Three-dimensional printing along curved surfaces

Abstract

This application relates to three-dimensional printing along a curved surface. A method and apparatus for printing onto a curved surface of an article (200) are disclosed. Embodiments of the method may include receiving the article and extruding a composite yarn (202) from a nozzle (118). The method may include attaching the composite yarn to the curved surface by moving the nozzle along the curved surface in a direction aligned with a first axis and in a direction aligned with a second axis. The first axis may be approximately normal to the printing surface, and the second axis may be approximately orthogonal to the first direction. The article may be repositioned during printing to accommodate the movement of the nozzle.

Description

[0001] This application is a divisional application of the application filed on September 21, 2016, with application number 201680076604.1 and invention title "Three-dimensional printing along curved surfaces". background

[0002] This implementation plan generally involves three-dimensional printing systems and methods.

[0003] Three-dimensional printing systems and methods can be associated with a variety of technologies, including fused deposition modeling (FDM), electron beam freeform fabrication (EBF), selective laser sintering (SLS), and other types of three-dimensional printing technologies. Summary of the Invention

[0004] This disclosure relates to a method of printing on a curved surface of an article, the method comprising: positioning the article at a first position on an upper surface of a base of a printing system; wherein the upper surface of the base defines a vertical axis perpendicular to the upper surface of the base; and wherein the upper surface of the base defines a first horizontal axis parallel to the upper surface of the base and perpendicular to the vertical axis; discharging printing material from a nozzle of the printing system; attaching the printing material to the printing surface by moving the nozzle on the printing surface of the article in a direction aligned with the vertical axis and simultaneously moving the nozzle on the printing surface in a direction aligned with the first horizontal axis, wherein the printing surface includes at least one curved region; and wherein, when attaching the printing material to the printing surface, the nozzle is spaced apart from the printing surface by a printing distance.

[0005] In one embodiment, the method further includes maintaining a substantially constant printing distance between the nozzle and the printing surface while printing on the printing surface.

[0006] In one embodiment, the method further includes attaching the printing material to the printing surface by moving the nozzle in a direction aligned with the vertical axis and simultaneously moving the nozzle in a direction aligned with a second horizontal axis, wherein the second horizontal axis is perpendicular to the first horizontal axis and parallel to the upper surface of the base.

[0007] In one embodiment, the printing system includes an actuation system.

[0008] In one embodiment, the method further includes reducing the printing distance between the nozzle and the printing surface by moving the nozzle downward in a direction aligned with the vertical axis when attaching the printing material to the printing surface.

[0009] In one embodiment, the printing material comprises a continuous composite yarn made of a thermoplastic material.

[0010] In one embodiment, the printing material comprises a series of droplets.

[0011] In one embodiment, the method further includes printing at least one three-dimensional structure onto the article.

[0012] In one embodiment, the method further includes forming at least one embroidered pattern on the article.

[0013] In one embodiment, the at least one embroidered pattern is formed on an area of ​​the article that is curved relative to the vertical axis.

[0014] In one embodiment, the method further includes using an actuation system to reposition the article such that the article moves to a second position, wherein the first position is different from the second position.

[0015] This disclosure relates to a method for printing a three-dimensional structure on a curved surface of an article, the method comprising: placing the article on a base of a printing system; discharging a continuous composite yarn from a nozzle of the printing system; attaching the continuous composite yarn to the curved surface of the article to form a first printed layer on the curved surface, the first printed layer having an exposed outer surface; attaching the continuous composite yarn to at least a portion of the outer surface of the first printed layer to form a second printed layer; and forming a three-dimensional first structure on the curved surface.

[0016] In one implementation, the first structure of the three dimensions is a shoe nail.

[0017] In one embodiment, the method further includes heating at least a portion of the continuous composite yarn of the first printed layer and at least a portion of the continuous composite yarn of the second printed layer to help attach the first printed layer to the second printed layer.

[0018] In one embodiment, discharging the continuous composite yarn includes extruding the continuous composite yarn from the nozzle.

[0019] In one embodiment, attaching the continuous composite yarn to the curved surface includes moving the nozzle in a direction aligned with a vertical axis and in a direction aligned with a horizontal axis, wherein the vertical axis is approximately normal to the base and wherein the horizontal axis is approximately perpendicular to the vertical axis.

[0020] This disclosure relates to an apparatus for printing onto a curved surface of an article, the apparatus comprising: a housing including a base disposed along the bottom of the housing; a nozzle configured to discharge a composite yarn onto the curved surface; a first actuation system configured to move the nozzle, wherein the first actuation system moves the nozzle in a direction aligned with a vertical axis extending normally to a surface of the base, and wherein the first actuation system moves the nozzle in a direction aligned with a first horizontal axis approximately parallel to the base; the apparatus is configured to attach the composite yarn to the curved surface by moving the nozzle downward toward the curved surface in a direction aligned with the vertical axis; and the apparatus is configured to attach the composite yarn to the curved surface by moving the nozzle in a direction aligned with the first horizontal axis.

[0021] In one embodiment, the device further includes: a second actuation system configured to adjust the position of the article relative to the nozzle, wherein the second actuation system moves the article in a direction parallel to the vertical axis, and wherein the second actuation system moves the article in a direction parallel to the first horizontal axis; the device is configured to facilitate the attachment of the composite yarn to the curved surface of the article by moving the article in a direction parallel to the vertical axis; and the device is configured to facilitate the attachment of the composite yarn to the curved surface of the article by moving the article in a direction parallel to the first horizontal axis.

[0022] In one embodiment, the device further includes a second actuation system configured to rotate the article, wherein the second actuation system rotates the article about a second horizontal axis that is approximately parallel to the base.

[0023] In one embodiment, the article is an upper for at least partial assembly of footwear articles.

[0024] In one embodiment, the first actuation system moves the nozzle in a direction aligned with a third horizontal axis, wherein the third horizontal axis is perpendicular to both the vertical axis and the first horizontal axis; and wherein the instrument is configured to attach the composite yarn to the curved surface by moving the nozzle in a direction aligned with the third horizontal axis. Brief description of the attached diagram

[0025] The following figures and descriptions will provide a better understanding of the embodiments. The components in the figures are not necessarily drawn to scale; rather, the emphasis is on the principles of the illustrated embodiments. Furthermore, in the figures, the same reference numerals refer to the corresponding parts in all the different views.

[0026] Figure 1 It is a schematic diagram of the components of a three-dimensional printing system and several articles that can be used with the three-dimensional printing system;

[0027] Figure 2 This is a schematic diagram of the implementation scheme for the printing apparatus and base;

[0028] Figure 3 This is a schematic diagram of the implementation scheme for the articles and printing apparatus;

[0029] Figure 4 This is a schematic diagram of the implementation scheme for the articles and printing apparatus;

[0030] Figure 5 This is a schematic diagram of the implementation scheme for the articles and printing apparatus;

[0031] Figure 6 This is a schematic diagram of the implementation scheme for the articles and printing apparatus;

[0032] Figure 7 This is a schematic diagram of the implementation scheme for the articles and printing apparatus;

[0033] Figure 8 This is a schematic diagram of the implementation scheme for the articles and printing apparatus;

[0034] Figure 9 An enlarged view of an embodiment that is part of an article and printing apparatus;

[0035] Figure 10 An enlarged view of an embodiment that is part of an article and printing apparatus;

[0036] Figure 11 An enlarged view of an embodiment that is part of an article and printing apparatus;

[0037] Figure 12 This is a schematic diagram of an implementation scheme for the article and nozzle assembly;

[0038] Figure 13 This is a schematic diagram of an implementation scheme for the article and nozzle assembly;

[0039] Figure 14 This is a schematic diagram of an implementation scheme for the article and nozzle assembly;

[0040] Figure 15 This is a schematic diagram of an implementation scheme for the article and nozzle assembly;

[0041] Figure 16 This is a schematic diagram of an implementation scheme for the article and nozzle assembly;

[0042] Figure 17 This is a schematic diagram of an implementation scheme for the article and nozzle assembly;

[0043] Figure 18 It is a schematic diagram of an implementation scheme for the article and nozzle assembly; and

[0044] Figure 19 This is a schematic diagram of an implementation scheme for the article and nozzle assembly. Detailed description

[0045] In one embodiment, a method of printing on a curved surface may include positioning an article in a first position on the upper surface of a base of a printing system. The upper surface of the base defines a vertical axis perpendicular to the upper surface of the base, and also defines a first horizontal axis parallel to the upper surface of the base and perpendicular to the vertical axis. The method may further include discharging printing material, such as composite yarn, from a nozzle. The printing surface may include at least one curved area. By moving a nozzle above the printing surface in a direction aligned with the vertical axis, and simultaneously moving the nozzle on the printing surface in a direction aligned with the first horizontal axis, the printing system can be used to attach printing material to the printing surface of the article. When attaching the printing material to the printing surface, the nozzle and the printing surface are spaced apart by a printing distance.

[0046] In another embodiment, a method of printing a three-dimensional structure on a curved surface of an article may include: placing the article on a base of a printing system; discharging a continuous composite yarn from a nozzle of the printing system; and attaching the continuous composite yarn to the curved surface of the article to form a first portion of a first printed layer on the curved surface. The method further includes: forming a first printed layer having an exposed outer surface; attaching the continuous composite yarn to at least a portion of the outer surface of the first printed layer to form at least a second printed layer; and forming a three-dimensional first structure on the curved surface.

