Method for printing a shaped object using a color layer and a structure layer

Abstract

The present application relates to a method of printing a shaped object using a color layer and a structural layer. A method of printing a three-dimensional color object having a shaped surface onto a substrate includes printing a color ink layer and a structural ink layer. The color ink layer is printed onto the substrate. The structural ink layer is printed onto the color ink layer to construct the three-dimensional shape of the object. The shaped surface is formed by changing the height of the pixel columns in the printed information. The height of the pixel columns can be changed by printing different numbers of layers in adjacent columns, or by printing the same number of layers in adjacent columns when some pixels in the columns have different thicknesses compared to other pixels in the columns.

Description

[0001] This application is a divisional application of an application with an application date of May 31, 2017, application number 201780033685.1, and invention name “Method for printing a formed object using a color layer and a structural layer”.

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This application claims the benefit of U.S. Provisional Patent Application No. 62 / 343,766, filed May 31, 2016, which is incorporated herein by reference in its entirety. background

[0004] Embodiments generally relate to printing a UV-curable graphic layer on a substrate, such as a fabric used to make articles of apparel such as shirts, shorts, pants, jackets, hats or caps, or a fabric used to make uppers for articles of footwear such as running shoes, training shoes, jogging shoes, hiking shoes, walking shoes, volleyball shoes, handball shoes, tennis shoes, lacrosse shoes, basketball shoes, and other similar articles of footwear, as well as fabrics used to make other articles such as backpacks or tents.

[0005] The clothing item may be made of woven or non-woven fabric or mesh material, or may be made of leather, synthetic leather or plastic material. The clothing item may have products such as logos or emblems on the sleeves, torso, trouser legs or other parts of the clothing item. The clothing item may also have wear-resistant layers, waterproof layers or protective layers, for example, at the elbows, shoulders and / or knees.

[0006] A printer or plotter may be programmed to deposit layers of acrylic ink, polyurethane ink, TPU ink, or silicone ink or other ink on a fabric or other item. Such a printer or plotter may be programmed to cover a two-dimensional portion of a fabric, for example, by moving the print head along a track in a first direction and moving the track in a second direction orthogonal to the first direction. Other printers or plotters may move the print head in a first direction while moving the printing platform in a second direction orthogonal to the first direction, or may move the printing platform in both directions while keeping the print head stationary.

[0007] The present disclosure relates to a method of printing a three-dimensional object onto a substrate using a printing system, the method comprising:

[0008] Receiving at the printing system:

[0009] a target thickness for a region of the three-dimensional object;

[0010] a predetermined structural layer thickness for the printed layer; and

[0011] Color layer information about each color layer;

[0012] receiving the substrate at the printing system;

[0013] calculating, based on the predetermined structural layer thickness, a number of structural layers to be printed to achieve the target thickness with respect to the zone;

[0014] printing the first color layer onto the substrate using the received color layer information about the first color layer;

[0015] printing a set of structural layers onto the first color layer, the number of layers in the set of structural layers in the zone being equal to the calculated number of structural layers, and each layer in the set of structural layers having the predetermined structural layer thickness; and

[0016] The second color layer is printed onto the set of structural layers using the received color layer information about the second color layer.

[0017] In one embodiment, the method further comprises printing one or more transparent layers onto the second color layer.

[0018] In one embodiment, each of the one or more transparent layers has a thickness equal to the predetermined structural layer thickness.

[0019] In one embodiment, the set of structural layers is transparent.

[0020] In one embodiment, a set of structural layers in another zone adjacent to said zone is printed to achieve another target thickness different from said target thickness for said zone.

[0021] In one embodiment, the first color layer is printed such that the thickness of the first color layer is visible at a specific viewing angle.

[0022] The present disclosure also relates to a method of printing a three-dimensional object onto a substrate using a printing system, the method comprising:

[0023] Receiving at the printing system:

[0024] a target thickness for a region of the three-dimensional object;

[0025] a predetermined number of structural layers to be printed; and

[0026] Color layer information about each color layer;

[0027] receiving the substrate at the printing system;

[0028] calculating a structural layer thickness for a printed layer to be printed to achieve the target thickness for the zone using the target thickness and the predetermined number of structural layers;

[0029] printing the first color layer onto the substrate using the received color layer information about the first color layer;

[0030] printing a set of structural layers onto the first color layer, the number of layers in the set of structural layers being equal to the predetermined number of structural layers, and each layer in the set of structural layers in the zone having the calculated structural layer thickness; and

[0031] The second color layer is printed onto the set of structural layers using the received color layer information about the second color layer.

[0032] In one embodiment, the combination of the first color layer, the set of structural layers, and the second color layer has a thickness equal to the target thickness.

[0033] In one embodiment, the method further comprises printing one or more transparent layers onto the second color layer.

[0034] In one embodiment, the combination of the first color layer, the set of structural layers, the second color layer, and the one or more transparent layers has a thickness equal to the target thickness.

[0035] In one embodiment, the combination of the one or more transparent layers is printed to have a thickness that is less than the combined thickness of the set of structural layers.

[0036] In one embodiment, the set of structural layers is transparent.

[0037] In one embodiment, a set of structural layers in another zone adjacent to said zone is printed to achieve another target thickness different from said target thickness for said zone.

[0038] In one embodiment, the second color layer is opaque, and wherein the first color layer is printed such that a thickness of the first color layer is visible at a specific viewing angle.

[0039] The present disclosure also relates to a method of printing a three-dimensional object onto a substrate using a printing system, the method comprising:

[0040] Receiving at the printing system:

[0041] a first target thickness for a first region of the three-dimensional object;

[0042] a second target thickness for a second region of the three-dimensional object; and

[0043] Color layer information;

[0044] receiving the substrate at the printing system;

[0045] printing a first color layer onto the substrate using the color layer information;

[0046] printing a set of structural layers onto the first color layer, the set of structural layers in the first zone being printed to achieve the first target thickness with respect to the first zone, and the set of structural layers in the second zone being printed to achieve the second target thickness with respect to the second zone;

[0047] printing a second color layer onto the set of structural layers using the color layer information; and

[0048] A transparent layer is printed onto the second color layer.

[0049] In one embodiment, the method further comprises:

[0050] receiving, at the printing system, a third target thickness for a third region of the three-dimensional object; and

[0051] The set of structural layers is printed in the third region to achieve the third target thickness about the third region.

[0052] In one embodiment, the first region is adjacent to the second region, and the second region is adjacent to the third region, such that the set of structural layers in the first region, the second region, and the third region are arranged to collectively form an upper surface having a surface contour.

[0053] In one embodiment, the surface profile is a target surface profile corresponding to the first target thickness for the first zone, the second target thickness for the second zone, and the third target thickness for the third zone.

[0054] In one embodiment, the second color layer has a surface profile that is the same as the target surface profile.

[0055] In one embodiment, the transparent layer has a surface profile that is the same as the target surface profile.

[0056] In one embodiment, the first color layer has a surface profile that is different from the target surface profile.

[0057] In one embodiment, the substrate has a surface profile that is different from the target surface profile.

[0058] In one embodiment, the substrate has a substrate color that is different from the first color layer color and the second color layer color, and wherein the three-dimensional object is printed onto the substrate so that the substrate color is visible when the three-dimensional object is viewed from a specific viewing angle. BRIEF DESCRIPTION OF THE DRAWINGS

[0059] The embodiments may be better understood with reference to the following drawings and descriptions. The components in the drawings are not necessarily drawn to scale, but emphasis is placed on illustrating the principles of the embodiments. In addition, in the drawings, like reference numerals indicate corresponding parts throughout the different views.

[0060] Figure 1 An embodiment of a printing system configured to print three-dimensional colored and contoured objects and various types of articles on which the three-dimensional colored and contoured objects may be printed is shown;

[0061] Figure 2 An article of footwear having printed three-dimensional colored and shaped objects printed in a forefoot region and a heel region, wherein the shaped objects are functional elements;

[0062] Figure 3 Shows Figure 2 a cross-sectional view of a portion of an article of footwear as shown in , wherein a contoured surface is formed by varying the height of columns of ink by printing fewer layers of ink in selected columns;

[0063] Figure 4 is a flow chart of an embodiment of a method of printing a profile;

[0064] Figure 5 Shows Figure 4 An embodiment of the steps of the method shown in , wherein a first color layer is printed onto a substrate;

[0065] Figure 6 Shows Figure 4 An embodiment of the steps of the method shown in , wherein the first structural layer is printed onto the first color layer;

[0066] Figure 7 Shows Figure 4 An embodiment of the steps of the method shown in , wherein alternating layers of color ink and structural ink are printed onto a first structural layer;

[0067] Figure 8 Shows Figure 4 An embodiment of the steps of the method shown in , wherein a color ink is selectively printed onto a previously printed structure ink;

[0068] Fig. 9 Shows Figure 3 An embodiment of the same profile as shown in , but in which the shaping surface has been formed by varying the column height of the ink by selectively varying the thickness of portions of the printed ink layer;

[0069] Fig.10 Shows Figure 4 An embodiment of the steps of the method shown in , wherein a first color layer is printed onto a substrate;

[0070] Fig.11 Shows Figure 4 An embodiment of the steps of the method shown in , wherein a first structural layer is printed on a first color layer, and wherein a thickness of the first structural layer is selectively varied;

[0071] Fig.12 Shows Figure 4 An embodiment of the steps of the method shown in , wherein the second structural layer is printed on the first structural layer, and wherein the thickness of the second structural layer is selectively varied;

[0072] Fig.13 Shows Figure 4 An embodiment of the steps of the method shown in , wherein the color ink layer is printed onto the second structural layer;

[0073] Fig.14 An embodiment of a shaped surface with a final structural layer printed on top of all layers is shown;

