Method of forming a functional razor cartridge

1. A method of forming a functional razor cartridge for repeated shaving, said method comprising the steps of:

a) rapid prototyping a housing of said razor cartridge, wherein said housing comprises a front wall, a rear wall and opposing side walls disposed transverse to and between said front and rear walls;

b) rapid prototyping a metal insert, the metal insert comprising a front wall, a rear wall, opposing side walls disposed transverse to and between said front and rear walls and a strut ( 38 ) extending between the front and rear walls;

c) wire eroding said opposing side walls and said strut to form slots for receiving therein said one or more elongate blade assemblies;

d) loading the metal insert with one or more elongate blade assemblies; and

e) disposing said metal insert in the housing such that said one or more blade assemblies extend between said opposing side walls.

2. A method as claimed in claim 1 , wherein the housing is formed in layers and step a) comprises:

f) applying ultra-violet light to a first layer of ultra-violet curable resin to form a first layer of said housing;

g) displacing said first layer of said housing to grant exposure of the ultra-violet light to a second layer of ultra-violet curable resin;

h) applying ultra-violet light to said second layer of ultra-violet curable resin to form a second layer of said housing;

i) repeating steps g) and h) for the second and subsequent layers of ultra-violet curable resin to form said housing.

3. A method as claimed in claim 2 , wherein the ultra-violet curable resin has suspended therein a filler.

4. A method as claimed in claim 2 , wherein the filler is aluminum-oxide.

5. A method as claimed in claim 1 , wherein the method of rapid prototyping of step a) is digital light processing.

6. A method as claimed in claim 1 , wherein step b) comprises:

melting metal powder with a laser beam; and

fusing said melted metal powder to form said metal insert.

7. A method as claimed in claim 6 , wherein said metal powder is stainless steel.

8. A method as claimed in claim 1 , wherein the method of rapid prototyping of step b) is direct laser metal sintering.

9. A method as claimed in claim 1 , wherein the razor cartridge comprises a connecting member pivotally attached to an underside of the housing, wherein said connecting member comprises a receiving member that pivotally connects the housing to a razor handle, wherein the method further comprises:

j) rapid prototyping said connecting member.

10. A method as claimed in claim 9 , wherein step j) comprises using a laser to fuse together small particles to form said connecting member, wherein said small particles are small particles of nylon.

11. A method as claimed in claim 9 , wherein the method of rapid prototyping of step j) is selective laser sintering.