[0047] In another embodiment, an apparatus for printing onto a curved surface of an article may include a housing and a nozzle, wherein the housing includes a base disposed along the bottom of the housing, and the nozzle is configured to discharge composite yarn onto the curved surface. The apparatus may also include a first actuation system configured to move the nozzle, wherein the first actuation system is movable in a direction aligned with a first vertical axis extending normally to the surface of the base, and wherein the first actuation system is movable in a direction aligned with a first horizontal axis approximately parallel to the base. The apparatus is configured to attach composite yarn to a curved surface by moving the nozzle downward toward the curved surface in a direction aligned with the first vertical axis, and the apparatus is also configured to attach composite yarn to the curved surface by moving the nozzle in a direction aligned with the first horizontal axis.

[0048] Other systems, methods, features, and advantages of the embodiments will be apparent or will become apparent to those skilled in the art after reviewing the following figures and detailed description. It is intended that all such additional systems, methods, features, and advantages are included in this description and overview, within the scope of the embodiments, and protected by the appended claims.

[0049] Figure 1 This is a schematic diagram of the implementation scheme of the three-dimensional printing system 100, hereinafter also referred to as the printing system 100. Figure 1 Several exemplary articles 130 that can be used with the printing system 100 are also shown. (Reference) Figure 1 The printing system 100 may also include a printing device 102, a computing system 104, and a network 106.

[0050] Implementations can utilize various types of 3D printing (or additive manufacturing) techniques. 3D printing, or “3D stenciling,” encompasses a variety of techniques for forming three-dimensional objects by depositing successive layers of material on top of each other. Exemplary 3D printing techniques that can be used include, but are not limited to: fused filament fabrication (FFF), electron beam freeform fabrication (EBF), direct metal laser sintering (DMLS), electron beam melting (EMB), selective laser melting (SLM), selective thermal sintering (SHS), selective laser sintering (SLS), plaster-based 3D printing (PP), laminated object fabrication (LOM), stereolithography (SLA), and digital light processing (DLP), as well as various other 3D printing or additive manufacturing techniques known in the art.

[0051] For consistency and convenience, directional adjectives are used throughout this detailed description corresponding to the illustrated embodiments. As used throughout this detailed description and in the claims, the term "longitudinal axis" refers to the axis of the length of the extending member. Therefore, as used throughout this detailed description and in the claims, the term "longitudinal direction" refers to a direction aligned with the longitudinal axis.

[0052] As used throughout this detailed description and in the claims, the term "lateral axis" refers to the axis of the width of the extending member from one side to the other. For example, the lateral axis may extend between the inner and outer surfaces of a footwear article, wherein the outer surface of the footwear article is the surface facing away from the other foot, and the inner surface is the surface facing the other foot. Therefore, as used throughout this detailed description and in the claims, the term "lateral direction" refers to a direction aligned with the lateral axis.

[0053] As used throughout this detailed description and in the claims, the term "horizontal" means any direction and axis that is substantially parallel to the longitudinal axis, the transverse axis, and all directions in between. When the component is placed on the ground, the horizontal axis may be parallel to the ground.

[0054] As used throughout this detailed description and in the claims, the term "vertical" means an axis that is generally vertical (upward and downward) oriented and substantially perpendicular to both the transverse and longitudinal axes. For example, when the component is laid flat on a ground surface, the vertical axis may extend upward from the ground surface.

[0055] It should be understood that each of these directional adjectives can be applied to various components of the sole. Furthermore, as used throughout this detailed description and claims, the term "outer surface" refers to the exposed or externally oriented surface of a component.

[0056] For the purposes of this disclosure, when referring to printing systems or footwear or other clothing articles, the aforementioned directional terms shall refer to articles arranged on a generally flat surface. Regarding footwear, the directional terms refer to articles in an upright position with the soles facing the ground, i.e., as the article would be positioned when worn by a wearer standing on a generally horizontal surface.

[0057] In the embodiment shown in the figure, the printing system 100 may be associated with fused filament fabrication (FFF), also known as fused deposition modeling. Figure 1 In the embodiment shown, the printing apparatus 102 of the printing system 100 can use fused filament fabrication to produce three-dimensional parts. An example of a printing apparatus using fused filament fabrication (FFF) is disclosed in U.S. Patent No. 5,121,329 to Crump, entitled “Apparatus and Method for Creating Three-Dimensional Objects,” issued June 9, 1992. This application is incorporated herein by reference and is hereinafter referred to as the “3D Objects Application.” Embodiments of this disclosure can be used with any of the systems, components, apparatuses, and methods disclosed in the 3D Objects Application.

[0058] Printing apparatus 102 may include a housing 110 that supports various systems, devices, components, or other provisions that facilitate the three-dimensional printing of objects (e.g., parts, components, structures). While exemplary embodiments depict a specific rectangular box-like geometry for housing 110, other embodiments may use any housing having any geometry and / or design. The shape and size of housing 110 may vary depending on factors including the required footprint for the device, the size and shape of components that can be formed within printing apparatus 102, and other possible factors. It should be understood that housing 110 may be open (e.g., providing a frame with a large opening) or closed (e.g., closed with a panel of glass or solid material, and a door).

[0059] In some embodiments, the printing apparatus 102 may include equipment for holding or accommodating a printed object (or a component supporting the printed object). In some embodiments, the printing apparatus 102 may include a table, base, platform, tray, or similar component to support, hold, and / or accommodate the object to be printed or the object on which printing material is applied. Figure 1 In some embodiments, the printing apparatus 102 includes a surface referred to as base 112. In some embodiments, base 112 may be fixed in place and serve as a stable base. However, in other embodiments, base 112 may be movable. For example, in some cases, base 112 may be configured to translate within housing 110 in various horizontal directions (e.g., front-to-back and / or left-to-right relative to housing 110) and vertical directions (e.g., up-and-down within housing 110). Furthermore, in some cases, base 112 may be configured to rotate and / or tilt about one or more axes associated with base 112. Thus, it is contemplated that, in at least some embodiments, base 112 may be configured in any desired relative configuration with the nozzle or printhead of printing apparatus 102. In other embodiments, printing apparatus 102 may not include base 112. In some embodiments, base 112 may be curved, irregularly shaped, or shaped to provide a custom platform on which articles or objects may be placed or fixed. However, in other embodiments, base 112 may include a generally flat surface. In some embodiments, the printing apparatus 102 may include an open space or cavity formed within the base 112.

[0060] In some embodiments, the printing apparatus 102 may include one or more systems, devices, components, or parts for conveying printing material (or printing substance) to a target location. The target location may include the surface of the base 112, a partially printed structure, or a portion of a non-printed structure or part. Equipment for conveying the printing material may include, for example, a printhead and nozzles. Figure 1 In one embodiment, the printing apparatus 102 includes a nozzle assembly 116.

[0061] The nozzle assembly 116 may include one or more nozzles for delivering printing material to a target location. For clarity, Figure 1 The exemplary embodiment depicts a single nozzle 118 of nozzle assembly 116. However, in other embodiments, nozzle assembly 116 may be configured with any number of nozzles, which may be arranged in an array or any particular configuration. In embodiments including two or more nozzles, the nozzles may be configured to move together and / or independently.

[0062] Nozzle 118 may be configured with nozzle orifice 119, which can be opened and / or closed to control the flow of material exiting nozzle 118. Specifically, nozzle orifice 119 may be in fluid communication with nozzle channel 121, which receives a material supply from a material source (not shown) within printing apparatus 102. Some examples of materials that may be accepted or used are disclosed in U.S. Patent Publication No. 2017 / 0129176A1 to Waatti et al., filed November 9, 2015, entitled “Tack and Drag Printing Method,” which is incorporated herein by reference in its entirety and is hereinafter referred to as the “Tack and Drag” case.

[0063] In some embodiments, a worm gear actuator may be used to push the filament into the nozzle 118 at a specific rate (which can be varied to achieve the desired volumetric flow rate of material from the nozzle 118). In other embodiments, the worm gear actuator is omitted. For example, an actuation system may be used to pull the material out of the nozzle 118. It should be understood that in some cases, the material supply may be provided at a location near the nozzle 118 (e.g., within a portion of the nozzle assembly 116), while in other embodiments, the material supply may be located at some other location on the printing apparatus 102 and supplied to the nozzle assembly 116 via a tube, conduit, or other device.

[0064] As will be described below, printing system 100 may include devices for facilitating the alignment of printed designs or graphics onto an article. In some embodiments, it may be useful to provide a user with a manner to align the article with printing system 100 in order to ensure that the graphic is printed in the desired portion of the article. In particular, printing system 100 may include devices for programming the orientation of the article via printing device 102 in such a way as to accommodate articles of various types, shapes, curves, and sizes.

[0065] In some embodiments, the nozzle assembly 116 is associated with a first actuation system 114. The first actuation system 114 may include various components, devices, and systems that facilitate movement of the nozzle assembly 116 within the housing 110. Specifically, the first actuation system 114 may include means for moving the nozzle assembly 116 in any horizontal direction (including, but not limited to, directions aligned with the longitudinal axis 124 and the transverse axis 126) and / or in a direction aligned with the vertical axis 122, to facilitate material deposition to form three-dimensional objects or to print along three-dimensional or curved surfaces. For this purpose, embodiments of the first actuation system 114 may include one or more guide rails, tracks, and / or similar devices to hold the nozzle assembly 116 in various positions and / or orientations within the housing 110. Embodiments may also include any type of motor, such as a stepper motor or a servo motor, to move the nozzle assembly 116 along the guide rails or tracks, and / or to move one or more guide rails or tracks relative to each other.

