MULTIMATERIAL 3D PRINTING ON A LIQUID BASIS FOR FULL SHOE MANUFACTURING
Patent Information
- Authority / Receiving Office
- DE · DE
- Patent Type
- Patents
- Current Assignee / Owner
- ADIDAS AG
- Filing Date
- 2024-05-17
- Publication Date
- 2026-07-23
AI Technical Summary
Conventional 3D printing methods are limited by single-material usage, leading to complex and costly processes, excess waste, and material residue issues, which compromise the quality and sustainability of printed products.
A method involving multiple material tanks, cleaning steps, and a movable build platform for precise material application and cleaning, utilizing Digital Light Processing (DLP) and photopolymerization with UV light, ensuring thorough cleaning with air knives or ultrasonic methods to maintain product integrity.
Enables high-precision multi-material printing with reduced waste, improved efficiency, and enhanced product quality by ensuring each layer is free of contaminants, allowing for complex geometries and tailored material properties.
Smart Images
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Abstract
Description
1. Field of the invention
[0001] This invention relates to a method for printing a three-dimensional object by providing at least a first and a second printing material, which are separated in at least a first and a second material tank. 2. Background
[0002] In the 3D printing industry, printing processes using Digital Light Processing (DLP) and photopolymerization are often limited to using only one type of material per print job, restricting overall material usage in conventional 3D printing. Parts printed from a single material often lack the functional and / or aesthetic qualities required in more complex applications. Printing processes that use multiple materials per print job are often cumbersome and expensive, as they require careful processing and assembly. Conventional 3D printing processes also frequently generate excess waste material, which is not only costly but also reduces the sustainability of manufacturing. Another drawback of conventional printing is the management of material residue left on the product, which can degrade the quality of the final product.
[0003] Overall, conventional methods have the disadvantage of limited material usage or an unnecessarily complex and meticulous printing process. These methods also generate excess waste material and leave material residue on the product. Therefore, there is a need for an improved 3D printing method.
[0004] In light of the above, there is a need for an improved 3D printing process. It is therefore an object of the present invention to overcome some or all of the shortcomings of the prior art. 3. Summary
[0005] The above problems are solved at least partially by the subject matter of independent claim 1. Preferred embodiments are the subject matter of the dependent claims, and the person skilled in the art will find references to other suitable aspects of the present invention in the overall disclosure of the present application.
[0006] One aspect of the invention relates to a method for printing a three-dimensional object, comprising at least the following steps: providing at least one first and one second printing material, separated in at least one first and one second material tank; providing a build platform; a first printing step of printing the object at least partially onto the build platform with the first printing material; a cleaning step of cleaning the object of the first and / or the second printing material; and a second printing step of printing the object at least partially onto the build platform with the second printing material.
[0007] This method could be particularly useful in applications where different properties, such as color, strength, or heat resistance, are required in different parts of the finished object. For example, a manufacturer could use a flexible material for the core of a part and a more stable, colored material for the outer layers to enhance aesthetic appeal and functionality. This method enables high precision in multi-material 3D printing, reducing material waste and increasing the efficiency of the printing process by cleaning the object between steps, thus helping to maintain the quality and integrity of the finished product. One step of printing the object, at least partially, onto the build platform also involves printing on a partially printed object that is attached to the build platform.
[0008] A further aspect of the invention is realized when the cleaning step comprises at least the following steps: providing one or more cleaning tanks with a cleaning solution; providing one or more air knives; and providing one or more standing waves of cleaning solution; cleaning the object by exposing it to the one or more standing waves of cleaning solution; and drying the cleaned object by exposing it to the one or more air knives.
[0009] This cleaning step offers a highly efficient way to ensure that each layer of the printed object is free of contaminants before the next material is applied, which is essential for maintaining the structural integrity and aesthetic quality of the final product. For example, such thorough cleaning can prevent the mixing of materials that could otherwise compromise functionality and / or aesthetics. The combination of standing waves and air knives provides a thorough yet gentle cleaning suitable for complex shapes or delicate details.