[0074] Fig.15 An embodiment of an article of footwear having a three-dimensional colored and shaped object printed on an upper, wherein the shaped object is a graphic element;

[0075] Fig.16 Another embodiment of an article of footwear having a three-dimensional colored and shaped object printed on an upper, wherein the shaped object is a graphic element;

[0076] Fig.17 Shows Fig.16 An exploded view of the article of footwear shown in , showing a substrate, a first planar printed color layer, a formed portion made of a structured ink layer, and a second formed printed color layer;

[0077] Fig.18 An embodiment of a method of manufacturing an article of footwear is shown;

[0078] Fig.19 An embodiment of a printing press for printing the outline and colored outline of a shoe upper onto a sheet is shown;

[0079] Fig. 20 An embodiment of a cutting tool for cutting a flat-shaped upper from a sheet of material is shown;

[0080] Fig.21 An embodiment of the steps of forming a shoe upper on a shoe last is shown;

[0081] Fig. 22 An embodiment showing the steps of attaching the upper to the sole; and

[0082] Fig.23 An embodiment is shown of how color is perceived when viewing a multi-layered color object. Detailed Description

[0083] For clarity, the detailed description herein describes certain exemplary embodiments, but the disclosure in this application can be applied to any method for manufacturing an article including any suitable combination of features described herein and recited in the claims. In particular, although the following detailed description describes certain exemplary embodiments, it should be understood that other embodiments can be used to manufacture other articles of footwear or articles of apparel.

[0084] As used herein, the term "printing device," "printing machine," "plotter," "3D printer," or "three-dimensional printing system" or "3D printing system" may refer to any type of system that can print multiple layers onto a fabric, an article of footwear, an article of apparel, or other article, including, for example, a logo and graphic printer. The printer may use any suitable type of UV curable ink, including acrylic ink, polyurethane ink, TPU ink, or silicone ink, or any other suitable ink.

[0085] Upon detailed study of the following drawings and detailed description, other systems, methods, features and advantages of the present embodiment will be or will become apparent to one of ordinary skill in the art. It is intended that all such additional systems, methods, features and advantages be included within this description, and this summary is within the scope of the present embodiment.

[0086] Although the figures and text descriptions herein describe only embodiments as they may be used on certain articles of footwear or certain articles of clothing, the description herein may also be applied to other articles of footwear and / or other articles of clothing, including, for example, articles of footwear such as running shoes, training shoes, jogging shoes, hiking shoes, walking shoes, volleyball shoes, handball shoes, tennis shoes, lacrosse shoes, basketball shoes, and other similar articles of footwear, or articles of clothing such as shorts, shirts, jerseys, jackets, pants, gloves, wristbands, headbands, armbands, hats with or without brim, and other articles that may be applied to such as backpacks or tents.

[0087] Figure 1 is a schematic diagram of an embodiment of a three-dimensional printing system 100 (also referred to as printing system 100). Some embodiments of the printing system may include a provision for distributing one or more functions among different devices of the printing system. As shown, the printing system 100 may include a printing device 102, a computing system 103, and a network 109. In other embodiments, the printing system may be a single device or component (not shown). Such a printing system is also described in the following patent application documents: co-owned U.S. Provisional Patent Application No. 62 / 343,757 filed on May 31, 2016 and related U.S. Non-Provisional Patent Application No. ___________ filed on May 31, 2017, both of which are entitled "Gradient Printing a Three-Dimensional Structural Component", and co-owned U.S. Provisional Patent Application No. 62 / 343,686 filed on May 31, 2016 and related U.S. Non-Provisional Patent Application No. ___________ filed on May 31, 2017, all of which are incorporated by reference in their entirety.

[0088] Some embodiments of the printing device may include a setting that allows color printing. In some embodiments, the printing system may use CMYK printing. In other embodiments, color printing may be performed using another suitable printing method.

[0089] In the embodiment of color printing using CMYK printing, any suitable equipment, protocols, standards and methods can be used to promote color printing. As used herein, "CMYK" can refer to four pigments used in color printing: "C" is used for cyan pigments, "M" is used for magenta pigments, "Y" is used for yellow pigments, and "K" is used for Key pigments. In some cases, the Key pigment can be a black pigment. An example of a printing device using CMYK printing is disclosed in Miller's U.S. Patent Publication No. 2015-0002567 entitled "Additive Color Printing" published on January 1, 2015, which is incorporated herein by reference and is referred to as the "color printing" application hereinafter. In some embodiments, the printing system 100 may include one or more features of the systems, components, equipment and methods disclosed in the color printing application to promote color printing. For example, the printing device can be configured to print an image by dispensing droplets of a printing material including one or more pigments onto a substrate. As used herein, droplets can refer to any suitable volume of printing material. For example, a droplet can be 1 ml of printing material. In other embodiments, the printing system may use other systems, components, devices, and methods.

[0090] In embodiments where the printing system includes settings for distributing one or more functions between different devices of the printing system, any suitable division may be used. In some embodiments, the printing system 100 may include settings for controlling and / or receiving information from the printing device 102. These settings may include a computing system 103 and a network 109. In general, the term "computing system" refers to the computing resources of a single computer, a portion of the computing resources of a single computer, and / or two or more computers that communicate with each other. Any of these resources may be operated by one or more human users. In some embodiments, the computing system 103 may include one or more servers. In some embodiments, the printing server may be primarily responsible for controlling and / or communicating with the printing device 102, while a separate computer (e.g., a desktop, laptop, or tablet) may facilitate interaction with the user. The computing system 103 may also include one or more storage devices, including, but not limited to, magnetic, optical, magneto-optical storage devices, and / or memories including volatile memory and non-volatile memory.

[0091] In some embodiments, any suitable hardware or hardware system can be used to facilitate the setting of controlling and / or receiving information from the printing device 102. In some embodiments in which a computing system is used, the computing system 103 may include a central processing device, an observation interface (e.g., a monitor or screen), an input device (e.g., a keyboard and a mouse), and software for generating a set of predetermined thicknesses for printing three-dimensional structural components. As used herein, a set of predetermined thicknesses may include any suitable information to facilitate the formation of a three-dimensional structural component having a shape represented by the set of predetermined thicknesses. Examples of shapes represented by a set of predetermined thicknesses may include cylindrical, conical, cubic, spherical, etc. In some cases, the set of predetermined thicknesses may be personalized for a specific customer. In other embodiments, other forms of hardware systems may be used.

[0092] In general, any suitable information may be used to facilitate providing settings to software for designing a set of predetermined thicknesses for a component of a three-dimensional structure. In at least some embodiments, software for designing a set of predetermined thicknesses for a printed structure may include not only information about the geometry of the structure, but also information related to the materials required for portions of the printed component. In other embodiments, different information may be used.

[0093] In general, any suitable design structure may be used to convert the design into information that can be interpreted by the printing device 102 (or an associated print server in communication with the printing device 102). In some embodiments, the printing system 100 may operate as follows to provide one or more parts formed using three-dimensional printing or additive processes. The computing system 103 may be used to design the structure. This may be accomplished using some type of CAD software or other type of software. The design may then be converted into information that can be interpreted by the printing device 102 (or an associated print server in communication with the printing device 102). In some embodiments, the design may be converted into a three-dimensional printable file, such as a stereolithography file (STL file); in other cases, the design may be converted into a different design part.

[0094] In embodiments where the printing system includes an arrangement that distributes one or more functions among different devices of the printing system 100, any suitable protocols, formats, and methods may be used to facilitate communications between the devices of the printing system 100. In some embodiments, these communications are conducted using the network 109. In other cases, these communications may be conducted directly between the devices of the printing system 100.

[0095] In some embodiments, the network can use any wired or wireless arrangement that facilitates the exchange of information between the computing system 103 and the printing device 102. In some embodiments, the network 109 can also include various components, such as network interface controllers, repeaters, hubs, bridges, switches, routers, modems, and firewalls. In some embodiments, the network 109 can be a wireless network that facilitates wireless communication between two or more systems, devices, and / or components of the printing system 100. Examples of wireless networks include, but are not limited to: wireless personal area networks (including, for example, Bluetooth), wireless local area networks (including networks utilizing the IEEE 802.11 WLAN standard), wireless mesh networks, mobile device networks, and other types of wireless networks. In other cases, the network 109 can be a wired network, including networks whose signals are facilitated by twisted pair wires, coaxial cables, and optical fibers. In still other cases, a combination of wired and wireless networks and / or connections can be used.

[0096] Some embodiments of the printing system may include a setting that allows the printing structure to be printed directly onto one or more articles. The term "article" is intended to include both footwear articles (e.g., shoes) and clothing articles (e.g., shirts, pants, etc.). As used throughout this disclosure, the terms "footwear articles" and "footwear" include any footwear and any material associated with footwear, including uppers, and may also be applicable to various athletic shoe types, including baseball shoes, basketball shoes, cross-training shoes, bicycle shoes, rugby shoes, tennis shoes, soccer shoes, and hiking boots. As used herein, the terms "footwear articles" and "footwear" also include footwear types that are generally considered to be non-sporting, formal, or decorative, including dress shoes, casual shoes, sandals, slippers, boat shoes, and work boots.

[0097] In some embodiments, any suitable material can be used to form the article to facilitate use of the article in the printing system 100. In some embodiments, the printing device 102 is capable of printing onto the surface of a variety of materials, such as textiles, natural fabrics, synthetic fabrics, knitted fabrics, woven materials, non-woven materials, meshes, leather, synthetic leather, polymers, rubbers, and foams, or any combination thereof, without requiring a release layer between the substrate and the bottom of the printed material, and without requiring a completely or nearly completely flat substrate surface to print on.