[0066] For the purposes of this description, an object or article having a curved surface refers to an article having one or more portions including curves, bumps, and regions of varying thickness, such as... Figure 1 Article 130. For example, the article may have flat, smooth, horizontal, or level areas with relatively small thickness. However, the same article may also include curved areas having a surface that deviates from straightness in some or all of its length or area. In some embodiments, the curved surface or curved area defines a portion of the article that increases and / or decreases in height or thickness associated with the vertical axis of the article. In some embodiments, the curved surface may include regular geometric curves, such as curves associated with circles, triangles, squares, and other geometries, and / or they may also be irregular, for example, in articles shaped to adapt to or include a particular uneven construction.

[0067] The actuation system can be configured to move the nozzle in one or more directions. In some embodiments, the actuation system can move the nozzle in a single linear direction. In other embodiments, the actuation system can move the nozzle in at least two vertical directions. Still in other embodiments, the actuation system can move the nozzle in three vertical directions. For example, in... Figure 1 In the exemplary embodiment shown, the first actuation system 114 may be configured to move the nozzle 118 in a first direction 160 (here analogous to an upward direction), a second direction 161 (here analogous to a downward direction), a third direction 162, a fourth direction 163, a fifth direction 164, and a sixth direction 165. Figure 1 As seen in some embodiments, the first direction 160 and the second direction 161 may be aligned with the vertical axis 122 and may represent generally opposite directions. Furthermore, in some embodiments, the third direction 162 and the fourth direction 163 may be aligned with the longitudinal axis 124 and may represent generally opposite directions. Additionally, in some embodiments, the fifth direction 164 and the sixth direction 165 may be aligned with the transverse axis 126 and may represent generally opposite directions. Therefore, the third direction 162, the fourth direction 163, the fifth direction 164, and the sixth direction 165 may represent generally horizontally oriented directions (e.g., length and width directions), while the first direction 160 and the second direction 161 may represent vertically oriented directions (e.g., height direction). Of course, although the exemplary embodiments depict an actuation system capable of moving the nozzle via three independent xyz or Cartesian directions, other embodiments may be configured to move the nozzle in six independent directions associated with a non-Cartesian coordinate system (e.g., a spherical or cylindrical coordinate system). In other cases, the actuation system can move the nozzle through six or more different directions that may not be orthogonal (e.g., directions of an inclined coordinate system).

[0068] In some embodiments, the first direction 160 and / or the second direction 161 may form a non-zero angle relative to a surface, such as the base 112 or the printed surface 148. For example, in Figure 2 In this embodiment, the first direction 160 and the second direction 161 are approximately normal to the base 112. As used herein, a direction is approximately normal to the surface when it is within 10 degrees of being perpendicular to the surface. Therefore, in different embodiments, the first direction 160, the second direction 161, and / or the nozzle 118 may form non-zero angles relative to the printing surface 148 and / or the base 112.

[0069] For the purposes of this discussion, the printing surface can be associated with the surface that the nozzle is printing on. For the purposes of this disclosure, printing surface 148 refers to the surface of an article that receives or is attached to a printed material, such as composite yarn or other material extruded or otherwise ejected or ejected from the nozzle 118 during printing. For example, in the case where the nozzle 118 prints directly onto the base 112, the printing surface is associated with or includes the surface of the base 112. Figure 1In one embodiment, the printing surface 148 is illustrated as a side of the base 112 facing upward toward the nozzle assembly 116. However, it should be noted that in other embodiments, the printing surface 148 may include a surface or side of an article or object printed thereon by the nozzle 118. The printing surface 148 may be generally flat, or it may be generally curved and include a contour. In one embodiment, the printing surface 148 may be a side or surface of an object or article that is generally normal to the vertical axis 122. However, in other embodiments, such as when the article is not flat, the printing surface 148 may not be normal to the vertical axis 122.

[0070] In some embodiments, the printing system 100 can selectively move the nozzle 118. In one embodiment, as noted above, the printing system 100 moves the nozzle 118 simultaneously in directions aligned with three different axes. In one example, the printing system 100 may move the nozzle 118 away from the base 112 in a first direction 160 while simultaneously moving the nozzle 118 above the printing surface 148 in a third direction 162 and / or a fifth direction 164. In another example, positioning along one direction is maintained when the printing system 100 selectively moves the nozzle 118 in another direction. The printing system 100 may move the nozzle 118 toward the printing surface 148 in a second direction 161 while maintaining the nozzle 118 in its base position above the printing surface 148 along the longitudinal axis 124 and the transverse axis 122. For example, printing system 100 can move nozzle 118 away from base 112 in a first direction 160 while simultaneously maintaining the base position of nozzle 118 in a third direction 162, a fourth direction 163, a fifth direction 164, and a sixth direction 165 (i.e., remaining stationary relative to these directions). In another example, printing system 100 can maintain a printing distance 216 from nozzle 118 relative to vertical axis 122 (see [link to printing system]). Figure 2 Meanwhile, the nozzle 118 is moved parallel to the printing surface 148 in the horizontal direction (e.g., third direction 162, fourth direction 163, fifth direction 164 and sixth direction 165).

[0071] For the purposes of this description, the printing distance is 216 (e.g., ...). Figure 2(As shown) refers to the distance or height extending along the vertical axis 122 between the nozzle 118 and the printing surface 148. Therefore, in some embodiments, since the printing surface 148 may be curved or otherwise vary in height, the printing distance 216 can increase or decrease without any corresponding vertical movement of the nozzle 118 as the nozzle moves in the horizontal plane. In other words, the printing distance 216 can change even if the distance between the nozzle 118 and the base 112 remains constant due to the undulating geometry of the object below. In other embodiments, the printing distance 216 may remain constant as the nozzle 118 moves in the horizontal plane. In one embodiment, the distance between the nozzle 118 and the base 112 can change due to the vertical movement of the nozzle 118 while the nozzle 118 maintains a constant printing distance 216 relative to the printing surface 148. Therefore, the printing system 100 can maintain a substantially constant distance between the nozzle 118 and the printing surface 148, which can be advantageous for direct printing onto objects with a certain curvature and / or surface texture.

[0072] In various embodiments, one or more articles 130 may be associated with a second actuation system 190 that may be included in the printing system 100. The second actuation system 190 may include various components, devices, and systems that facilitate movement of the articles 130 within the housing 110. Although exemplary embodiments depict a specific rectangular box-like geometry for the second actuation system 190, other embodiments may use any system having any geometry and / or design. The shape and size of the actuation system may vary depending on factors including the articles being printed, the size and shape of components that may be formed within the printing apparatus 102, and other possible factors.

[0073] Specifically, the second actuation system 190 may include means for moving the article 130 in any horizontal and / or vertical orientation to facilitate positioning of the article 130 below the nozzle 118 for printing along a three-dimensional surface. For this purpose, embodiments of the second actuation system 190 may include one or more guide rails, tracks, and / or similar means to hold the article 130 in various positions and / or orientations within the housing 110. Embodiments may also include any type of motor, such as a stepper motor or servo motor, to move the article 130 along the guide rails or tracks, and / or to move one or more guide rails or tracks relative to each other. In some embodiments, a fixing device 192, such as a clamp, jaw, or other adjustable gripping member, may be present in the second actuation system 190 to provide attachment between the second actuation system 190 and the article 130. In other embodiments, the fixing device 192 may not be present. It should be noted that portions of the second actuation system 190 may be positioned in various locations within the printing system 100 to provide the necessary orientation for the article 130.

[0074] Therefore, the second actuation system 190 can be configured to move the article in one or more directions. In some embodiments, the actuation system can move the article in a single linear direction or in two linear directions. In other embodiments, the actuation system can move the article in at least two vertical directions. In still other embodiments, the actuation system can move the article in at least three vertical directions. For example, in Figure 1 In the exemplary embodiment shown, the second actuation system 190 may be configured to move the item 130 in a first direction 160, a second direction 161, a third direction 162, a fourth direction 163, a fifth direction 164, and a sixth direction 165. Figure 1 As seen, the first direction 160 and the second direction 161 can be associated with the vertical axis of the housing 110, while the third direction 162, the fourth direction 163, the fifth direction 164, and the sixth direction 165 can be associated with the horizontal directions of the housing 110 (e.g., the length and width directions). Of course, although the exemplary embodiment depicts a second actuation system 190 capable of moving an article via three independent xyz or Cartesian directions, other embodiments can be configured to move the article in six independent directions associated with a non-Cartesian coordinate system (e.g., a spherical or cylindrical coordinate system). Additionally, in other cases, the actuation system can cause the article to move via six different directions that may be non-orthogonal (e.g., directions in an inclined coordinate system).

[0075] In some embodiments, the printing system 100 may selectively move the article using a second actuation system 190 or another mechanism. In one embodiment, the printing system 100 may move the article in three directions simultaneously. For example, the printing system 100 may move the article 130 away from the base 112 in a first direction 160, while simultaneously moving the article 130 in a third direction 163 and / or a fifth direction 164, which are generally parallel to the base 112. In other embodiments, positioning along one direction is maintained while the printing system 100 selectively moves the article 130 in another direction. In some embodiments, the printing system 100 may move the article 130 away from or toward the base 112 relative to the vertical axis 122 while maintaining the base position of the article 130 relative to the transverse axis 126 and the longitudinal axis 124. For example, the printing system 100 can move the article 130 away from the base 112 in a first direction 160, while simultaneously maintaining the base position of the article 130 in a third direction 162, a fourth direction 163, a fifth direction 164, and a sixth direction 165. In some embodiments, the printing system 100 can maintain a printing distance 216 from the article 130 along the vertical axis 122 while moving the article 130 parallel to the base of the housing 110. For example, the printing system 100 can maintain a printing distance 216 from the article 130 along the vertical axis 122 while simultaneously moving the article 130 in directions aligned with the transverse axis 126 and the longitudinal axis 124.