[0010] A further aspect of the invention is achieved if the cleaning step instead comprises at least the following steps: providing one or more cleaning tanks containing a cleaning solution, wherein at least one of the cleaning tanks is an ultrasonic cleaning tank configured and dedicated for ultrasonic cleaning; and providing one or more air knives; cleaning the object by immersing the object in the ultrasonic cleaning tank; and drying the cleaned object by exposing it to the one or more air knives.
[0011] Such a cleaning step could be very advantageous in applications requiring a high degree of purity and precision. Ultrasonic cleaning ensures the thorough removal of residues and contaminants. This process not only improves the structural and surface integrity of the printed object but also enhances the bonding and layering of different materials in subsequent printing steps, as less contaminated material is present in the layers, resulting in higher quality and a more reliable final product.
[0012] The process for printing a three-dimensional object can be further improved if at least one of the material tanks and / or at least one of the cleaning tanks is horizontally movable.
[0013] This feature significantly improves the efficiency and flexibility of the printing process. For example, in a large-scale manufacturing environment where multiple objects or parts of an object need to be printed simultaneously or sequentially, the ability to move tanks horizontally can reduce the time required to change materials or initiate cleaning cycles. This adaptability is particularly advantageous in production lines that require rapid changes between different types of materials or frequent cleaning of objects. The tanks' mobility could also lead to better space management within the printing system, optimizing the overall workflow and reducing downtime.
[0014] A further improvement of the process is achieved when the tanks are arranged on a rotating disc.
[0015] Such an arrangement proves particularly advantageous in environments where rapid production and high throughput are crucial. For example, in industrial applications requiring multiple colors or material properties within short production timelines, the rotating disc enables quick tank changes, thereby reducing downtime. Additionally, this method improves the precision of the material handling process, ensuring that the correct material or cleaning solution is readily available precisely when needed.
[0016] Such a process can be further improved if at least one cleaning tank is arranged between the printing material tanks.
[0017] Such a configuration is advantageous in settings where multiple material properties are crucial for product functionality. For example, the central placement of the cleaning tank helps maintain high-quality printing by ensuring that each material adheres properly without contamination from previous materials. Additionally, this arrangement optimizes workflow by minimizing the movement required between different stages of the printing process, resulting in faster production and reduced operating costs.
[0018] The process can be further improved if the construction platform is movable both vertically and horizontally.
[0019] Such a vertically and horizontally movable build platform could be advantageous in the production of complex, multi-layered objects where precise layer alignment is required for structural integrity and functional performance. This adaptability not only improves the quality of the final product but also enables the production of more complex geometries that might not be feasible with a fixed platform, thus expanding the capabilities of the 3D printing process.
[0020] This process is further improved if the construction platform includes a Stewart platform.
[0021] The inclusion of a Stewart platform is ideal for manufacturing contexts where high precision is required. The ability to fine-tune the platform's orientation and position ensures that each layer of a 3D-printed object adheres correctly and with the appropriate orientation relative to other layers, thereby improving the structural integrity and functional precision of the final product. Additionally, such a configuration can accommodate complex print trajectories and material deposition patterns necessary for creating advanced geometries and structures with high performance and reliability.
[0022] A further improvement is achieved if at least one of the printing materials is a liquid photopolymer resin.
[0023] The use of liquid photopolymer resin is advantageous for applications requiring high detail and smooth surface finishes. The precision achievable with photopolymer resins surpasses that of many other 3D printing materials, enabling the production of parts with complex geometries and fine features that would be difficult to achieve with more conventional materials. Furthermore, photopolymer resins can be formulated with a variety of properties, including different colors, transparencies, and mechanical characteristics, enhancing the versatility and applicability of the 3D printing process across various industries.
[0024] An even further improved process is achieved when printing uses Digital Light Processing (DLP).
[0025] The use of DLP in the 3D printing process is particularly advantageous for producing parts that require high-speed manufacturing without compromising detail and accuracy. DLP's ability to cure entire layers simultaneously enables faster creation of complex, high-resolution structures compared to other, more time-consuming printing methods. Additionally, DLP technology can be optimized for use with a wide range of photopolymer resins, allowing for variations in material properties such as flexibility, strength, and opacity, thus expanding the scope and versatility of 3D-printed applications.