[0098] refer to Figure 1, which shows an embodiment including a set of articles 110, in other embodiments, different articles may be used. As shown, the set of articles 110 includes footwear articles, shin guards, clothing articles, and sports equipment like helmets. In other embodiments, the set of articles 110 may be different. In general, any suitable surface of an article may be used as a base or substrate to receive a printed three-dimensional object.

[0099] Although the disclosed embodiments are described in the context of articles of footwear, various embodiments may also be equally applicable to any article of clothing, apparel, or equipment including three-dimensional printing. For example, various embodiments may be applicable to hats, caps, shirts, jerseys, jackets, socks, shorts, pants, underwear, athletic support garments, gloves, wrist / armbands, sleeves, headbands, any knitted material, any woven material, any non-woven material, athletic equipment, and the like. Thus, as used herein, the term "article of apparel" may refer to any garment or clothing, including any article of footwear, as well as hats, caps, shirts, jerseys, jackets, socks, shorts, pants, underwear, athletic support garments, gloves, wrist / armbands, sleeves, headbands, any knitted material, any woven material, any non-woven material, and the like.

[0100] Some embodiments of the printing system may include a configuration that allows printing directly onto an item regardless of the size and shape of the item, such as Figure 1 In other cases, the three-dimensional structural component is first printed onto a release layer and then transferred to the article. In other embodiments, such as Fig.19 In the embodiment shown in , three-dimensional structural components are printed onto components of an article and then assembled into the article.

[0101] Printing device 102 can be any type of printing device known in the art. In some embodiments, printing device 102 is an inkjet printer. In some embodiments, printing device 102 can include a device that prints directly onto a three-dimensional object, such as Figure 1 , where the print head 104 is positioned near a printing platform 106 that can support and properly position the article for the duration of the printing process. The print head 104 is in fluid communication with an ink source 108. The ink source 108 can contain any or all of the different types of inks discussed above. The ink source 108 can contain any number of different colored inks and transparent structural inks. The print head 104 can not only dispense a specified volume of ink received from the ink source 108, but can also include a setting for curing the ink. Such a setting can include a UV lamp, a heat source, or a dryer.

[0102] In some embodiments, such as Figure 2 In the embodiment shown in , the printing device 102 can be directed to print a colored three-dimensional object onto the surface of the article to form a shaped surface. In some embodiments, such as in Figure 2 In the embodiment shown in , these shaped surfaces may be primarily functional. In other embodiments, such as Fig.15 and Fig.16 In the embodiments shown in and discussed further below, these shaped surfaces can be primarily aesthetic.

[0103] In some embodiments, a colored three-dimensional object is formed by printing a color layer directly onto the surface of the article, then building a three-dimensional shape and outline by printing a transparent structural ink, and then printing a second color layer on top of the transparent structural ink layer. The structural ink layer is sandwiched between color ink layers to improve the appearance of the three-dimensional color printed object. The transparent structural layer allows the color layer adjacent to the substrate to be clearly seen, and the color layer printed on top of the transparent structural layer can work with the bottom color layer to provide a unique three-dimensional visual effect. Using transparent ink to build structures and outlines may be more cost-effective than using color inks throughout the structure.

[0104] exist Figure 2 In the embodiment shown in , the footwear article 120 includes a printed functional element, a first functional element 126 and a second functional element 128. The first functional element 126 is a ball control portion positioned in the forefoot area of ​​the footwear article 120 for use in sports (such as soccer) where precise control of kicking a ball is required. The second functional element 128 includes a reinforcement positioned in the heel area of ​​the footwear article 120, such as an additional support for a heel cup or as a wear-resistant surface. Both the first functional element 126 and the second functional element 128 are three-dimensional multi-layer colored objects, which include a shaped surface obtained by printing a structural ink onto the footwear article 120. Both the first functional element 126 and the second functional element 128 can be formed in the same manner, however, for simplicity, only the first functional element 126 is further discussed below.

[0105] Figure 3An embodiment of a cross section of a first functional element 126 is shown. In this embodiment, the first functional element 126 is formed by a plurality of printed layers of uniform thickness. In this embodiment, the plurality of printed layers in the first functional element 126 include a first layer 132, a second layer 134, a third layer 136, and a fourth layer 138, each of which has a prohibited thickness, so that the accumulation of layer thicknesses builds the desired thickness or target thickness of the first functional element 126. The layers are printed so that portions of the functional element 126 can have different heights and form a shaped surface 130. In this embodiment, the shaped surface 130 is formed by a first short raised portion 123, a first high raised portion 125, a second short raised portion 127, and a second high raised portion 129 positioned adjacent to each other to form a three-dimensional object having a shaped surface 130. Therefore, in this embodiment, the shaped surface 130 has a wavy shape. Because digital printing technology allows precise control of the distribution of ink, the first functional element 126 can have any shape and any shaped surface formed by different regions of different thicknesses.

[0106] The first functional element 126 is also a colored element. In order to achieve the desired color and shape of the three-dimensional object, the first functional element 126 includes a color ink layer and a structural ink layer. In some embodiments, the structural ink layer can be colored, while in other embodiments, the structural ink layer can lack a specific color and be transparent, translucent or colorless (clear). In some embodiments, different types of inks can be provided for the color ink layer and the structural ink layer, while in other embodiments, the color ink layer and the structural ink layer are formed by the same type of ink. In some embodiments, based on the same color information, all color layers can have the same color or color pattern. In other embodiments, using different, unique or layer-specific color information, individual color layers can each have different colors or color patterns. In some embodiments, parts of individual color layers can have the same color or color pattern as parts of other color layers, while other parts or areas of the color layer can have different colors or color patterns.

[0107] In some embodiments, such as Figure 3 In the embodiment shown in , a first color ink layer is printed as a layer adjacent to and abutting a substrate or base (such as upper 122), then a structural ink layer is printed on top of the first color ink layer to build a three-dimensional object and a shaped surface, and then a second color ink layer is printed on top of the structural ink layer. The color ink can be the same type of ink as the structural ink, so that the color ink pixels and layers have a similar volume and structure as the transparent structural pixels and layers. Figure 3In the embodiment shown in , the first layer 132 is a color ink layer and is positioned adjacent to and adjacent to the upper 122. The second layer 134 is a structural layer and is printed adjacent to and adjacent to the first layer 132. The third layer 136 includes alternating regions of color pixels and structural pixels printed in selected pixel positions adjacent to and adjacent to the second layer 134. The fourth layer 138 is a color layer and is printed adjacent to and adjacent to portions of the second layer 134 and portions of the third layer 136. The fourth layer 138 is discontinuous because the color pixels are only printed on top of the transparent pixels to establish regions with different heights to form a shaped surface. In this embodiment, the printed color pixels of the third layer 136 and the fourth layer 138 form the top surface or outermost surface of the first functional element 126.

[0108] Those of ordinary skill in the art will recognize that the number of layers of the functional element 126 and the pattern established by the structural layers can vary significantly depending on the target thickness of the first functional element 126, the desired shape of the forming surface 130, the type of ink used, and the capabilities of the printing device 102. For example, for simplicity, Figure 3 Only four layers are provided in the embodiment shown. In other embodiments, depending on the factors discussed above, the number of layers can be less or more. In order to build a functional element like the first functional element 126, the number of printed layers can be greater than four, and the printed pattern can be more complicated than the shown pattern.

[0109] The first functional element 126 having a shaped surface 130 may be used, for example, as in Figure 4 The printing method of the printed profile 140 shown in is formed. In the first step 142 of the method 140, the profile information is received from the computing system 103, such as by the printing device 102, and the profile information is input into the printing device 102. The profile information can be provided for the entirety of the first functional element 126 or layer by layer. The profile information can be developed by the computing system 103, such as by analyzing the image or other information provided by the user and determining how the printing device 102 can be programmed pixel by pixel or based on other printing positions, how to build the profile. The profile information can include a target thickness for a three-dimensional object like the first functional element 126. For example, the profile information can include a target thickness for a portion or zone of the three-dimensional object. A zone can be a portion of the entire three-dimensional object having the same or similar thickness. For example, the first functional element 126 has four zones: a first zone corresponding to the first short raised portion 123, a second zone corresponding to the first high raised portion 125, a third zone corresponding to the second short raised portion 127, and a fourth zone corresponding to the second high raised portion 129. The zones are positioned adjacent to each other such that the zones are arranged to jointly form a shaped surface 130 , which is an upper surface of the first functional element 126 .

[0110] The contour information may include predetermined structural thicknesses for the three-dimensional object and / or each layer in the three-dimensional object. In some embodiments, the computing system 103 may calculate the number of layers based on the three-dimensional shape and the predetermined thicknesses for the layers. The computing system 103 may calculate the thickness of any individual layer based on the capabilities of the printing device 102 and / or the type of ink to be used.

[0111] In a second step 143, color information is input to the printing device 102, such as by the printing device 102 receiving the color information from the computing system 103. The color information can be provided for the first functional element 126 as a whole or layer by layer. The color information can be developed by the computing system 103, such as by analyzing an image or other information provided by a user and determining how the printing device 102 can be programmed on a pixel by pixel or other printing position basis. The color information can include color information about each color layer in the three-dimensional object. The color information can include a specific mixture of primary colors, such as when using the CMYK protocol. The color information can also include color intensity information, which can be programmed as the concentration of color particles within the structural ink matrix. Due to the capabilities of digital printing systems, this color information can be provided pixel by pixel.

[0112] As will be apparent to one skilled in the art, the order of the first step 142 and the second step 143 may be interchanged or may occur simultaneously.

[0113] The third step 144 includes printing the first color layer onto a substrate or base, such as the upper 122. The third step 144 may include introducing a base material to the printing device 102. The third step 144 may also include printing the first color layer onto a base, such as the upper 122, using the color information provided for the first color layer.