[0076] In some embodiments, components of the printing system 100 associated with the second actuation system 190 may be particularly adapted to hold the article 130 in a fixed position or orientation. For example, some embodiments may include various types of mounting devices, harnesses, temporary adhesives, or other equipment that can temporarily hold or maintain the position of the article relative to the housing 110. Such equipment can help precisely orient specific portions of the article toward the nozzle 118 (and correspondingly toward other components of the printing apparatus 102). For example, some embodiments may utilize harnesses that hold the article in orientation and position above the base 112, allowing three-dimensional designs to be printed onto any desired portion of the article, such as footwear. These devices can also reduce the tendency for the article to move or be squeezed as the position of the base 112 is adjusted or as the nozzle 118 extrudes printing material onto the article 130.

[0077] Furthermore, in some embodiments, another mechanism of the second actuation system 190 or printing system 100 may rotate or reposition the article 130 in a horizontal plane about a horizontal axis oriented relative to the vertical axis 122, or in a vertical plane about a vertical axis oriented relative to the longitudinal axis 124 and / or the transverse axis 126. For example, in some embodiments, there may be a mechanism that allows the article 130 to rotate between about 10 degrees and about 90 degrees. In other embodiments, there may be a mechanism that allows the article 130 to rotate at least about 180 degrees. In one embodiment, there may be a mechanism that allows rotation of about 360 degrees. In other embodiments, the printing system 100 may have rotation of the article 130 between about 180 degrees and about 360 degrees. For example, in one embodiment, the printing system 100 may include means for rotating the article 130 in a horizontal plane about a horizontal axis oriented relative to the vertical axis 122. In another embodiment, the printing system 100 may include means for rotating the article 130 in a vertical plane about a vertical axis oriented relative to the longitudinal axis 124 and / or the transverse axis 126. In some embodiments, the printing system 100 may include means for rotating the article 130 in both a horizontal and a vertical plane. In one embodiment, the repositioning movement of the article 130 may not be circular (i.e., rotational), but may involve non-circular, linear, or other irregular repositioning of the article 130.

[0078] Therefore, in some embodiments, the article 130 can be oriented in multiple locations within the housing 110 during printing. It should be noted that the first actuation system 114 and the second actuation system 190 can operate simultaneously or independently during use of the printing system 100. Additionally, the first actuation system 114 and the second actuation system 190 can be coupled to allow them to operate collaboratively with each other during printing. Furthermore, in some embodiments, the printing apparatus 102 may include a base 112 that is movable independently of the second actuation system 190. In other embodiments, the second actuation system 190 may be fixed to the base 112, causing components to move or operate uniformly. In one embodiment, the base may be absent, allowing the second actuation system 190 to operate to move articles independently of the platform or tray surface.

[0079] In some implementations, repositioning can be initiated or performed by a user. For example, in some implementations, the first actuation system 114 and / or the second actuation system 190 can be manually operated by a user. In other implementations, the repositioning of the article 130 can occur automatically via the printing system 100. For example, there may be devices that automate the operation of the first actuation system 114 and the second actuation system 190. In one example, some implementations may include motors and / or other devices for automatically driving the nozzle 118 along one or more tracks to various positions. Moreover, in automated implementations, the position or speed of the nozzle 118 and / or the article 130 can be adjusted using a controller provided in the printing system 100 or using an associated system such as the computing system 104, which will be discussed in further detail below.

[0080] It should be understood that, for the purpose of explanation, Figure 1 The components, devices, and systems of the printing apparatus 102 are schematically illustrated. Therefore, it should be understood that embodiments may include additional equipment (not shown), including specific portions, components, and devices that facilitate the operation of the first actuation system 114, the second actuation system 190, and the nozzle assembly 116. For example, the first actuation system 114 is schematically shown as including several guide rails or tracks, but the specific construction and number of portions including the first actuation system 114 may vary depending on the embodiment.

[0081] As discussed above, printing system 100 may include devices for controlling and / or receiving information from printing apparatus 102. These devices may include computing system 104 and network 106. Generally, 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 communicating with each other. Any of these resources may be operated by one or more human users. In some embodiments, computing system 104 may include one or more servers. In some cases, the printing server may be primarily responsible for controlling and / or communicating with printing apparatus 102, while separate computers (e.g., desktops, laptops, or tablets) may facilitate interaction with the user. Computing system 104 may also include one or more storage devices, including but not limited to magnetic storage devices, optical storage devices, magneto-optical storage devices, and / or memories (including volatile and non-volatile memories).

[0082] exist Figure 1In exemplary embodiments, the computing system 104 may include a central processing unit 185, a viewing interface 186 (e.g., a monitor or screen), an input device 187 (e.g., a keyboard and mouse), and software for designing a computer-aided design (“CAD”) representation 189 of the printed structure. In at least some embodiments, the CAD representation 189 of the printed structure may include not only information about the geometry of the structure, but also information related to the materials required for the various parts of the printed structure.

[0083] In some embodiments, computing system 104 may communicate directly with printing apparatus 102 via network 106. Network 106 may include any wired or wireless device that facilitates information exchange between computing system 104 and printing apparatus 102. In some embodiments, network 106 may also include various components such as network interface controllers, repeaters, hubs, bridges, switches, routers, modems, and firewalls. In some cases, network 106 may be a wireless network that facilitates wireless communication between two or more systems, devices, and / or components of 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, and mobile device networks, as well as other types of wireless networks. In other cases, network 106 may be a wired network including networks whose signals are facilitated via twisted-pair wires, coaxial cables, and optical fibers. In still other cases, a combination of wired and wireless networks and / or connections may be used.

[0084] The printing system 100 can operate as follows to form one or more structures using 3D printing or additive processes. The computing system 104 can be used to design the structures. This can be achieved using some type of CAD software or other types of software. The design can then be converted into information that can be interpreted by the printing apparatus 102 (or an associated printing server communicating with the printing apparatus 102). In some cases, the design can be converted into a 3D printable file, such as a stereolithography file (STL file).

[0085] Before printing, the article can be placed on the base 112 or secured using the second actuation system 190. Once the printing process begins (e.g., by a user), the printing apparatus 102 can begin depositing material onto the article. This can be achieved by moving the nozzle 118 (using the first actuation system 114) to build layers of structure using the deposited material. In embodiments using molten filament fabrication, the material extruded from the nozzle 118 can be heated to increase its flexibility during the deposition of the heat moldable material.

[0086] While some embodiments shown in the accompanying drawings depict systems using filament melting printing technology, it should be understood that other embodiments may incorporate one or more different 3D printing technologies. For example, printing system 100 may use a tack printing method, as described in the tack printing section. Furthermore, other embodiments may incorporate a combination of filament melting and another type of 3D printing technology to achieve desired results for specific printed structures or parts.

[0087] In various embodiments, the printing apparatus 102 may use a variety of different materials to form 3D parts, including but not limited to: thermoplastics (e.g., polylactic acid and acrylonitrile butadiene styrene), high-density polyethylene, eutectic metals, rubber, clay (including metallic clay), room temperature vulcanizing silicone (RTV silicone), and ceramic materials, as well as other possible types of materials known in the art. In embodiments where two or more different printing or extrusion materials are used to form parts, any two or more of the materials disclosed above may be used. In some embodiments, the printing apparatus 102 may extrude, discharge, or use materials or threads and / or yarns as described in U.S. Patent Publication No. 2016 / 0053410A1, published February 25, 2016 by Sterman et al. (now U.S. Patent Application No. 14 / 466,319, filed August 22, 2014) entitled “Thread Structure Composition and Method of Making,” the disclosure of which is incorporated herein by reference in its entirety and is referred to hereinafter as the “Thread Structure Composition” case.

[0088] As discussed above, in some embodiments, the printed structure may be printed directly onto one or more articles 130. The term "article" is intended to include both footwear articles (e.g., shoes) and clothing articles (e.g., shirts and trousers), as well as a variety of other objects. As used throughout this disclosure, the terms "footwear article" and "footwear" include any type of footwear and any material associated with footwear including the upper, and may also apply to various types of athletic footwear, such as baseball shoes, basketball shoes, cross-training shoes, cycling shoes, rugby shoes, tennis shoes, soccer shoes, and hiking boots. As used throughout this disclosure, the terms "footwear article" and "footwear" also include types of footwear that are generally considered non-athletic, formal, or decorative, including dress shoes, casual shoes, sandals, slippers, boat shoes, and work boots.