[0026] Even greater improvements are achieved when printing is carried out through photopolymerization.
[0027] The use of photopolymerization in the 3D printing process offers significant advantages for the production of highly detailed and accurate parts. The ability to precisely control exposure enables complex designs with smooth surfaces and intricate details that may not be achievable with more conventional manufacturing methods. Additionally, photopolymerization can be used with a range of different resins, each offering distinct mechanical and thermal properties, allowing for the production of customized items tailored to specific functional requirements and environmental conditions.
[0028] Further improvements are achieved when photopolymerization is enabled by UV light.
[0029] The use of UV light for photopolymerization in, for example, a DLP-based 3D printing system offers several advantages. First, UV light can cure certain resins very quickly, improving the speed of the printing process, which is important for high-throughput production. Furthermore, the use of UV light allows for very precise control of the curing process, enabling the production of parts with extremely fine details and high dimensional accuracy. This method also supports the use of a wide range of UV-curable resins, allowing for the customization of material properties to suit specific applications.
[0030] A further improvement is achieved if the first and second printing materials differ in their mechanical properties.
[0031] Such an approach can be particularly advantageous when components frequently require areas of varying stiffness and flexibility within a single part to achieve optimal performance and safety. The ability to print with materials exhibiting diverse mechanical properties in a single print session also enhances product design and innovation, enabling the creation of parts that are both lightweight and durable, or rigid in some areas while elastic in others. This not only simplifies the manufacturing process by reducing the need for assembling multiple parts but also opens up new possibilities for designing more complex and functionally integrated products.
[0032] The process is further improved when the first material has a Shore A hardness in the range of 70 to 80.
[0033] A material with a Shore A hardness of 70 to 80 would be suitable for applications requiring a balance between flexibility and structural strength. This hardness level is appropriate for parts that must withstand physical stress and deformation without fracture. Using such a material in 3D printing allows for the production of parts that can resist bending and kinking while maintaining their shape and integrity. This property is particularly advantageous when components must frequently withstand dynamic loads and still deliver reliable performance.
[0034] Even greater improvement is achieved if the first material has an elongation at break in the range of 240% to 360%.
[0035] Such elongation makes the first material particularly suitable for manufacturing parts that must withstand significant deformation under load without breaking, or parts subjected to frequent stretching and compression. The combination of a Shore A hardness of 70 to 80 with high elongation at break provides a material that is not only tough and tear-resistant, but also highly adaptable to dynamic mechanical conditions.
[0036] This can be further improved if the first material has a tensile strength in the range of 20 to 30 kN / m.
[0037] The combination of moderate Shore A hardness (70 to 80), high elongation at break (240% to 360%), and significant tensile strength (20 to 30 kN / m) makes this material ideal for manufacturing parts exposed to harsh conditions. The material's properties ensure that such parts function reliably without failure, thus providing safety and durability.
[0038] The process could also be improved if the second material has a Shore D hardness in the range of 68 to 74.
[0039] A second material with this degree of hardness is suitable for applications requiring high structural integrity and resistance to mechanical stress and deformation. Combining, for example, the flexibility of the first material with the hardness of the second allows for the production of composite objects that are both elastic and durable, thus optimizing performance across various operational requirements.
[0040] A further improvement is achieved if the second material has a tensile modulus in the range of 1000 MPa to 1200 MPa.
[0041] This range of tensile modulus makes the second material suitable for structural applications where stiffness and the ability to bear loads without excessive deformation are important. These types of applications benefit from the material's high stiffness, ensuring that structural components maintain their shape and functionality under mechanical stress and contributing to the overall integrity and safety of the system. Such a material, with a Shore D hardness of 68 to 74 and a tensile modulus of 1000 to 1200 MPa, complements the more flexible first material, enabling a balanced combination of properties in the finished printed object.
[0042] A further improvement is achieved if the second material has an elongation at break of more than 50%.
