Patent ID: 8691370

Claim:
A layered support structure comprising: a first layer formed from a cavity mold comprising: a support rail comprising: a first strap comprising: multiple aligned regions defined along a length of the first strap, wherein the aligned regions comprise aligned material that is one of a compression aligned polymer material or a tension aligned polymer material; multiple unaligned regions defined along the length of the first strap such that the first strap comprises alternating aligned and unaligned regions along the length of the first strap; and a gate position corresponding to an opening in the cavity mold, where each of the multiple aligned regions of the first strap comprises a cross-sectional area in a direction substantially perpendicular to the length of the first strap that is between approximately 0.1% to approximately 1% greater than a cross-sectional area of an adjacent aligned region immediately closer to the gate position along the first strap; a second strap substantially parallel to the first strap and comprising: multiple aligned regions defined along a length of the second strap, wherein the aligned regions comprise aligned material that is one of a compression aligned polymer material or a tension aligned polymer material; and multiple unaligned regions defined along the length of the second strap such that the second strap comprises alternating aligned and unaligned regions along the length of the second strap, wherein each of the unaligned regions of the second strap is adjacent to a corresponding unaligned region of the first strap; and multiple nodes, each connected between adjacent unaligned regions of the first and second straps.