[0089] Although the disclosed embodiments are described in the context of footwear, the disclosed embodiments are equally applicable to any clothing, garment, or equipment, including 3D-printed items. For example, the disclosed embodiments are applicable to hoodies, caps, shirts, sweatshirts, jackets, socks, shorts, trousers, underwear, athletic support clothing, gloves, wristbands / armbands, sleeves, headbands, any knitted material, any woven material, any non-woven material, sports equipment, etc. Therefore, as used throughout this disclosure, the term "clothing article" can refer to any garment or clothing, including any footwear article and hoodies, caps, shirts, jackets, socks, shorts, trousers, underwear, athletic support clothing, gloves, wristbands / armbands, sleeves, headbands, any knitted material, any woven material, any non-woven material, etc. As used throughout this disclosure, the terms "clothing article," "clothing," "footwear article," and "footwear" can also refer to textiles, natural fabrics, synthetic fabrics, knitted fabrics, woven materials, non-woven materials, mesh, leather, synthetic leather, polymers, rubber, and foam.

[0090] In an exemplary embodiment, printing apparatus 102 may be configured to print one or more structures directly onto a portion of one of articles 130. Articles 130 include exemplary articles that can receive printed structures directly from printing apparatus 102, such as footwear article 132, helmet 136, or gloves 134, each having a three-dimensional construction. Article 130 may also include a shoe upper or T-shirt with a flat construction. Therefore, it should be understood that printing apparatus 102 can be used to apply printing material to article 130 in a three-dimensional and / or flat construction.

[0091] To apply printing material directly to one or more articles, printing device 102 can be capable of printing onto the surface of a variety of materials. Specifically, in some cases, printing device 102 can be capable of printing onto the surface of a variety of materials (e.g., fabrics, natural fabrics, synthetic fabrics, knitted fabrics, woven materials, non-woven materials, meshes, leather, synthetic leather, polymers, rubber, and foams, or any combination thereof) without requiring a release layer between the substrate and the bottom of the printing material, and without requiring a completely or nearly completely flat substrate surface on which it is printed. For example, the disclosed methods may include printing resin, acrylic, thermoplastic, or ink materials onto fabrics, such as knitted materials, wherein the material is adhered or bonded to the fabric, and wherein the material generally does not delaminate when folded, rolled, processed, or undergoes other assembly processes or steps. As used throughout this disclosure, the term "fabric" is generally used to refer to a material selected from any textile, natural fabric, synthetic fabric, knitted fabric, woven material, non-woven material, mesh, leather, synthetic leather, polymers, rubber, foam, and combinations thereof.

[0092] While some embodiments may use printing apparatus 102 to print the structure directly onto the surface of the material, other embodiments may include printing the structure onto a tray, base, or release paper, and then attaching the printed structure to the article in a separate step. In other words, in at least some embodiments, the printed structure does not need to be printed directly onto the surface of article 130.

[0093] As previously noted, the printing apparatus 102 can be configured to print directly onto various articles 130. Similarly, the printing apparatus 102 can be configured to print on various surface topography. For example, such as... Figure 2 As shown, a three-dimensional (non-flat) first object 204 is depicted. Figure 2 In this case, the first article 204 includes a forefoot region 210, a midfoot region 212, and a heel region 214, as described above. Additionally, the first article 204 includes an inner side 206 and an outer side 208.

[0094] In other embodiments, the first article 204 may include one or more protrusions and / or cavities, curves, contours, and other non-flat surfaces. Furthermore, the printing device 102 can print on surfaces of various shapes. For example, as shown, the first article 204 is an irregularly shaped object that is generally oblong, including an upper for partial assembly of footwear articles. In other embodiments, the first article 204 may include various three-dimensional contours, geometries, or shapes, including, for example, circular geometry, triangular geometry, rectangular geometry, sock-like geometry, sandal-like geometry, irregular geometry, or geometry corresponding to other parts of the footwear article. Figure 2 As shown, the first article 204 includes a printing surface 148 facing the nozzle 118 and a lower surface (not shown) that contacts the base 112.

[0095] In some embodiments, sensor 218 may be used to adjust the horizontal or vertical position of article 130. In some embodiments, sensor 218 may be adjacent to nozzle 118. Sensor 218 can help align the position of article 130 with the printing nozzle 118. In other words, for example, as described above with reference to the actuation system, during repositioning of article 130 in any typical x, y, and z spatial orientations, sensor 218 can provide the printing system 100 with mechanisms for determining the movement of article 130 relative to nozzle 118. Furthermore, some examples may include the step of adjusting nozzle 118 to better align nozzle 118 with a selected surface of article 130 on which it will be printed. Thus, in some embodiments, printing system 100 may include sensor 218, which provides the printing system 100 with information about the position of article 130 and / or nozzle 118. Sensor 218 may cooperate with computing system 104 to provide a greater degree of automation to printing system 100.

[0096] It should be noted that in some embodiments, the base 112 can be removed and the article 130 can be secured in the printing apparatus 102 by other means. For example, the footwear article 132 can be attached to a device or component that holds the footwear article 132 in place within the printing apparatus 102, such as a securing device 192. The securing device 192 can be part of the second actuation system 190 or can be a separate device. In one embodiment, the securing device 192 can be moved or rotated, causing the first article 204 to change orientation or position, allowing the nozzle 118 to print along substantially the entire area and surface of the first article 204. Figure 2 As shown, the fixing device 192 can be used to hold, clamp, or reposition the first article 204.

[0097] As previously mentioned, nozzle 118 is configured to extrude various materials. For example, as shown, nozzle 118 can extrude a generally elongated continuous composite yarn 202, or nozzle 118 can extrude multiple elongated continuous composite yarn segments. The composite yarn can include the configurations described in the in-line structure configuration. For example, in some embodiments, composite yarn 202 can include a melt-resistant material and / or a thermoplastic material. As used herein, thermoplastic materials include thermoplastics. In some embodiments, the composite yarn is at least partially formed of a thermoplastic.

[0098] It should be noted that in different embodiments, the printing material may be ejected via nozzle 118 in the form of droplets or otherwise extruded. Those skilled in the art will recognize that the form of the droplets can vary depending on the actual material ejected from nozzle 118 or otherwise extruded. In some embodiments, the droplets may therefore be any viscous liquid material, or even a semi-solid material. Consistent with the embodiments, the droplets may be any desired material or material phase suitable for use in printing system 100.

[0099] In different embodiments, the continuous segment of composite yarn 202 extends above the base 112 of the printing apparatus 102, which includes the first article 204. For example, composite yarn 202 in Figure 2 The composite yarn 202 or other printed materials extend above the curved surface 200. Various techniques and materials can be used to attach the composite yarn 202 to the curved surface 200. In some embodiments, the thermoplastic material is directly bonded to the attachment surface. Furthermore, in some embodiments, the thermoplastic material is bonded to a melt-resistant material.

[0100] In some embodiments, the heating system is configured to heat a portion of the composite yarn 202 into a liquid state. Therefore, in various embodiments, the printing system 100 can be configured to heat the nozzle 118 in various directions (see [reference]). Figures 3-10 The nozzle 118 moves to advance a portion of the composite yarn 202 onto the curved surface 200. The composite yarn 202 can then transition from a liquid to a solid state to bond with the attachment surface. As discussed below, the nozzle 118 can maintain a printing distance 216 between the nozzle 118 and the curved surface 200 to allow the composite yarn 202 to bond with the curved surface 200 (see [link]). Figures 3-10 ).

[0101] exist Figures 3-18 The image depicts a portion of the printing system 100. For convenience, some components of the printing system 100 are not shown. It should be understood that... Figures 3-18 This is merely for illustrative purposes, and the above is about Figure 1 and Figure 2The components described may be included in or referred to in the following description but not shown in the accompanying drawings. As shown in the figures, in different embodiments, the fixing device 192 may be used to hold, clamp, or reposition the article or printed surface 148. In other embodiments, different components or systems may be used to hold, rotate, or reposition the article.

[0102] In some cases, it is necessary to print directly onto the surface of an object or article 130 that includes a contour or is constructed in three dimensions. Selectively attaching composite yarns 202 along curved surfaces 200 allows designs, structures, and other features to be formed directly onto pre-assembled or prefabricated objects. Figures 3-10 An embodiment of a method for printing material along a series of curved surfaces of a second article 300 is illustrated. The illustrated method can be implemented on various devices, using various materials and different types of bases. Accordingly, Figures 3-10 The exemplary methods illustrated herein are for illustrative purposes only. In some embodiments, printing may occur on article 130 that has been previously manufactured or made or partially manufactured, and printing may occur after manufacturing. This allows customization of article 130 to be processed more quickly and cost-effectively. Furthermore, printing system 100 can allow for the formation of designs incorporating multiple surfaces (including surfaces incorporating varying materials) and curves of article 130, and can provide a more seamless design appearance.

[0103] exist Figure 3 In this arrangement, the second article 300 is positioned in a first location 302 within the housing 110 (not shown), such that a portion of the inner surface 206 is presented as a printing surface 148 to the nozzle 118. The nozzle 118 has begun depositing composite yarn 202 in a direction substantially aligned with the longitudinal axis 124 of the second article 300. Specifically, the nozzle 118 deposits composite yarn 202 along the heel region 214 of the inner surface 206 of the second article 300. Figure 4 In the middle, the nozzle 118 continues to move in a direction that is generally aligned with the longitudinal axis 124 and toward the middle area 212 of the shoe.

[0104] For reference Figure 2 As described, in some embodiments, the printing system 100 maintains a printing distance 216 between the nozzle 118 and the printing surface 148 to allow the composite yarn 202 to attach along the curved surface 200. The first actuation system 114 (in...) Figure 1(As shown in the figure) the nozzle 118 may be allowed to move in multiple directions. Some embodiments may use one or more features of Waatti et al., entitled “Selective Attachment of a Thread Structure”, published May 11, 2017, the disclosure of which is incorporated herein by reference in its entirety.