[0114] The fourth step 145 includes printing a set of transparent structural layers onto the first color layer to build a three-dimensional shape with a shaped surface. The printing device may be a digital printer that uses the contour information received from the computing system 103 to print the structural layers in a pixel-by-pixel mode.

[0115] The fifth step 146 includes printing a second color layer onto the set of transparent structural layers. The fifth step 146 may also include printing the second color layer onto the set of transparent structural layers using the color information provided for the second color layer.

[0116] exist Figures 5 to 8 An implementation scheme for implementing method 140 is shown in FIG. In this implementation scheme, a Figure 3. In this embodiment, each printed layer or portion of a layer has the same thickness. The profile is constructed by printing only in selected locations. Each pixel or designated printing location can be designated as having ink or not having ink by the received profile information; in each pixel or other type of designated location, the print head 104 can be designated to distribute ink / print or be off / not print.

[0117] Figure 5 Depicted is an embodiment of implementing the third step 144, wherein the first color layer is printed onto the substrate. Some embodiments of the printing apparatus may include a setting that allows the print head to move on the substrate to cause features (such as images, graphics, designs, and text) to be printed onto the substrate. In some embodiments, the printing apparatus may move the print head along the substrate. In other embodiments, the printing apparatus may move the substrate relative to the print head.

[0118] In embodiments where the printing device moves the print head, the printing device can move the print head in directions parallel to any suitable number of axes. In some embodiments, the printing device can move the print head along the printing surface. Figure 5 , the printing device 102 can move the printing head 104 along the upper 122 to facilitate printing on the upper 122. Figure 6 In the embodiment shown in , the printing device 102 can translate the print head 104 along a carriage bar 107 in a direction generally parallel to the surface of the upper 122. The print head 104 can be translated along the carriage bar 107 using any method known in the art, such as using a servo motor or other drive mechanism. In other embodiments, the printing device 102 can move the print head 104 in different ways relative to the substrate. In some embodiments, the printing device 102 can move the article relative to the stationary print head. For example, the printing platform 106 (shown in Figure 1 ) can be moved relative to the print head 104, such as in Figure 1 Any of the directions shown in : the vertical direction 50 , the horizontal direction 54 , and the third orthogonal direction 52 .

[0119] exist Figure 5In the embodiment shown in , the substrate (upper 122) has been divided into eight pixel printing positions: a first pixel position 161, a second pixel position 162, a third pixel position 163, a fourth pixel position 164, a fifth pixel position 165, a sixth pixel position 166, a seventh pixel position 167, and an eighth pixel position 168. These pixel printing positions are arranged to form a row. The print head 104 moves from the first pixel position 161 to the eighth pixel position 168 along the conveying rod 107. The print head 104 can distribute the color ink as a specified volume 150 of the color ink droplet according to the contour information and color information provided by the computing system 103 in the first step 142 and the second step 143 (which are not depicted). In this embodiment, the print head 104 prints a continuous color ink line to form the first layer 132. Each pixel printing position is printed with color ink: the first pixel position 161, the second pixel position 162, the third pixel position 163, the fourth pixel position 164, the fifth pixel position 165, the sixth pixel position 166, the seventh pixel position 167, and the eighth pixel position 168, and the first layer 132 has a uniform thickness at each pixel printing position. In some embodiments, the first layer 132 may have the same surface profile as the upper 122. In other embodiments, the first layer 132 may have a different surface profile from the upper 122.

[0120] The printhead 104 may dispense and cure all color inks to form the first layer 132 in a single pass (ie, movement of the printhead 104 along the feed bar 107), or the printhead 104 may dispense and cure color inks to form the first layer 132 in multiple passes.

[0121] Figure 6 An embodiment of performing the fourth step 145 is depicted, wherein a transparent structural layer is printed onto the first color layer. Figure 6In the embodiment shown in , the substrate (upper 122) has been divided again into eight pixel printing positions: the ninth pixel position 171, the tenth pixel position 172, the eleventh pixel position 173, the twelfth pixel position 174, the thirteenth pixel position 175, the fourteenth pixel position 176, the fifteenth pixel position 177 and the sixteenth pixel position 178. These pixel positions are aligned with the pixel printing positions of the first layer 132 in the first direction: the first pixel position 161 corresponds to the ninth pixel position 171; the second pixel position 162 corresponds to the tenth pixel position 172; the third pixel position 163 corresponds to the eleventh pixel position 173; the fourth pixel position 164 corresponds to the twelfth pixel position 174; the fifth pixel position 165 corresponds to the thirteenth pixel position 175; the sixth pixel position 166 corresponds to the fourteenth pixel position 176; the seventh pixel position 167 corresponds to the fifteenth pixel position 177; and the eighth pixel position 168 corresponds to the sixteenth pixel position 178. However, the ninth pixel position 171, the tenth pixel position 172, the eleventh pixel position 173, the twelfth pixel position 174, the thirteenth pixel position 175, the fourteenth pixel position 176, the fifteenth pixel position 177, and the sixteenth pixel position 178 are respectively stacked on top of the first pixel position 161, the second pixel position 162, the third pixel position 163, the fourth pixel position 164, the fifth pixel position 165, the sixth pixel position 166, the seventh pixel position 167, and the eighth pixel position 168. Therefore, the ninth pixel position 171, the tenth pixel position 172, the eleventh pixel position 173, the twelfth pixel position 174, the thirteenth pixel position 175, the fourteenth pixel position 176, the fifteenth pixel position 177, and the sixteenth pixel position 178 are unique positions and thus may correspond to unique profile printing information for digital printing.

[0122] exist Figure 6 In the embodiment shown in , the print head 104 is translated along the delivery rod 107 to print a continuous line of transparent structural ink 152 to form the second layer 134. Each pixel printing position is printed with transparent structural ink: the ninth pixel position 171, the tenth pixel position 172, the eleventh pixel position 173, the twelfth pixel position 174, the thirteenth pixel position 175, the fourteenth pixel position 176, the fifteenth pixel position 177 and the sixteenth pixel position 178, and the second layer 134 has a uniform thickness at each pixel printing position. In this embodiment, the surface profile of the second layer 134 can be the same as the surface profile of the first layer 132. The print head 104 can dispense and cure all of the structural ink to form the second layer 134 in a single pass (i.e., the movement of the print head 104 along the delivery rod 107), or the print head 104 can dispense and cure the transparent structural ink to form the second layer 134 in multiple passes.

[0123] Figure 7 An embodiment is depicted that continues with a fourth step 145, wherein a transparent structural layer is printed to form a pattern to build a three-dimensional object having a shaped surface. Figure 7 In the embodiment shown in , the substrate (upper 122) has been divided again into eight pixel printing positions: the seventeenth pixel position 181, the eighteenth pixel position 182, the nineteenth pixel position 183, the twentieth pixel position 184, the twenty-first pixel position 185, the twenty-second pixel position 186, the twenty-third pixel position 187, and the twenty-fourth pixel position 188. Like the pixel printing positions of the second layer 134, these pixel positions of the third layer 136 are aligned with the pixel printing positions of the first layer 132 in the first direction: the first pixel position 161 corresponds to the seventeenth pixel position 181; the second pixel position 162 corresponds to the eighteenth pixel position 182; the third pixel position 163 corresponds to the nineteenth pixel position 183; the fourth pixel position 164 corresponds to the twentieth pixel position 184; the fifth pixel position 165 corresponds to the twenty-first pixel position 185; the sixth pixel position 166 corresponds to the twenty-second pixel position 186; the seventh pixel position 167 corresponds to the twenty-third pixel position 187; and the eighth pixel position 168 corresponds to the twenty-fourth pixel position 188. However, the seventeenth pixel position 181, the eighteenth pixel position 182, the nineteenth pixel position 183, the twentieth pixel position 184, the twenty-first pixel position 185, the twenty-second pixel position 186, the twenty-third pixel position 187 and the twenty-fourth pixel position 188 are pixels stacked on top of the first pixel position 161, the second pixel position 162, the third pixel position 163, the fourth pixel position 164, the fifth pixel position 165, the sixth pixel position 166, the seventh pixel position 167 and the eighth pixel 168, respectively, and on top of the ninth pixel position 171, the tenth pixel position 172, the eleventh pixel position 173, the twelfth pixel position 174, the thirteenth pixel position 175, the fourteenth pixel position 176, the fifteenth pixel position 177 and the sixteenth pixel position 178, respectively. Thus, the seventeenth pixel position 181, the eighteenth pixel position 182, the nineteenth pixel position 183, the twentieth pixel position 184, the twenty-first pixel position 185, the twenty-second pixel position 186, the twenty-third pixel position 187 and the twenty-fourth pixel position 188 are unique positions and, therefore, may correspond to unique contour printing information received from the computing system 103 for digital printing.

[0124] In this embodiment, the print head 104 prints a continuous line of ink to form the third layer 136; however, the third layer 136 has alternating sections of colored ink and transparent ink. Some pixel print positions are printed with color ink, such as the seventeenth pixel position 181, the eighteenth pixel position 182, the twenty-first pixel position 185, and the twenty-second pixel position 186. Other positions are printed with transparent structural ink, such as the nineteenth pixel position 183, the twentieth pixel position 184, the twenty-third pixel position 187, and the twenty-fourth pixel position 188. The printing device 102 can be programmed to print these alternating colored sections and transparent sections, which correspond to different areas of the first functional element 126.

