Systems and methods for creating soft deformable high-density haptic bubble displays

1. A method comprising:

creating a computer-generated model for a haptic feedback system comprising:

a plurality of actuators arranged in a first layer of the haptic feedback system; and

a plurality of channels routed in a second layer of the haptic feedback system, the second layer being below the first layer;

printing a three-dimensional wax mold structure of the computer-generated model; and

forming the haptic feedback system in a single step using the three-dimensional wax mold structure.

2. The method of claim 1 , wherein forming the haptic feedback system in a single step using the three-dimensional wax mold structure comprises:

molding the haptic feedback system; and

curing the haptic feedback system.

3. The method of claim 2 , wherein the haptic feedback system comprises a material capable of being molded and cured at an ambient temperature.

4. The method of claim 3 , wherein the material is one of a silicone or urethane acrylate.

5. The method of claim 1 , wherein the plurality of actuators are arranged in the first layer such that a density of the plurality of actuators is at a human perceptual resolution.

6. The method of claim 5 , wherein the density of the plurality of actuators is approximately twenty-two actuators per square centimeter.

7. The method of claim 1 , wherein the three-dimensional wax mold structure of the computer-generated model is printed at a resolution of approximately sixteen micrometers.

8. The method of claim 1 , wherein a thickness of the haptic feedback system is approximately 1.3 millimeters.

9. The method of claim 1 , wherein a shape of each of the plurality of actuators determines a surface actuation efficiency for the haptic feedback system.

10. The method of claim 1 , wherein the haptic feedback system is actuated by providing air at one of many possible inflation pressures into the channels.

11. A method comprising:

creating a computer-generated model for a wax mold comprising a plurality of channels and actuators;

printing a three-dimensional representation of the wax mold in wax, the wax mold comprising support wax;

removing the support wax from the wax mold; and

forming a haptic feedback system comprising performing a single-shot molding process between two polycarbonate plates using the wax mold.

12. The method of claim 11 , wherein removing the support wax from the wax mold further comprises placing the wax mold in an isopropyl alcohol bath.

13. The method of claim 11 , wherein:

performing the single-shot molding process comprises supplying silicone to the wax mold; and

forming the haptic feedback system further comprises, subsequent to performing the single-shot molding process, curing the silicone.

14. The method of claim 13 , wherein the printing of the three-dimensional representation of the wax mold in wax, the removing of the support wax from the wax mold, the single-shot molding process, and the curing of the silicone are performed in an ambient temperature environment.

15. The method of claim 13 , wherein:

the wax mold further comprises build wax; and

forming the haptic feedback system further comprises, subsequent to curing the silicone, removing the build wax.

16. The method of claim 15 , wherein removing the build wax comprises placing the haptic feedback system in a mineral oil bath.

17. The method of claim 16 , wherein removing the build wax further comprises repeated vacuuming of the haptic feedback system.