[0105] For example, nozzle 118 can move in a first direction 160 or a second direction 161 (i.e., nozzle 118 can move up and down relative to base 112). Figure 4 As shown in the enlarged area 402, in one embodiment, the printing system 100 can maintain a constant printing distance 216 between the nozzle 118 and the printing surface 148. In other embodiments, the composite yarn 202 can be pushed into the printing surface 148, and the composite yarn 202 can be bonded to the printing surface 148 as the composite yarn 202 is poked or adhered to the printing surface 148. In such embodiments, the printing distance 216 can decrease as the nozzle 118 poks into the printing surface 148, and the printing distance 216 can increase as the nozzle 118 withdraws from the printing surface 148 after poking.

[0106] It should be noted that in some embodiments, the composite yarn 202 is not pushed into the printing surface 148, and therefore the printing distance 216 can remain relatively constant during printing. For example, once the composite yarn 202 has been deposited onto the printing surface 148 at a constant printing distance 216, the composite yarn 202 can bond with the printing surface 148. Bonding may occur in some embodiments due to the composition of the composite yarn 202 or other features of the printing system 100.

[0107] In different implementations, the printing distance 216 may include a variable distance. In some implementations, the printing distance 216 may be selected by the user via the central processing unit 185, such as... Figure 1 As illustrated in the figure. In one embodiment, the printing distance 216 is greater than the thickness of the composite yarn 202. In some embodiments, the printing distance 216 may be less than the thickness of the composite yarn 202 when the composite yarn 202 is pushed or poked onto the printing surface 148.

[0108] In some cases, it may be necessary to move the nozzle 118 along the printing surface 148 of the second article 300 while maintaining a substantially constant printing distance 216 between the nozzle 118 and the printing surface 148. For example, to allow the composite yarn 202 to flow in a substantially smooth and consistent manner along the three-dimensional curved surface 200, the printing distance 216 may be kept substantially constant as the nozzle 118 moves along the printing surface 148. In some embodiments, such as Figures 3-7 As shown, the printing system 100 moves the nozzle 118 along the printing surface 148 in a direction generally aligned with the longitudinal axis 124, while maintaining a constant printing distance 216 between the nozzle 118 and the printing surface 148.

[0109] In various embodiments, when the composite yarn 202 is released or extruded, the composite yarn 202 may be arranged, attached, printed, or otherwise coupled to any non-flat and / or flat area of ​​the printing surface 148. The composite yarn 202 may be coupled to the printing surface 148, thereby allowing printing along one or more curved surfaces 200 (e.g., as shown in enlarged area 402). In other embodiments, the printing method applied to the curved surface 200 may be characterized by one or more of the methods described in the adhesive dragging scheme.

[0110] Therefore, in different embodiments, the printing system 100 can be configured to position or attach threads or composite yarns to any part of an article including various curved surfaces 200. In some embodiments, the printing system 100 moves the nozzle 118 toward and / or above the second article 300. For example, as Figure 3 As shown, when the printing system 100 deposits the composite yarn 202 along the printing surface 148, the printing system 100 moves the nozzle 118 along the third direction 162, the fourth direction 163, the fifth direction 164, and / or the sixth direction 165. Figure 4 As shown, in some cases, it may be necessary to move the nozzle 118 along the printing surface 148 while maintaining a constant printing distance 216 between the nozzle 118 and the printing surface 148 to allow the composite yarn 202 to attach to the second article 300.

[0111] For example, such as Figures 3-7 As shown, when the nozzle 118 moves in the horizontal plane, the printing system 100 maintains a constant printing distance 216 between the nozzle 118 and the printing surface 148 by moving the nozzle 118 in a first direction 160 or a second direction 161. In this way, the composite yarn 202 is deposited along the printing surface 148 and can bond with the printing surface 148, thereby allowing three-dimensional surface printing. For example, as in... Figure 4As seen in magnified region 402, the composite yarn 202 is laid along the first curvature region 404. By adjusting the height of the nozzle 118 along the vertical axis 122, the nozzle 118 maintains a constant printing distance 216, and the composite yarn 202 can be laid or deposited along the first curvature region 404 in a stable, smooth, and continuous manner. It should be noted that in other embodiments, the printing distance 216 can be increased or decreased at different portions of the second article 300 while maintaining print quality.

[0112] exist Figure 5 In this process, nozzle 118 has moved further toward the forefoot region 210 in a direction generally aligned with the longitudinal axis 124. In some embodiments, it may be necessary to continue printing along different sides or surfaces of the second article 300. In some cases, for example, it may be necessary to print along the bottom surface or sole area of ​​the second article 300. Figure 6 In this embodiment, the orientation of the second article 300 has been changed to allow the sole area 600 to include the printed surface 148. In other words, in some embodiments, the second article 300 can be rotated or otherwise reoriented to supply or provide the various areas of the second article 300 to the nozzle 118. In one embodiment, reorientation can be performed by the second actuation system 190 (see reference). Figure 1 (As discussed).

[0113] exist Figure 6 In this process, the second article 300 is arranged in a second position 602 within the housing 110 (not shown), such that the sole region 600 is presented as a printing surface 148 to the nozzle 118. The nozzle 118 has begun depositing composite yarn 202 along the forefoot region 210 of the sole region 600 of the second article 300 in a direction substantially aligned with the longitudinal axis 124. Figure 7 In the middle, the nozzle 118 continues to move in a direction that is generally aligned with the longitudinal axis 124 and has moved past the mid-shoe region 212 and into the heel region 214.

[0114] Similarly, in some embodiments, it may be necessary to continue printing along different sides or surfaces of the second article 300. In some cases, for example, it may be necessary to print along the outer side 208 of the second article 300. Figure 8 In this embodiment, the orientation of the second article 300 has been changed to allow the outer surface 208 to include the printing surface 148. In other words, in some embodiments, the second article 300 can be rotated or otherwise reoriented to supply or provide different areas of the second article 300 to the nozzle 118. Figure 8In this configuration, the second article 300 is arranged in a third position 802 within the housing 110 (not shown), such that the outer surface 208 is presented as a printing surface 148 to the nozzle 118. The nozzle 118 has deposited composite yarn 202 from the heel region 214 of the outer surface 208 of the second article 300 toward the forefoot region 210 in a direction substantially aligned with the longitudinal axis 124. Thus, in various embodiments, the printing system 100 can print along three-dimensional objects, articles, and various curved or non-flat surfaces.

[0115] exist Figure 9 The image depicts an enlarged area of ​​a portion of the second article 300. The nozzle 118 is shown moving along the curved region 900 in a fourth direction 163. The nozzle 118 is positioned at a first height 906 above the first surface 904. In this case, the first height 906 is substantially similar to the printing distance 216. Figure 10 During the movement of nozzle 118 in the fourth direction 163, nozzle 118 begins to move upward along the first direction 160 to accommodate the slope of the second surface 1000, which includes the curved region 900. As nozzle 118 moves along the second surface 1000, the height of nozzle 118 relative to the first surface 904 increases. The change in height is depicted as nozzle 118 shifting from a first height 906 and increasing relative to the first surface 904 to a second height 1002. While nozzle 118 maintains a relatively constant printing distance 216 from the printing surface 148 of the second article 300, composite yarn 202 is deposited along the slope.

[0116] Figure 11 The image depicts a nozzle 118 that has completed printing of the composite yarn 202 along the second surface 1000 and begins printing along the relatively flat third surface 1102. The nozzle 118 ceases to move in either the first direction 160 or the second direction 161, while continuing to move above the third surface 1102 in a fourth direction 163. During this stage, the nozzle 118 has increased to a third height 1100 relative to the first surface 904. The third height 1100 is greater than both the first height 906 and the second height 1002. In other embodiments, the curved areas may include different curves, and the nozzle 118 may move downwards in a direction aligned with the vertical axis 122 (i.e., the second direction 161). In some embodiments, although the nozzle 118 may vary in height relative to different undulating portions or surfaces of the article 130, the printing distance 216 may remain constant, such as... Figures 9-11 As illustrated in the figure. In other embodiments, the nozzle 118 may move along the printing surface 148 in a first direction 160 and / or a second direction 161, while also moving in a horizontal orientation direction, and the printing distance 216 may be increased or decreased.

[0117] It should be noted that although the illustrations included herein depict the first position 302, the second position 602, and the third position 802 as stationary, the rotation or movement of the second article 300 can be continuous throughout the printing process. In one embodiment, the second article 300 may be rotated or otherwise moved (e.g., by means of...) at different times or points during printing. Figure 1 The first actuation system 190 shown is illustrated. In some embodiments, the second article 300 can rotate, move, or spin over continuous or intermittent time periods to provide an optimal printing surface 148 for the nozzle 118. Adjustment of the positioning or orientation of the second article 300 can provide improved print quality and better attachment of the composite yarn 202 to the three-dimensional surface.

[0118] As previously noted, various embodiments allow for any number of attachment surfaces, such as printing surface 148. Therefore, different three-dimensional structures can be formed along undulating or three-dimensional surfaces. In some embodiments, structures can be formed using any of the methods described in US Patent Publication No. US2014 / 0020192, entitled “Footwear Assembly Method with 3D Printing,” published January 23, 2014, by Jones et al., the disclosure of which is incorporated herein by reference in its entirety. It should be understood that in the case of an uneven printing surface 148, article 130 can be repositioned to provide an optimal printing surface for nozzle 118. In other words, article 130 can be moved, rotated, or otherwise adjusted in position to accommodate movement of nozzle 118, as referenced... Figures 1-11 As described. Therefore, in the embodiments discussed below, article 130 can move between a first position 302, a second position 602, and other positions to allow, for example, nozzle 118 to form a three-dimensional structure along any curved surface of article 130.

