US Patent 11242905 Void cells with outwardly curved surfaces

Implementation described and claimed herein include a cushioning structure and method for manufacturing a cellular cushioning system, which allows for maximum comfort through the compression and shock cycle. Specifically, a cushioning structure comprises void cells formed in an array, which comprise multiple outwardly curved surfaces, with varying radius measurements. Stiffness in the void cells can vary by varying the Radii. Outwardly curved surfaces prevent buckling and provide support for high impact by absorbing energy.