optical discs, such as compact discs (CDs) or digital video discs (DVDs), flash memory, floppy discs, magnetic tape, and Zip drives.

[0062] The processor 610 also may be coupled to an input device 630 and an output device 640 for, respectively, receiving input from and providing output to a user of the computer 502a. Suitable input devices include, but are not limited to, a keyboard, buttons, keys, switches, a pointing device, a mouse, a joystick, a remote control, an infrared detector, a bar code reader, a scanner, a video camera (possibly coupled with video processing software to, e.g., detect hand gestures or facial gestures), a motion detector, or a microphone (possibly coupled to audio processing software to, e.g., detect voice commands). Suitable output devices include, but are not limited to, visual output devices, including displays and printers, audio output devices, including speakers, headphones, earphones, and alarms, additive manufacturing devices, and haptic output devices.

[0063] The processor 610 further may be coupled to a network interface card 660. The network interface card 660 prepares data generated by the processor 610 for transmission via a network according to one or more data transmission protocols. The network interface card 660 also decodes data received via a network according to one or more data transmission protocols. The network interface card 660 can include a transmitter, receiver, or both. In other embodiments, the transmitter and receiver can be two separate components. The network interface card 660, can be embodied as a general purpose processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any suitable combination thereof designed to perform the functions described herein.

[0064] Figure 7 illustrates a process 700 for manufacturing a 3D object or device, such as the eyewear temple pieces described above in connection with Figures 1-3. As shown, block 705, a digital representation of the object is designed using a computer, such as the computer 502a. For example, 2-D or 3D data may be input to the computer 502a for aiding in designing the digital representation of the 3D object. Continuing block 710, information is sent from the computer 502a to an additive manufacturing device, such as additive manufacturing device 506, and the device 506 commences the manufacturing process in accordance with the received information. The process continues to block 715, where the additive manufacturing device 506 continues manufacturing the 3D object using suitable materials, such as a polymer or metal powder. At block 720, the 3D object is generated.

[0065] Figure 8 illustrates an exemplary additive manufacturing apparatus 800 for generating a three-dimensional (3D) object. In this example, the additive manufacturing apparatus 800 is a laser sintering device. The laser sintering device 800 may be used to generate one or more 3D objects layer by layer. The laser sintering device 800, for example, may utilize a powder (e.g., metal, polymer, etc.), such as the powder 814, to build an object a layer at a time as part of a build process.

[0066] Successive powder layers are spread on top of each other using, for example, a recoating mechanism 815A (e.g., a recoater blade). The recoating mechanism 815A deposits powder for a layer as it moves across the build area, for example in the direction shown, or in the opposite direction if the recoating mechanism 815A is starting from the other side of the build area, such as for another layer of the build.

[0067] After deposition, a computer-controlled C02 laser beam scans the surface and selectively binds together the powder particles of the corresponding cross section of the product. In some embodiments, the laser scanning device 812 is an X-Y moveable infrared laser source. As such, the laser source can be moved along an X axis and along a Y axis in order to direct its beam to a specific location of the top most layer of powder. Alternatively, in some embodiments, the laser scanning device 812 may comprise a laser scanner which receives a laser beam from a stationary laser source, and deflects it over moveable mirrors to direct the beam to a specified location in the working area of the device. During laser exposure, the powder temperature rises above the material (e.g., glass, polymer, metal) transition point after which adjacent particles flow together to create the 3D object. The device 800 may also optionally include a radiation heater (e.g., an infrared lamp) and/or atmosphere control device 816. The radiation heater may be used to preheat the powder between the recoating of a new powder layer and the scanning of that layer. In some embodiments, the radiation heater may be omitted. The atmosphere control device may be used throughout the process to avoid undesired scenarios such as, for example, powder oxidation.

[0068] Turning now to Figure 9, a flow chart provide an example of a process by which a shape-adjustable 3D printed eyewear temple piece may be designed using 3D modelling software according to one or more embodiments. The process begins at block 902, where the direction of the desired flexibility is determined. Typically, an eyewear temple piece will be designed to bend inward toward the side of the head of the wearer. This is so the eyewear temple piece can be made to have a more snug fit on the head of the wearer. However, as discussed above, it may also be desirable for the eyewear temple piece to flex in other directions. For example, it may be desirable for the eyewear temple piece to flex downward. The ability to flex in a downward direction allows the eyewear temple piece to be adjusted to better fit against the ear of the wearer. And, as discussed above, in some embodiments, it may be desirable to allow the eyewear temple piece to flex in some other direction.

