Patent ID: 7718105

Claim:
A method for fabricating a product with an artificial skin system, comprising: creating a prototype of the product based on a 3D base geometry model of at least one exterior surface of the product; forming an exterior skin mold using the product prototype mounted on an alignment block, wherein a recess matching the alignment block is formed in the exterior skin mold; fabricating an inner support structure based on the 3D base geometry model, wherein the inner support structure has an exterior geometry selected to be smaller than the 3D base geometry model by an offset distance; positioning the inner support structure within the exterior skin mold, wherein the inner support structure is mounted upon the alignment block and the alignment block is received in the matching recess in the exterior skin mold to align the inner support structure with the exterior skin mold; and filling material for an exterior skin layer into the mold to occupy a cavity between the inner support structure and the exterior skin mold.