[0119] For example, in some embodiments, one or more traction elements may be formed along a portion of the article. In another embodiment, one or more cleats 1204 may be printed. Figures 12-17 The illustration shows an isometric view of a printing sequence comprising multiple 3D layers forming a series of studs 1204. In different embodiments, the studs 1204 can be printed along irregular, curved, or otherwise generally uneven surfaces. During printing, the nozzle 118 can adapt to the varying curvature of the printing surface 148.

[0120] As previously mentioned, nozzle 118 is configured to extrude various materials. For example, as shown, nozzle 118 may extrude a generally elongated continuous composite yarn 202, or nozzle 118 may extrude multiple elongated continuous segments. Composite yarn 202 may include the configuration described in embodiments of the in-line structure configuration.

[0121] In different embodiments, the nozzle 118 can move in a direction aligned with the vertical axis 122, a direction aligned with the longitudinal axis 124, a direction aligned with the transverse axis 126, or other directions to print along curved surfaces, as per [reference to...]. Figures 1-11 As described. In other words, the printing system 100 can be used to provide the printing of three-dimensional structures along a three-dimensional or generally undulating surface. Therefore, in some embodiments, the three-dimensional structure can be formed along different types of articles during points of variation in the manufacture of the article. For example, in some embodiments, the structure can be printed on a partially formed article. In other embodiments, the structure can be printed on a fully formed or manufactured article. In one embodiment, the shoe upper can be formed and shaped using any process known in the art (e.g., on a shoe last), and subsequently, additional structures can be formed or printed on the shoe upper using the printing system 100.

[0122] exist Figures 12-17 In the middle, the shoe nail 1204 is formed along the outer curved surface 1202 (“curved surface” 1202) of the sole structure of the third article 1200. Figure 12 The illustration shows printed material 1210 deposited on a curved surface 1202 near the forefoot region 210. Figure 12 In this design, a series of cleats 1204 have been formed along the heel region 214 and the midfoot region 212. A first portion 1212 of the first layer 1214 has been printed onto the curved surface 1202. It should be noted that the first portion 1212 and the printed surface 148 can be joined, attached, bonded, coupled, or otherwise connected by a linear structure comprising one of the techniques described herein. For example, in one embodiment, heat can be applied during printing to form a molten layer of material between the first portion 1212 and the printed surface 148. The molten layer can bond the first portion 1212 (or a portion thereof) to the printed surface 148.

[0123] The printing material 1210 can be ejected from the nozzle 118 or otherwise extruded in the form of droplets, threads, yarns, or any viscous liquid or semi-solid material. The printing material 1210 can be any desired material or material phase suitable for use in the printing system 100 as described above.

[0124] Those skilled in the art will recognize that the printed layers forming the printed material 1210 can originate from different materials, colors, chemical properties, optional fillers, etc., in order to fully customize the desired properties of the third article 1200. The printed material 1210 may also include layers with color gradients between layers, or may include elastic gradients caused by variations in the material ejected from the nozzle 118 during printing of the printed material 1210. For example, the printed material 1210 may include layers of low-elasticity printed material alternating with or in combination with layers of high-elasticity material, as described in the adhesive labeling section.

[0125] Those skilled in the art will also recognize that the printed layers forming the printed material 1210 may include material layers having at least a first color, which may alternate or combine with layers having at least a second color. For example, the printed material 1210 may be designed to impart high strength and low elasticity in the heel region 214, while maintaining high elasticity and flexibility in the forefoot region 210, and these properties can be achieved by altering the properties of the printed material 1210 by printing different combinations of materials and layers on any surface of the third article 1200 in any desired manner.

[0126] In different implementations, the three-dimensional printed structure can have various shapes and sizes, and can be arranged along different areas and different types of surfaces of the third article 1200. For example, in Figure 12 In this design, the cleat 1204 includes a first cleat 1206 and a second cleat 1208. The first cleat 1206 and the second cleat 1208 are generally circular cylindrical in shape. Figure 12 In one embodiment, the first stud 1206 is larger than the second stud 1208. Additionally, the first stud 1206 includes a hollow internal region, while the second stud 1208 has a solid or continuous internal volume and surface. Furthermore, the second stud 1208 is formed along a generally curved region of the heel region 214, while the first stud 1206 is formed along a relatively flat region of the heel region 214. In other embodiments, the first stud 1206 and the second stud 1208 may be larger or smaller, may be other geometric or irregular three-dimensional shapes, and may be positioned along other regions of the third article 1200.

[0127] In some implementation schemes, refer to Figure 13 and Figure 14The first segment 1300 can be cured by UV light. However, in other embodiments, the first segment 1300 can be deposited without curing the deposited material. Depending on the material used for printing on the printing material 1210, the material can be deposited as a liquid, semi-liquid, or other gel-like or viscous phase. Then, for various reasons, or to achieve desired properties, such as enhancing the durability, adhesion, or bonding of the printing material 1210 to the curved surface 1202, the material can be at least partially solidified or cured. For the purposes of this description, a “segment” of the printing material 1210 refers to an accumulation of one or more layers of printing material 1210 forming at least a portion of a three-dimensional structure. In some embodiments, a segment can include an area or portion of the printing material 1210 that is smaller or larger than the segment shown in the figure below. In some cases, for example, the shoe spikes 1204 can vary in height relative to each other and can each include a different number of layers or segments.

[0128] exist Figure 13 The description states that printing is continuing. Figure 13 In this configuration, a first segment 1300 has been formed along a curved surface 1202. The first segment 1300 includes a first layer 1214, which now comprises a first portion 1212 and an additional second portion 1302. The bottom surface 1306 of the first segment 1300 contacts the curved surface 1202, and the upper surface 1304 is associated with the top of the first segment 1300. Therefore, in some cases, the curved surface 1202 includes a reference... Figures 1-11 The described "printing surface" 148 provides a printing surface for the nozzle 118. In some embodiments, printing of the stud 1204 may include movement of the nozzle 118 in a generally repetitive or irregular arcuate, cyclic, repetitive, or circular motion to form a structure. In other embodiments, the nozzle 118 may be moved in other ways to form, for example, a solid (filled) structure, such as the second stud 1208.

[0129] exist Figure 14In this embodiment, a first portion 1402 of the second segment 1400 (including at least one printed layer) of the printed material 1210 is deposited onto the upper surface 1304 of the previously printed first segment 1300. It should be noted that the second segment 1400 (and any subsequent segments) need not be deposited only on the immediately following segment. Variations in the thickness of the printed pattern or layer are possible in different embodiments. For example, the second segment 1400 may be deposited on any desired portion of the curved surface 1202, which may include partial or complete coverage of the first segment 1300, or may not include coverage of the first segment 1300. For example, the second segment 1400 may be partially deposited on the first segment 1300 and partially deposited on the bottom surface of the curved surface 1202. It should also be noted that the first segment 1300 and the second segment 1400 may be joined, attached, bonded, coupled, or otherwise connected by a line structure constituting one of the techniques described in this invention. For example, in one embodiment, heat can be applied during the printing process to form a molten material layer between the upper surface 1304 of the first portion 1300 and the bottom surface of the second portion 1400. The molten layer can bond the first segment 1300 (or a portion of the first layer 1214) to the second segment 1400.

[0130] Figure 15 The illustration shows the completion of the second segment 1400 printed on the first segment 1300, forming a structure including the first segment 1300 and the second segment 1400 (see Figure 1400). Figure 13 and Figure 14 The first composite segment 1500 has an upper surface 1502. Figure 16 In this configuration, the first portion 1602 of the third segment 1600 (including at least one printed layer) is formed on the upper surface 1502 of the first composite segment 1500. It should be noted that although the printing of the cleat 1204 is depicted as comprising discrete segments or portions, the segments can be formed in a continuous manner. For example, the first segment 1300, the second segment 1400, and / or the third segment 1600 can be printed such that there is no identifiable distinction between any segments.

[0131] exist Figure 17 In this process, the third stud 1700 has been formed, comprising the first segment 1300, the second segment 1400, and the third segment 1600. As the three-dimensional structure is completed along the undulating printing surface 148, the nozzle 118 can move in any direction to separate the printed material 1210 from the third stud 1700. For example, in Figure 17 In the middle, the nozzle 118 has moved upward along the vertical axis and toward the forefoot area 210 in a direction aligned with the longitudinal axis, and has separated from the third stud 1700.

[0132] In other embodiments, the printing system 100 can be used to form various patterns, designs, color forms, and other fabric effects along flat or curved surfaces. For example, in some embodiments, the printing system 100 can be used to print decorative accents that provide an article with a pattern similar to that created by embroidery. As is known to those skilled in the art, embroidery can be used to decorate fabrics or other materials with needles and thread or yarn. Embroidery can also incorporate other materials such as metal strips, pearls, beads, feather tubes, and sequins in its patterns. For the purposes of this description, the term "embroidery pattern" refers to any type of design, decorative art, production, or other expression added to a material. "Embroidery patterns" are traditionally formed by stitching or sewing. However, in different embodiments, the printing system 100 can be used to provide, form, or attach embroidery patterns to curved surfaces. This application of the printing system 100 can allow the formation of embroidered designs without piercing the surface of the fabric or textile, improving the efficiency of embroidery pattern formation and allowing embroidery patterns to be formed more easily on a variety of objects. In one implementation, an embroidery pattern can be added to a pre-manufactured or pre-fabricated three-dimensional object 130.