[0125] At the first point 204, the printhead 104 may dispense a first volume 153 of colored ink drops to fill the seventeenth pixel position 181 and the eighteenth pixel position 182. At the second point 304, the printhead 104 may dispense a first volume 154 of transparent structured ink drops to fill the nineteenth pixel position 183 and the twentieth pixel position 184. At the third point 404, the printhead 104 may dispense a second volume 155 of colored ink drops to fill the twenty-first pixel position 185 and the twenty-second pixel position 186. At the last point, the printhead 104 may dispense a second volume 156 of transparent structured ink drops to fill the twenty-third pixel position 187 and the twenty-fourth pixel position 188.

[0126] In this embodiment, the third layer 136 has a uniform thickness at each pixel printing location. The print head 104 can dispense and cure all of the ink to form the third layer 136 in a single pass (i.e., movement of the print head 104 in a single direction along the transport bar 107), or the print head 104 can dispense and cure the transparent structural ink to form the third layer 136 in multiple passes of the print head 104.

[0127] Figure 8 An embodiment of performing a fifth step 146 is depicted wherein a second layer of colored ink is printed onto the structural layer and the shaping layer. Figure 8In the embodiment shown in , the substrate (upper 122) has been divided again into eight pixel printing positions: the 25th pixel position 191, the 26th pixel position 192, the 27th pixel position 193, the 28th pixel position 194, the 29th pixel position 195, the 30th pixel position 196, the 31st pixel position 197 and the 32nd pixel position 198. Like the pixel printing positions of the second layer 134 and the third layer 136, these fourth layer pixel printing positions are aligned with the pixel printing positions of the first layer 132, the second layer 134 and the third layer 136. However, the twenty-fifth pixel position 191, the twenty-sixth pixel position 192, the twenty-seventh pixel position 193, the twenty-eighth pixel position 194, the twenty-ninth pixel position 195, the thirtieth pixel position 196, the thirty-first pixel position 197, and the thirty-second pixel position 198 are stacked on top of the first pixel position 161, the second pixel position 162, the third pixel position 163, the fourth pixel position 164, the fifth pixel position 165, the sixth pixel position 166, the seventh pixel position 167, and the eighth pixel position 168, respectively, and are stacked on top of the first pixel position 161, the second pixel position 162, the third pixel position 163, the fourth pixel position 164, the fifth pixel position 165, the sixth pixel position 166, the seventh pixel position 167, and the eighth pixel position 168, respectively. 171, 172, 173, 174, 175, 176, 177, and 178, and are also stacked on top of the 17th, 181st, 182nd, 183rd, 184th, 185th, 186th, 187th, and 188th pixel positions, respectively. Thus, the 25th, 191st, 192nd, 193rd, 194th, 195th, 196th, 197th, and 198th pixel positions are unique positions and, therefore, may correspond to unique outline printing information and color printing information received from the computing system 103.

[0128] In this embodiment, the print head 104 prints discontinuous lines of ink to form the fourth layer 138. Some pixel print positions such as the 25th pixel position 191, the 26th pixel position 192, the 29th pixel position 195, and the 30th pixel position 196 are not printed. In these positions, the print head 104 is turned off and does not dispense ink. Other positions such as the 27th pixel position 193, the 28th pixel position 194, the 31st pixel position 197, and the 32nd pixel position 198 are printed with color ink. The printing device 102 can be programmed to print these alternating sections. At the first point 204, the print head 104 can be placed in the first closed state 160 and guided to not dispense ink to keep the 25th pixel position 191 and the 26th pixel position 192 empty. At the second point 304, the print head 104 can dispense a third volume 157 of colored ink droplets to fill the 27th pixel position 193 and the 28th pixel position 194. At the third point 404, the print head 104 can be placed in the second closed state 169 and directed to not dispense ink to keep the twenty-ninth pixel position 195 and the thirtieth pixel position 196 empty. At the last point, the print head 104 can dispense a fourth volume 158 of colored ink drops to fill the thirty-first pixel position 197 and the thirty-second pixel position 198.

[0129] In this embodiment, the printed pixel positions of the fourth layer 138 have a uniform thickness at each pixel printing position. The empty pixel positions produce an upper surface formed by the color ink printed portion of the third layer 136 and the color ink printed portion of the fourth layer 138. The contour of the upper surface is the target contour. The print head 104 can dispense and cure all the ink to form the fourth layer 138 in a single pass (i.e., the movement of the print head 104 along the conveyor rod 107 in a single direction), or the print head 104 can dispense and cure the ink to form the fourth layer 138 in multiple passes of the print head 104.

[0130] exist Figure 3 As shown and used Figures 5 to 8 In the embodiment of printing by the method shown in , all layers and pixels have the same thickness. The forming surface 130 is formed by varying the height of adjacent pixel columns in adjacent areas. As discussed above, this height variation occurs when some potential pixel positions for printing are not printed so that these pixels remain empty or without ink to form short columns, while all potential pixel printing positions in some adjacent columns or columns separated from the short columns are printed with ink to form tall columns. Therefore, in Figure 3In the embodiment shown in , some columns have three printed pixels, while other columns have four printed pixels, and each pixel has approximately the same size. The pattern of short and tall columns forms a shaped surface 130. The shaped surface 130 has a different contour than the surface of the upper 122, so the first functional element 126 is a raised three-dimensional object that can be distinguished from the rest of the upper 122.

[0131] However, in other embodiments, slightly different printing methods may be used to achieve the same profile. Fig. 9 A cross section obtained using the alternating printing method is shown in FIG. Fig. 9 As shown in , the forming surface 130 is also formed by a pattern of short columns (such as short columns 230) and tall columns (such as tall columns 240). However, Fig. 9 Each column shown includes four printed pixels. Some of the printed pixels have full thickness, while other printed pixels have a height that is half the height of the full thickness pixels or 50% of the height of the full thickness pixels. For example, the short column 230 includes two 50% height pixels and two full thickness pixels. The tall column 240 includes four full thickness printed pixels. The net effect is similar to Figure 3 The embodiment shown in FIG. 1 is the same as that shown in FIG. 1 : the tall columns are 25% taller than the short columns. The ability to print digitally allows the system to precisely control the distribution of discrete ink volumes in the pixels. These ink volumes correspond to the thickness of the printed pixels. When printing Fig. 9 In the embodiment shown in FIG. 1 , printing by the print head 104 is never interrupted, which results in less printing time.

[0132] exist Figures 10 to 13 The implementation is shown in Fig. 9 The printing method of the cross-section shown in . These drawings also follow Figure 4 The general method shown in .

[0133] exist Fig.10In the embodiment shown in , the substrate (upper 122) has been divided into eight pixel printing positions: a first pixel position 261, a second pixel position 262, a third pixel position 263, a fourth pixel position 264, a fifth pixel position 265, a sixth pixel position 266, a seventh pixel position 267, and an eighth pixel position 268. These pixel printing positions are arranged adjacent to each other to form a row. The print head 104 moves from the first pixel position 261 to the eighth pixel position 268 along the conveyor rod 107. The print head 104 can distribute the color ink as a specified first color ink volume 250 according to the contour information and color information provided by the computing system 103 in the first step 142 and the second step 143 (which are not depicted). In this embodiment, the print head 104 prints a continuous color ink line to form a first color layer 232. In this embodiment, the color ink can also be a structural ink, so that the first color layer 232 is also a structural layer. Each pixel printing position is printed with the same volume of color ink: the first pixel position 261, the second pixel position 262, the third pixel position 263, the fourth pixel position 264, the fifth pixel position 265, the sixth pixel position 266, the seventh pixel position 267, and the eighth pixel position 268. The first color layer 232 has a uniform thickness at each pixel printing position. The print head 104 can distribute and cure all the color inks to form the first color layer 232 in a single pass (i.e., the movement of the print head 104 along the conveying rod 107), or the print head 104 can distribute and cure the color inks to form the first color layer 232 in multiple passes.

[0134] Fig.11 An embodiment of implementing the fourth step 145 is depicted, wherein a transparent structure layer is printed onto the first color layer. Fig.11In the embodiment shown in , the substrate (upper 122) has been divided again into eight pixel printing positions: the ninth pixel position 271, the tenth pixel position 272, the eleventh pixel position 273, the twelfth pixel position 274, the thirteenth pixel position 275, the fourteenth pixel position 276, the fifteenth pixel position 277 and the sixteenth pixel position 278. These pixel positions are aligned with the pixel printing positions of the first color layer 232 in the first direction: the first pixel position 261 corresponds to the ninth pixel position 271; the second pixel position 262 corresponds to the tenth pixel position 272; the third pixel position 263 corresponds to the eleventh pixel position 273; the fourth pixel position 264 corresponds to the twelfth pixel position 274; the fifth pixel position 265 corresponds to the thirteenth pixel position 275; the sixth pixel position 266 corresponds to the fourteenth pixel position 276; the seventh pixel position 267 corresponds to the fifteenth pixel position 277; and the eighth pixel position 268 corresponds to the sixteenth pixel position 278. However, the ninth pixel position 271, the tenth pixel position 272, the eleventh pixel position 273, the twelfth pixel position 274, the thirteenth pixel position 275, the fourteenth pixel position 276, the fifteenth pixel position 277, and the sixteenth pixel position 278 are respectively stacked on top of the first pixel position 261, the second pixel position 262, the third pixel position 263, the fourth pixel position 264, the fifth pixel position 265, the sixth pixel position 266, the seventh pixel position 267, and the eighth pixel position 268. Therefore, the ninth pixel position 271, the tenth pixel position 272, the eleventh pixel position 273, the twelfth pixel position 274, the thirteenth pixel position 275, the fourteenth pixel position 276, the fifteenth pixel position 277, and the sixteenth pixel position 278 are unique positions and thus may correspond to unique contour printing information.