[0069] Once the direction of desired flex has been determined, the process moves to block 904. At block 904, the amount of desired flexibility is determined. In some designs, a high degree of flexibility may be desired, while in other designs a lower degree of flexibility may be needed. In addition, a high degree of flexibility may be desired for flexing in one direction (such as inward, for example), while a lower degree of flexibility may be desired for flexing in another direction (such as downward, for example). In addition, different parts of the eyewear frame temple piece may have different degrees of flexibility. For example, in areas near the ears and at the distal end of the eyewear temple piece, a high degree of flexibility may be desired to allow the temple piece to be fitted around the ear. In contrast, it may also be beneficial to limit the flexibility of the eyewear temple piece in locations closer to the eyewear frame front portion.

[0070] Next, the process moves to block 906, where cut up locations are determined based on the determined direction or directions of desired flex. As noted above, the cutouts may be placed in the outer surface of the eyewear temple piece which is closest to the desired direction of flexibility. For example, where downward and inward flexibility is desired for an eyewear temple piece, the determined cutout locations may be on the bottom and inner (closest to the head) surfaces of the eyewear temple piece.

[0071] Next, the process moves to block 908. There the size of the cutouts is determined. The size of the cutouts may be based on the degree of desired flex that was determined in block 904 above. For example, where high flexibility is desired, the cutouts may have a larger size (or alternatively, there may be a larger number of cutouts). In addition, because the outer wall thickness influences the flexibility of the eyewear temple piece, the outer wall thickness may also be considered in determining the size of the cutouts. In those designs having a larger outer wall thickness, larger cutouts may be needed. Conversely, in designs having a smaller outer wall thickness, there is intrinsic flexibility in the design, so fewer cutouts may be needed. For example, a design having an outer wall thickness of 2 to 3 mm may be very rigid. In contrast, an outer wall thickness of .5 mm may be extremely flexible on its own. Other outer wall thicknesses such as .8 mm or 1 mm can often provide good rigidity in areas where rigidity is needed, while still allowing for a great deal of flexibility with the addition of appropriately sized cutouts. [0072] Once the cutout locations have been determined, and the size of the cutouts have also been defined, the process moves to block 910. There, cutouts are added to the eyewear temple piece design according to the determined location and sizes of the cutouts. The process then moves to block 912, where a channel is added throughout the interior of the eyewear temple piece to receive the metal support core. Once the internal channel has been added, the process then moves to block 914 where the eyewear temple piece is manufactured and finished using an additive manufacturing device such as a selective laser sintering device as described above.

[0073] Figure 10 is a flow diagram showing a more detailed view of the manufacturing and finishing process shown in block 914 from Figure 9. The process begins at block 1001, where the eyewear temple piece 3D print design data is inputted into the additive manufacturing device. Next, the process moves to block 1003 where the additive manufacturing device creates the eyewear temple piece using a layer by layer building process. As discussed above, this process is generally a powder-based process.

[0074] Once the powder based 3D printing process has completed, the eyewear temple piece may be removed from the print area of the printer at block 1005. The process then moves to block 1007, where access powder is expelled from the hollow chamber using pressurized air. As discussed above, the addition of the cutouts to the design significantly decreases the difficulty of removing the powder from inside the eyewear temple piece. Next, the process moves to block 1009, where the metal support for is inserted into the hollow chamber. Once the metal support core has been inserted into the hollow chamber, it is then affixed to the temple piece using some sort of fixation device such as a screw or peg or some other means for securing the metal support core to the eyewear temple piece. As noted above in connection with Figure 4, the metal support core may be integral with the eyewear hinge that is used to attach the eyewear temple piece to the front of the eyewear frame.

[0075] It is to be understood that any feature described in relation to any one embodiment may be used alone, or in combination with other features described, and may also be used in combination with one or more features of any other of the embodiments, or any combination of any other of the embodiments. Furthermore, equivalents and modifications not described above may also be employed without departing from the scope of the invention, which is defined in the accompanying claims. The preceding description and the accompanying figures are directed to certain specific embodiments. The embodiments described in any particular context are not intended to limit this disclosure to the specified embodiment or to any particular usage. Those of skill in the art will recognize that the disclosed embodiments, aspects, and/or features are not limited to any particular embodiments. The devices, systems, and methods described herein may be designed and optimized for use in a variety of fields.