[0133] For example, in Figures 18-19 In the image, nozzle 118 is shown printing along the inner side 206 of the fourth article 1800, extruding printing material 1808. Figure 18 In the process, the printing system 100 moves the nozzle 118 from a non-zero printing distance 216 (as shown in the reference). Figures 1-17 The nozzle 118 moves into the printing surface 148 as described, so that the nozzle 118 directly contacts the printing surface 148, and the printing distance 216 becomes zero. Therefore, as Figure 18 As shown, the printing system 100 has moved the nozzle 118 from the printing distance 216 into the printing surface 148, so that the nozzle 118 is in direct contact with the attachment surface. In other embodiments, the embroidery pattern 1806 can be formed while maintaining a non-zero printing distance 216.

[0134] In some embodiments, the embroidered pattern 1806 may be formed along various portions of the fourth article 1800. For example, the first embroidered pattern 1802 has been formed along the curved area along the heel region 214 of the fourth article 1800. Figure 19 In this process, a series of embroidered patterns 1806, including the second embroidered pattern 1804, have been formed along the three-dimensional contour or curve of the fourth article 1800, specifically the forefoot region 210, the midfoot region 212, and the heel region 214. The printing of the embroidered patterns 1806 may involve any of the features of the previously described printing system 100, including the first actuation system 114 and the second actuation system 190.

[0135] Although various embodiments have been described, this description is intended to be exemplary and not restrictive, and it will be apparent to those skilled in the art that many more embodiments and implementations are possible within the scope of these embodiments. While many possible combinations of features are shown in the accompanying drawings and discussed in this detailed description, many other combinations of the disclosed features are also possible. Any feature of any embodiment may be used in combination with or in lieu of any other feature or element in any other embodiment, unless specifically limited. Therefore, it should be understood that any feature shown and / or discussed in this disclosure can be implemented together in any suitable combination. Thus, the embodiments are not limited except as provided in the appended claims and their equivalents. Moreover, various modifications and changes may be made within the scope of the appended claims.

Claims

1. A method for printing on a curved surface of an article, the method comprising: Position the article in a first position on the upper surface of the base of the printing system; Wherein, the upper surface of the base defines a vertical axis perpendicular to the upper surface of the base; and Wherein, the upper surface of the base defines a first horizontal axis, which is parallel to the upper surface of the base and perpendicular to the vertical axis; Printing material is discharged from the nozzle of the printing system; The printing material is attached to the printing surface of the article by moving the nozzle in a direction at an angle to the vertical axis and the first horizontal axis, wherein the printing surface includes at least one curved area. When the printing material is attached to the printing surface, the nozzle is spaced apart from the printing surface by a printing distance. The method further includes moving the article by using an actuation system to attach the printing material to the printed surface of the article, wherein the actuation system is configured to enable the article to move in a direction aligned with the vertical axis and simultaneously in a direction aligned with the first horizontal axis, and wherein the actuation system is configured to move independently of the base. The method further includes aligning the position of the article with the nozzle using a sensor, wherein the sensor is configured to operate in conjunction with a computing system to improve the automation level of the printing system; and The method further includes pushing the printing material into the printing surface by causing the nozzle to puncture into the printing surface, so that the printing material bonds with the printing surface.

2. The method of claim 1, further comprising attaching the printing material to the printing surface by moving the nozzle in a direction angled to the vertical axis and the second horizontal axis, wherein the second horizontal axis is perpendicular to the first horizontal axis and parallel to the upper surface of the base.

3. The method according to claim 1, wherein, The printing system includes the actuation system.

4. The method of claim 1, further comprising reducing the printing distance between the nozzle and the printing surface by moving the nozzle downward in a direction aligned with the vertical axis when attaching the printing material to the printing surface.

5. The method according to claim 1, wherein, The printing material comprises continuous composite yarns made of thermoplastic material.

6. The method according to claim 1, wherein, The printing material comprises a series of droplets.

7. The method of claim 1, further comprising printing at least one three-dimensional structure onto the article.

8. The method of claim 1, further comprising forming at least one embroidered pattern on the article.

9. The method according to claim 8, wherein, The at least one embroidered pattern is formed on an area of ​​the article that is curved relative to the vertical axis.

10. The method of claim 1, further comprising using the actuation system to reposition the article such that the article moves to a second position, wherein the first position is different from the second position.

11. An apparatus for printing onto a curved surface of an article, the apparatus comprising: A housing, the housing including a base arranged along the bottom of the housing; A nozzle configured to discharge composite yarns onto the curved surface; The first actuation system is configured to enable the nozzle to move in a direction aligned with a vertical axis and simultaneously in a direction aligned with a first horizontal axis, the vertical axis extending normally to the surface of the base, the first horizontal axis being approximately parallel to the base. A second actuation system for adjusting the position of the article relative to the nozzle, wherein the second actuation system is configured to enable the article to move in a direction aligned with the vertical axis and simultaneously in a direction aligned with the first horizontal axis, and wherein the second actuation system is configured to move independently of the base; A sensor configured to help align the position of the article with the nozzle, wherein the sensor works in conjunction with a computing system to improve the automation of the instrument; The device is configured to attach the composite yarn to the curved surface by moving the nozzle downward toward the curved surface in a direction aligned with the vertical axis; and The device is configured to attach the composite yarn to the curved surface by moving the nozzle in a direction aligned with the first horizontal axis. The first actuation system is configured to cause the nozzle to puncture the curved surface to push the composite yarn into the curved surface, thereby bonding the composite yarn with the curved surface.

12. The apparatus according to claim 11, wherein: The device is configured to facilitate the attachment of the composite yarn to the curved surface of the article by moving the article in a direction parallel to the vertical axis; and The device is configured to facilitate the attachment of the composite yarn to the curved surface of the article by moving the article in a direction parallel to the first horizontal axis.

13. The apparatus according to claim 11, wherein: The second actuation system is configured to rotate the article, wherein the second actuation system rotates the article about a second horizontal axis that is approximately parallel to the base.

14. The apparatus according to claim 11, wherein, The article is an upper for at least part of the fitting of footwear.

15. The apparatus according to claim 11: in, The first actuation system moves the nozzle in a direction aligned with a third horizontal axis, wherein the third horizontal axis is perpendicular to both the vertical axis and the first horizontal axis; and The device is configured to attach the composite yarn to the curved surface by moving the nozzle in a direction aligned with the third horizontal axis.

16. A method for printing a three-dimensional structure on a curved surface of an article, the method comprising: Place the article on the base of the apparatus according to any one of claims 11-15; The composite yarn is discharged from the nozzle of the device, wherein the composite yarn is a continuous composite yarn; The continuous composite yarn is attached to the curved surface of the article to form a first printed layer on the curved surface, the first printed layer having an exposed outer surface; The continuous composite yarn is attached to at least a portion of the outer surface of the first printed layer to form a second printed layer; and A three-dimensional first structure is formed on the curved surface. The method further includes pushing the continuous composite yarn into the curved surface by puncturing it with the nozzle, so that the continuous composite yarn is bonded to the curved surface.

17. The method according to claim 16, wherein, The first structure of the three dimensions is a shoe nail.

18. The method of claim 17, further comprising heating at least a portion of the continuous composite yarn of the first printed layer and at least a portion of the continuous composite yarn of the second printed layer to assist in attaching the first printed layer to the second printed layer.

19. The method of claim 16, wherein, Discharging the continuous composite yarn includes extruding the continuous composite yarn from the nozzle.

20. The method according to claim 19, wherein, Attaching the continuous composite yarn to the curved surface includes moving the nozzle in a direction aligned with the vertical axis and moving the nozzle in a direction aligned with the horizontal axis.

21. A three-dimensional printing system, comprising: Printing apparatus, the printing apparatus comprising: - A nozzle assembly comprising one or more nozzles for conveying printing material to a target location, the one or more nozzles being configured to move together and / or independently, and - A base configured to support, hold and / or contain an object to be printed or an object on which printing material is applied; - wherein the one or more nozzles are configured to puncture into the printing surface of the object to push the printing material into the printing surface, thereby bonding the printing material with the printing surface; A computing system for controlling and / or receiving information from the printing apparatus, the computing system comprising: - One or more printing servers, said one or more printing servers being used to control the printing apparatus and / or communicate with the printing apparatus, and - A computer-aided design representation of a printed structure, which includes information about the geometry of the printed structure and information related to the materials required for printing the various parts of the printed structure; and A network for communication between the computing system and the printing apparatus, the network including any wired or wireless devices that facilitate information exchange between the computing system and the printing apparatus.

22. The three-dimensional printing system according to claim 21, wherein, The three-dimensional printing system also includes a device for programming the orientation of the object through the printing apparatus in such a way as to accommodate objects of various types, shapes, curves and sizes.

23. A method for forming an embroidered pattern on a curved printed surface of an article, the method comprising: Position the article in the printing system; Printing material is extruded from the nozzle of the printing system; Move the nozzle from a non-zero printing distance to the curved printing surface of the article, so that the nozzle directly contacts the curved printing surface; as well as An embroidery pattern is formed along the curved printed surface of the article without piercing the printed surface.

24. The method of claim 23, further comprising forming the embroidery pattern while maintaining a non-zero printing distance.

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