[0135] exist Fig.11 In the embodiment shown in , the print head 104 is translated along the delivery rod 107 to print a continuous line of transparent structural ink to form a first transparent layer 234. Each pixel printing position is printed with transparent structural ink: the ninth pixel position 271, the tenth pixel position 272, the eleventh pixel position 273, the twelfth pixel position 274, the thirteenth pixel position 275, the fourteenth pixel position 276, the fifteenth pixel position 277 and the sixteenth pixel position 278. However, the first transparent layer 234 has different pixel thicknesses in the selected positions. For example, the ninth pixel position 271, the tenth pixel position 272, the thirteenth pixel position 275 and the fourteenth pixel position 276 have 50% of the thickness of the eleventh pixel position 273, the twelfth pixel position 274, the fifteenth pixel position 277 and the sixteenth pixel position 278, which are full-thickness pixels.

[0136] In some embodiments, variation in pixel thickness may be achieved by programming the print head 104 to dispense different volumes of ink in different pixel locations as the print head 104 travels at a constant speed on the delivery rod 107. For example, to achieve a 50% reduction in thickness of a selected pixel compared to other pixels, a 50% reduction in ink volume may be dispensed at the selected print location. Fig.11 In the embodiment shown in FIG. 5 , at a first print dot 504, the print head 104 dispenses a first volume 255 of transparent ink onto a ninth pixel location 271 and a tenth pixel location 272. The first volume 255 of transparent ink is sufficient to produce a short pixel in the ninth pixel location 271 having a short height 270. At a second print dot 604, the print head 104 dispenses a second volume 256 of transparent ink onto an eleventh pixel location 273 and a twelfth pixel location 274. The second volume 256 of transparent ink is sufficient to produce a full thickness pixel in the eleventh pixel location 273 having a full thickness 280. The first volume 255 of transparent ink is half of the second volume 256 of transparent ink, and the short height 270 is half of the full thickness 280. In other embodiments, different volumes of ink may produce different thicknesses.

[0137] At the third print dot 704, the print head 104 dispenses the third volume 257 of transparent ink onto the thirteenth pixel position 275 and the fourteenth pixel position 276. The third volume 257 of transparent ink is sufficient to produce a short pixel in the ninth pixel position 271 having a short height 270. At the second print dot 604, the print head 104 dispenses the second volume 256 of transparent ink onto the eleventh pixel position 273 and the twelfth pixel position 274. The second volume 256 of transparent ink is sufficient to produce a full thickness pixel in the eleventh pixel position 273 having a full thickness 280.

[0138] In other embodiments not shown, when the print head 104 dispenses ink at a constant flow rate, the height variation of selected pixels can be produced by changing the speed of the print head 104 on the delivery rod 107. In selected positions, the print head 104 can move faster on the delivery rod 107 to dispense less ink to those selected positions for thinner pixels. In other designated positions, the print head 104 can move slower so that more ink is dispensed into those positions for thicker pixels.

[0139] The printhead 104 may dispense and cure all of the structural ink to form the first transparent layer 234 in a single pass (ie, movement of the printhead 104 along the delivery bar 107), or the printhead 104 may dispense and cure the transparent structural ink to form the second layer 134 in multiple passes.

[0140] Fig.12An embodiment is depicted that continues with a fourth step 145, wherein a transparent structural layer is printed to form a pattern to build a three-dimensional object having a shaped surface. Fig.12 In the embodiment shown in , the substrate (upper 122) has been divided again into eight pixel printing positions: the seventeenth pixel position 281, the eighteenth pixel position 282, the nineteenth pixel position 283, the twentieth pixel position 284, the twenty-first pixel position 285, the twenty-second pixel position 286, the twenty-third pixel position 287 and the twenty-fourth pixel position 288. Like the pixel printing positions of the first transparent layer 234, these pixel positions for the pixel printing positions of the second transparent layer 236 are aligned with the pixel printing positions of the first color layer 232 in the first direction: the first pixel position 261 corresponds to the seventeenth pixel position 281; the second pixel position 262 corresponds to the eighteenth pixel position 282; the third pixel position 263 corresponds to the nineteenth pixel position 283; the fourth pixel position 264 corresponds to the twentieth pixel position 284; the fifth pixel position 265 corresponds to the twenty-first pixel position 285; the sixth pixel position 266 corresponds to the twenty-second pixel position 286; the seventh pixel position 267 corresponds to the twenty-third pixel position 287; and the eighth pixel position 268 corresponds to the twenty-fourth pixel position 288. However, the seventeenth pixel position 281, the eighteenth pixel position 282, the nineteenth pixel position 283, the twentieth pixel position 284, the twenty-first pixel position 285, the twenty-second pixel position 286, the twenty-third pixel position 287, and the twenty-fourth pixel position 288 are pixels stacked on top of the pixels of the first color layer 232 and the first transparent layer 234. Therefore, the seventeenth pixel position 281, the eighteenth pixel position 282, the nineteenth pixel position 283, the twentieth pixel position 284, the twenty-first pixel position 285, the twenty-second pixel position 286, the twenty-third pixel position 287, and the twenty-fourth pixel position 288 are unique positions and, therefore, may correspond to unique contour printing information received from the computing system 103.

[0141] In this embodiment, the print head 104 continuously prints ink to form the second transparent layer 236. In this embodiment, the pattern of the printed pixels of the second transparent layer 236 is the same as the pattern of the printed pixels of the first transparent layer 234.

[0142] exist Fig.12In the embodiment shown in , the print head 104 is translated along the delivery rod 107 to print a line of transparent structural ink to form the second transparent layer 236. Each pixel printing position is printed with transparent structural ink: the seventeenth pixel position 281, the eighteenth pixel position 282, the nineteenth pixel position 283, the twentieth pixel position 284, the twenty-first pixel position 285, the twenty-second pixel position 286, the twenty-third pixel position 287 and the twenty-fourth pixel position 288. However, as specified by the profile information received from the computing system 103, the first transparent layer 234 has different pixel thicknesses in the selected positions. For example, the printed pixels in the seventeenth pixel position 281, the eighteenth pixel position 282, the twenty-first pixel position 285 and the twenty-second pixel position 286 have 50% of the thickness of the full thickness pixels.

[0143] Fig.13 An embodiment of performing a fifth step 146 is depicted wherein a second layer of colored ink is printed onto the structural layer and the shaping layer. Fig.13 In the embodiment shown in , the substrate (upper 122) has been divided again into eight pixel printing positions: the 25th pixel position 291, the 26th pixel position 292, the 27th pixel position 293, the 28th pixel position 294, the 29th pixel position 295, the 30th pixel position 296, the 31st pixel position 297 and the 32nd pixel position 298. These fourth layer pixel printing positions also form rows. Like the pixel printing positions of the second layer 134 and the third layer 136, these fourth layer pixel printing positions are aligned with the pixel printing positions of the first layer 132, the second layer 134 and the third layer 136 and are stacked on top of the pixel printing positions of the first layer 132, the second layer 134 and the third layer 136. Thus, the twenty-fifth pixel position 291, the twenty-sixth pixel position 292, the twenty-seventh pixel position 293, the twenty-eighth pixel position 294, the twenty-ninth pixel position 295, the thirtieth pixel position 296, the thirty-first pixel position 297 and the thirty-second pixel position 298 are unique positions and may therefore correspond to unique contour printing information and color printing information received from the computing system 103.

[0144] In this embodiment, the print head 104 prints lines of ink to form a second color layer 238. As each print position receives ink, some pixel print positions, such as the 25th pixel position 191, the 26th pixel position 192, the 29th pixel position 195, and the 30th pixel position 196, are printed on top of columns with reduced thickness pixels. Other positions, such as the 27th pixel position 293, the 28th pixel position 294, the 31st pixel position 297, and the 32nd pixel position 298, are printed on top of columns with only full thickness pixels. Thus, in some areas, the second color layer 238 is printed on top of short columns, while in other areas, the second color layer 238 is printed on top of tall columns. Thus, the print head 104 can print a continuous volume of ink. At the first previous point 204, the print head 104 can dispense a first color ink volume 251. At the second previous point 304, the print head 104 can dispense a second color ink volume 252. At the third previous point 404, the print head 104 may dispense the third color ink volume 253. At the current printing point, the print head 104 may dispense the fourth color ink volume 254. The first color ink volume 251, the second color ink volume 252, the third color ink volume 253, and the fourth color ink volume 254 are all the same, so that the second color layer 238 has a uniform thickness in all pixels even if the pixels of the second color layer 238 are printed at different distances above the upper 122. In this embodiment, the target surface contour of the three-dimensional object provided by the computing system 103 is the same as the surface contour of the top color layer.

[0145] In some embodiments, all color layers may have the same color or color pattern based on the same color information. In other embodiments, individual color layers may each have different colors or color patterns using different, unique, or layer-specific color information. In some embodiments, portions of individual color layers may have the same color or color pattern as portions of other color layers, while other portions or regions of the color layer may have different colors or color patterns.

[0146] Fig.14 Another embodiment of a cross-section of a three-dimensional color object that has been printed on a substrate such as upper 122 is shown. Fig.14 The embodiment shown in is similar in most respects to Figure 3, where different regions of the element have different heights to create a three-dimensional element with a shaped surface. A first region 323 is a short column formed by four printed pixels. A second region 325 is adjacent to the first region 323 and is a tall column formed by five printed pixels. A third region 327 is adjacent to the second region 325 and is a short column formed by four printed pixels. A fourth region 329 is adjacent to the third region 327 and is a tall column formed by five printed pixels.

