Dec 2, 2025

US12485679 - Method of creating a projectile launcher by depositing ink on shell parts

A non-lethal projectile launcher toy that comprises a full-colour, high DPI, printed aggregate coating on an outer shell ( 101, 301 ); the decal coating is not limited to flat surfaces, allowing for substantially unrestricted product design, and is substantially undisturbed visual continuity when crossing part lines between discrete parts that make up the outer shell. Methods of producing the decal-coated toy gun using inkjet printing technology are also provided, allowing for high-detail and comprehensive colour range aggregate coatings that may be programmatically controlled to maximise the visual quality of the applied decal.

Assignee: Zuru IP Limited
Inventors: Mathew Peter Mowbray

The patent describes a method for creating a non-lethal projectile launcher toy using inkjet printing technology to apply high-detail, full-color coatings on abutting shell parts. This method allows for intricate designs and visual continuity across the surfaces of the toy, enhancing its aesthetic appeal while maintaining functionality.

Claim 1

1 . A method of creating a projectile launcher having two abutting shell parts configured to be selectively separable from one another, a first shell part of the two abutting shell parts defining a first surface and a second shell part of the two abutting shell parts defining a second surface, the first surface and the second surface each forming at least part of an outermost surface of the projectile launcher and each of the first surface and the second surface has at least two faces that are not coplanar and non-parallel, the method comprising: when said two abutting shell parts are separated from each other, depositing ink onto the first and second surfaces to form a first sub-coating on the first surface and a second sub-coating on the second surface in a single printing orientation on the at least two faces; and assembling the first and second shell parts to abut each other and to position the first sub-coating contiguously to the second sub-coating to define an aggregate coating on the outermost surface of the projectile launcher that is visually continuous. when said two abutting shell parts are separated from each other, depositing ink onto the first and second surfaces to form a first sub-coating on the first surface and a second sub-coating on the second surface in a single printing orientation on the at least two faces; and assembling the first and second shell parts to abut each other and to position the first sub-coating contiguously to the second sub-coating to define an aggregate coating on the outermost surface of the projectile launcher that is visually continuous.

Google Patents

https://patents.google.com/patent/US12485679

USPTO PDF

https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/12485679