[0147] like Figure 3 In the embodiment shown in , pixels are arranged in layers. A first printed color layer 332 is printed on a substrate such as the upper 122. The first printed color layer 332 is a continuous color ink layer of uniform thickness. A first printed transparent layer 334 is printed on the first printed color layer 332. The first printed transparent layer 334 is a continuous transparent ink layer of uniform thickness. A first alternating layer 336 is printed on the first printed transparent layer 334. The first alternating layer 336 is a continuous ink layer in which color ink is printed in the first area 323 and the third area 327, and transparent ink is printed in the second area 325 and the fourth area 329. A second alternating layer 338 is printed on the first alternating layer 336. The second alternating layer 338 is a continuous ink layer in which transparent ink is printed in the first area 323 and the third area 327, and color ink is printed in the second area 325 and the fourth area 329. The alternating pattern of color ink and transparent ink of the first alternating layer 336 is opposite to the alternating pattern of color ink and transparent ink of the second alternating layer 338. The final layer 339 is a discontinuous transparent ink layer. Because the first area 323 and the third area 327 already have a color layer covered with a transparent layer on top, the final layer 339 is only printed in the second area 325 and the fourth area 329.

[0148] In this way, with the formation of Figure 3 The three-dimensional color object is formed in the same manner as the three-dimensional color object shown in FIG. However, Figure 3 The top layer of the three-dimensional color object shown in is the color layer, while Fig.14 The top layer of the three-dimensional color object shown in is a transparent layer covering the color layer. In this embodiment, the target surface contour provided by the computing system 103 about the three-dimensional object is the same as the surface contour of the top transparent layer. Fig.14 The second color layer in the embodiment shown in can be protected by a clear layer, or the clear layer can add gloss to the otherwise matte appearance of the three-dimensional object.

[0149] The embodiments discussed above show and discuss functional elements as three-dimensional color objects printed on articles. Fig.15 Another embodiment is shown where one three-dimensional color object is primarily aesthetic and the other is primarily functional. Fig.15A second article of footwear 420 is shown, which is shown as a sneaker, but can be any type of article of footwear known in the art. Second article of footwear 420 includes an upper 422 attached to a sole 424. Upper 422 includes a three-dimensional color aesthetic object, a graphic element 426. The term "graphic" used throughout this detailed description and in the claims refers to any visual design element, including but not limited to: photos, logos, text, illustrations, lines, shapes, various types of images, and any combination of these elements. Moreover, the term graphic is not intended to be limiting and can be combined with any number of continuous or discontinuous visual features. For example, in one embodiment, the graphic can include a logo applied to a small area of ​​the article of footwear. In another embodiment, the graphic can include a large color area applied to one or more areas of an article of clothing.

[0150] In this embodiment, upper 422 also includes a three-dimensional functional element, eyelet reinforcement 428. Both types of three-dimensional color objects can be printed using any of the methods described above. In addition, both types of three-dimensional color objects can be printed at different times or simultaneously. The printing methods discussed above can be applied to any combination of functional and aesthetic three-dimensional color objects with a shaped surface.

[0151] Fig.16 and Fig.17 Examples of the types of three-dimensional effects that can be created when printing a three-dimensional object onto an article are shown. Fig.16 An article of footwear 520 is shown having a three-dimensional color object 526 having a shaped surface positioned in a forefoot region of an upper 522 of article 520. Upper 522 may be associated with sole 524. Upper 522 and sole 524 may be made of any material known in the art for use as an upper and / or sole. In this embodiment, three-dimensional color object 526 is a face.

[0152] To give the face a three-dimensional look and feel, a three-dimensional color object 526 may be printed onto the upper 522 according to any of the methods discussed above, where the upper 522 is the substrate onto which the object is printed. Fig.17 is an exploded view of the three-dimensional color object 526 , illustrating the arrangement and interaction of the multiple layers of the three-dimensional color object 526 .

[0153] The first color layer 532 is printed on the upper 522. The first color layer 532 is a color image of the face. In this embodiment, the first color layer 532 is a flat layer with a uniform thickness. The first color layer 532 can have the same contour as the upper 522.

[0154] A set of transparent structural layers are printed to form multiple parts of a three-dimensional object, and a first structural portion 534, a second structural portion 535, and a third structural portion 536 are printed on the first color layer 532. The size and shape of the set of transparent structural layers are designed to correspond to the basic curvature of the face. For example, the first structural portion 534 generally raises the face; the second structural portion 535 gives the definition of the forehead, cheeks and lips; and the third structural portion 536 provides a shape for the nose. In order to simulate the contours of a real face, the first structural portion 534, the second structural portion 535, and the third structural portion 536 are combined to form a forming surface. The first structural portion 534 is raised above the upper 522 to a first height that is the lowest. The second structural portion 535 is raised above the upper 522 to a second height. The third structural portion 536 is raised above the upper 522 to a third height that is the highest.

[0155] A second color layer 538 is printed on top of the set of transparent structural layers to complete the image of the face. In some embodiments, the second color layer 538 can be a copy of the color information of the first color layer 532 to increase the intensity of the color. In other embodiments, the color information used in the second color layer 538 can be different from the color information of the first color layer 532 so that the two color layers work together to produce the desired color effect.

[0156] In the embodiments discussed above, manufactured articles are printed. The size, shape, and configuration of the printing apparatus 102 described above are designed to receive manufactured articles, such as shoes, articles of clothing, or athletic equipment. In other embodiments, such as Figures 18 to 22 In the embodiment shown in , the components of the article can be printed before assembling the article. An article of footwear is used as an example to discuss the method.

[0157] Fig.18 A flow chart of an embodiment of a method 1800 of manufacturing an article having a printed component is shown. In a first method step 1801, a component is printed. Fig.19An embodiment of the first method step 1801 for footwear articles is shown. For footwear articles, a sheet 1815 of a shoe upper material such as leather, knitted material and / or woven or non-woven material is printed with a three-dimensional color object, such as a first shaped object 1826 and a second shaped object 1828. The contour line 1817 of the shoe upper is also printed on the sheet 1815. In this embodiment, the printing device 1805 can be a flat printer because the printing device does not need to be designed in size and shape to accommodate the manufactured articles. The use of the sheet 1815 can simplify the printing process because the substrate (sheet 1815) is flat and the distance between the print head and the substrate is constant. Any calculation for determining where to print a specific pixel can be simplified. In addition, the actual printing process can be simplified by limiting the movement of the print head to a single plane. When printing the manufactured article, the print head may need to move in a horizontal plane to print a layer, but also needs to move in a vertical plane to adapt to the change in the curvature of the article.

[0158] In a second manufacturing step 1802, the printed upper pattern is cut from the sheet. Fig. 20 Cutting of printed upper 1822 from sheet 1815 using cutting tool 1821 is shown. Cutting tool 1821 may be bladed, such as scissors, rotary cutting tools, and die cutting tools, or bladeless tools, such as laser cutters and water jets, automated cutting tools, or any other cutting tools known in the art. Cutting tool 1821 follows the pattern established by contour line 1817 to remove waste material from unformed printed upper 1822.

[0159] In a third manufacturing step 1803, printed upper 1822 is shaped and formed. Fig.21 An embodiment of a third manufacturing step 1803 is shown in which a last 2100 is used to form a printed upper 1822. The last 2100 may be any type of last known in the art, and the printed upper 1822 may be formed on the last 2100 using any method known in the art.

[0160] In the fourth manufacturing step 1804, as Fig. 22 As shown in , formed and printed upper 1822 is attached to sole 1824. Printed upper 1822 can be attached to sole 1824 using any method known in the art (e.g., using adhesives, welding, bonding, heat bonding, and stitching).

[0161] In addition to other three-dimensional effects that can be produced by printing color objects having the formed surfaces discussed above, the multi-layer printing techniques discussed above can also allow color mixing. In some embodiments, the first color layer information received at the printing device can include different color information about the second color layer received at the printing device, so that the color perceived by an observer of the finished printed object is different from the color printed on either layer. In other embodiments, the first color layer information received at the printing device can be the same as the color information about the second color layer received at the printing device, so that the color perceived by an observer of the finished printed object is more intense than the color printed on either layer. Such color mixing using multi-layer printing is described in U.S. Patent Publication 2015-002567, which has been previously incorporated herein by reference. Fig.23 An embodiment of color mixing is shown which is particularly suitable for a multi-layer object having a color layer sandwiching a plurality of transparent structural layers, such as in the above Figure 3 and Fig. 9 In some embodiments, the desired color intensity is provided as color information by a computer system 2 ( Figure 1 The color intensity is calculated or input into a computer system as shown in FIG. 1. To obtain this color intensity, the system does not need to print two color layers with the desired color intensity because the colors of the two layers will optically mix and reflect to enhance the aggregation of the desired color intensity.

[0162] For example, Fig.23 Shown is a multilayer three-dimensional color object 2326 that has been printed on substrate 2322.Substrate 2322 can be any type of article discussed above.In this embodiment, object 2326 is a three-layer object, which has a first color layer 2332 located adjacent to substrate 2322, a transparent structural layer 2334 located adjacent to the first color layer 2332, and a second color layer 2338 located adjacent to the transparent structural layer 2334. The second color layer 2338 is the topmost or outermost layer of object 2326. These color layers and structural layers can be printed using any method discussed above. These color layers and structural layers can be made of any type of ink discussed above.

[0163] In this embodiment, the second color layer 2338 has the same color as the first color layer 2332, but the color of the second color layer 2338 is not as intense as the color of the first color layer 2332. To achieve this difference in color intensity, a smaller number of color particles may be provided in the ink of the second color layer 2338 than in the ink of the first color layer 2332. Fig.23In the embodiment shown in , the second color layer 2338 has a color intensity of 50% of the color intensity of the first color layer 2332. For example, the second color layer 2338 may be provided with color particles half of the color particles provided to the first color layer 2332.

[0164] In addition, the color intensity of the first color layer 2332 may be only half of the intended object color specified in the color information. For example, if the intended object color of the object 2326 is red with an intensity of 100%, then the first color layer 2332 may have an intensity of 50%. If the second color layer 2338 has an intensity that is half of the first color layer 2332, then the second color layer 2338 has an intensity that is only 25% of the intended color. Even though neither color layer has 100% of the intended color intensity and the intensity of the print is less than 100% saturation, the observer 2350 may perceive the intended 100% intensity due to optical mixing.

[0165] When the observer 2350 observes the object 2326, the observer 2350 is perceiving light reflected from the object 2326. A light source 2360, such as the sun or an artificial light source, generates an incident light ray 2362 that travels toward the object 2326 and reflects to the observer 2350. The incident light ray 2362 enters the object 2326 through the second color layer 2338. The second color layer 2338 has a color intensity of 25%. The incident light ray 2362 carries a portion of the color intensity of the second color layer 2338 further into the object 2326. In some embodiments, the portion that carries the color intensity may be about 12.5% ​​or half of the color intensity of the second color layer 2338. The light ray 2362 passes through the transparent layer 2334 and enters the first color layer 2332. The first color layer 2332 has a color intensity of 50%. The light ray 2362 carries a portion of the color intensity of the first color layer and a portion of the color intensity of the second color layer 2338 previously acquired to the substrate 2322. In some embodiments, the carried portion of the color intensity of the first color layer 2332 is approximately 25% or half of the color intensity of the first color layer. Light 2362 is reflected from the substrate 2322 toward the observer 2350. As the light 2362 passes back through the first color layer 2332 and the second color layer 2338, additional visible color is added to the reflected light 2362: 50% of the color intensity of the first color layer 2332 and 25% of the color intensity of the second color layer 2338. The aggregate color intensity of the carried and reflected color intensity of the reflected light 2362 when the light 2362 reaches the observer 2350 is greater than the color intensity of the first color layer 2332 or the color intensity of the second color layer 2338. In some embodiments, the aggregate color intensity is 100% of the intended color intensity.

[0166] This type of aggregated and reflective color mixing can save costs because fewer color particles can be used to print a multi-layer object compared to printing a single-layer object with the same visible color. In addition, this type of color mixing can produce pleasing aesthetic effects because the visible color appears darker than the visible color of a single-layer color object.

[0167] Use something like Fig.23 , other visual effects are possible. For example, when viewed from different angles, object 2326 may appear different. In some embodiments, the color of first color layer 2332 may be different from second color layer 2338. As described above, when viewed from the front, an observer may perceive the composite color of first color layer 2332 and second color layer 2338. In such an embodiment, the color of first color layer 2332 may be hidden or obscured by the composite color of first color layer 2332 and second color layer 2338. However, when viewed from different angles, such as from the side, the aesthetic appearance of object 2326 may be different. When viewed from the side, the thickness of first color layer 2332 may be perceived, and therefore the color of first color layer 2332 may be seen, thereby giving object 2326 a different appearance. Object 2326 may be printed using any of the techniques and methods disclosed above, wherein the color of first color layer 2332 may be observed from certain selected angles, such as from the side, such as by printing object 2326 so that the thickness of first color layer 2332 is sufficient to be visible.

[0168] In another embodiment, the color layer may be omitted. When viewed from the front or from certain angles, the observer may perceive only the second color layer 2338, while the color of the first color layer 2332 is obscured by the opaque second color layer 2338. When viewed from other angles (such as from the side), the thickness of the first color layer 2332 may become visible. Because the first color layer 2332 has a uniform color throughout the thickness in some embodiments, the color of the first color layer 2332 is no longer obscured by the opaque second color layer 2338. The object 2326 can be printed using any of the techniques and methods disclosed above, wherein the color of the first color layer 2332 can be observed from certain selected angles, such as from the side, such as by printing the object 2326 so that the thickness of the first color layer 2332 is sufficient to be visible.

[0169] Although various embodiments have been described, this description is intended to be exemplary rather than restrictive, and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations within the scope of the embodiments are possible. Any feature of any embodiment may be used in combination with any other feature or element in any other embodiment or in place of any other feature or element in any other embodiment, unless specifically limited. Therefore, the embodiments are not limited except in accordance with the appended claims and their equivalents. Moreover, various modifications and variations may be made within the scope of the appended claims.

Claims

1. A method for printing a three-dimensional object onto a substrate using a printing system, the method comprising: Receiving at the printing system: a first target thickness for a first region of the three-dimensional object; a predetermined structural layer thickness with respect to the printed layer; and color layer information about each of the first color layer and the second color layer; receiving the substrate at the printing system; calculating, based on the predetermined structural layer thickness, a number of structural layers to be printed to achieve the first target thickness with respect to the first zone; printing the first color layer onto the substrate using the received color layer information about the first color layer; printing a set of structural layers onto the first color layer, the number of layers in the set of structural layers in the first region being equal to the calculated number of structural layers, and each layer in the set of structural layers in the first region having the predetermined structural layer thickness; and printing the second color layer onto the set of structural layers using the received color layer information about the second color layer; wherein the set of structural layers in a second zone adjacent to the first zone is printed onto the first color layer to achieve a second target thickness different from the first target thickness; The method further includes receiving, at the printing system, the second target thickness for the second zone, printing the set of structural layers in the second zone onto the first color layer in the second zone to achieve the second target thickness for the second zone; wherein the set of structural layers in the first region and in the second region are arranged to jointly form an upper surface having a surface contour; and Wherein, the set of structural layers is at least partially transparent, so that light reflected from the substrate passes through the first color layer, passes through the set of structural layers, and passes through the second color layer to reflect toward an observer. 2 . The method of claim 1 , further comprising printing one or more transparent layers onto the second color layer.

3. The method according to claim 2, wherein: Each of the one or more transparent layers has a thickness equal to the predetermined structural layer thickness.

4. The method according to claim 1, wherein: The first color layer is printed such that a thickness of the first color layer is visible at a specific viewing angle.

5. The method according to claim 1, wherein: The set of structural layers is transparent.

6. A method of printing a three-dimensional object onto a substrate using a printing system, the method comprising: Receiving at the printing system: a first target thickness for a first region of the three-dimensional object; a predetermined number of structural layers to be printed; and color layer information about each of the first color layer and the second color layer; receiving the substrate at the printing system; calculating a structural layer thickness for a printed layer to be printed to achieve a target thickness for the first zone using the first target thickness and the predetermined number of structural layers; printing the first color layer onto the substrate using the received color layer information about the first color layer; printing a set of structural layers onto the first color layer, the number of layers in the set of structural layers being equal to the predetermined number of structural layers, and each layer in the set of structural layers in the first zone having the calculated structural layer thickness; and printing the second color layer onto the set of structural layers using the received color layer information about the second color layer; wherein the set of structural layers in a second zone adjacent to the first zone is printed onto the first color layer to achieve a second target thickness different from the first target thickness; The method further includes receiving, at the printing system, the second target thickness for the second zone, printing the set of structural layers in the second zone to achieve the second target thickness for the second zone; wherein the set of structural layers in the first region and in the second region are arranged to jointly form an upper surface having a surface contour; and Wherein, the set of structural layers is at least partially transparent, so that light reflected from the substrate passes through the first color layer, passes through the set of structural layers, and passes through the second color layer to reflect toward an observer.

7. The method according to claim 6, wherein: A combination of the first color layer, the set of structural layers in the first zone, and the second color layer has a thickness equal to the first target thickness.

8. The method of claim 6, further comprising printing one or more transparent layers onto the second color layer.

9. The method according to claim 8, wherein: A combination of the first color layer, the set of structural layers in the first zone, the second color layer, and the one or more transparent layers has a thickness equal to the first target thickness.

10. The method according to claim 8, wherein: The combination of the one or more transparent layers is printed to have a thickness that is less than a combined thickness of the set of structural layers in the first region.

11. The method according to claim 6, wherein: The first color layer is printed such that a thickness of the first color layer is visible at a specific viewing angle.

12. The method according to claim 6, wherein: The set of structural layers is transparent.

13. A method of printing a three-dimensional object onto a substrate using a printing system, the method comprising: Receiving at the printing system: a first target thickness for a first region of the object; a second target thickness for a second region of the object; as well as Color layer information; receiving the substrate at the printing system; printing a first color layer onto the substrate using the color layer information; printing a set of structural layers onto the first color layer, the set of structural layers in the first zone being printed to achieve the first target thickness with respect to the first zone, and the set of structural layers in the second zone being printed to achieve the second target thickness with respect to the second zone, the second target thickness with respect to the second zone being different from the first target thickness with respect to the first zone; printing a second color layer onto the set of structural layers using the color layer information; and printing a transparent layer onto the second color layer; wherein the first region is adjacent to the second region, so that the set of structural layers in the first region and in the second region are arranged to jointly form an upper surface having a surface contour; and Wherein, the set of structural layers is at least partially transparent, so that light reflected from the substrate passes through the first color layer, through the set of structural layers, through the second color layer and through the transparent layer to reflect toward an observer.

14. The method according to claim 13, wherein: The surface profile is a target surface profile corresponding to the first target thickness with respect to the first region and the second target thickness with respect to the second region.

15. The method according to claim 14, wherein: The second color layer has a surface profile that is the same as the target surface profile.

16. The method according to claim 14, wherein: The transparent layer has a surface profile that is the same as a surface profile of the target.

17. The method according to claim 14, wherein: The first color layer has a surface profile that is different from the target surface profile.

18. The method according to claim 14, wherein: The substrate has a surface profile that is different from the target surface profile.

19. The method according to claim 13, wherein: The substrate has a substrate color that is different from the first color layer color and the second color layer color, and wherein the object is printed onto the substrate such that the substrate color is visible when the object is viewed from a particular viewing angle.

20. The method according to claim 13, wherein: The set of structural layers is transparent.

Images