[0043] Such a property could make the second material suitable for components that must withstand both static and dynamic loads. The combination of a Shore D hardness of 68 to 74, a tensile modulus in the range of 1000 to 1200 MPa, and an elongation at break exceeding 50% provides a robust material profile suitable for manufacturing parts expected to function reliably under various operating conditions. This ensures that the parts can bear loads while also accommodating movement and minor deformations.
[0044] Examples of the first and second materials can include commonly known printing materials such as EPU 43, EPU 44, EPU 45, EPU 46, LOCTITE® 3D IND405 Clear, RPU 70, UMA 90, and / or other suitable materials. The choice of materials may also depend on the desired properties, for example, to achieve toughness and / or stiffness with polyamides (PA), or to achieve varying degrees of hardness, elasticity, and damping with thermoplastic polyurethane (TPU).
[0045] To further improve the process, the fill level of the printing material in the material tank is controlled by a control device to maintain a constant fill level.
[0046] The ability to maintain a constant fill level in the material tanks is advantageous when printing large or complex structures. The control system could include sensors that monitor the material level and adjust it by adding material from a reserve when levels drop, or by stopping the addition when the optimal level is reached. This automated adjustment helps achieve a high degree of precision in the final product, optimizes material usage, and reduces waste, thereby improving the overall efficiency and cost-effectiveness of the manufacturing process.
[0047] This can also be achieved if the method includes an estimate of a tank refill volume based on a volume of a pressure layer.
[0048] Estimating tank refill volume is beneficial for maintaining efficiency and material consistency in continuous or high-volume printing operations. Being able to accurately calculate and refill the precise amount of material used per shift helps prevent both bottlenecks that can slow down or stop the printing process and overfilling that could lead to material waste or overflow. This approach not only improves printing precision but also optimizes material usage, thereby reducing overall production costs and minimizing waste.
[0049] To further improve this process, the fill level of the printing material in the material tank is controlled by a control device so that it lies in the range of 0.5 mm to 4 mm, preferably in the range of 1 mm to 2 mm.
[0050] Maintaining such a fill level range is particularly important in applications requiring extreme precision and uniformity of material deposition. The specified range ensures that the printing mechanism always has optimal access to the material. Additionally, such precise control helps maintain a constant viscosity and temperature of the material. Through its improved control mechanism, this method contributes to the reliability and efficiency of the printing process.
[0051] To further improve this process, the fill level of the printing material in the material tank is controlled by a control device so that it is at the minimum volume required to print a layer.
[0052] Such a procedure is advantageous for high-precision manufacturing processes where material efficiency and layer quality are paramount. Maintaining the required minimum volume for each layer minimizes the risk of material degradation due to prolonged exposure to environmental factors and reduces overall material costs by preventing overuse. This approach not only improves the sustainability of the printing process by conserving resources but also ensures that each layer is printed uniformly with fresh material, which can enhance the structural integrity and resolution of the final product. This material management helps achieve the high standards required in advanced manufacturing applications.
[0053] A further improvement to this procedure is achieved if the tax revenue includes an overflow dam.
[0054] The inclusion of an overflow dam is advantageous in 3D printing setups: by preventing overfilling, the overflow dam helps maintain a constant material flow to the print head, which is necessary for achieving uniform layer deposition. Additionally, it helps reduce material waste by capturing any excess that might otherwise overflow or be wasted, thus improving the efficiency and cost-effectiveness of the printing process. An overflow dam can also help maintain a clean and controlled printing environment by containing overflow and splashes, thereby improving the operational reliability and ease of maintenance of the printing equipment.
[0055] This method can be further improved if the control device includes a non-contact level sensor, wherein the sensor includes an ultrasonic transducer and / or a laser.
[0056] Adding these types of sensors provides improved pressure build-up, as level monitoring can be seamlessly integrated into the pressure build-up process by sensing the fill level with a non-contact sensor. This allows the control system to regulate the fill level of a material tank to maintain a constant level.
[0057] Further improvements to this process are achieved if the control device includes a weight sensor.
[0058] Such a weight sensor offers another way to measure the fill level of a material tank by knowing the total weight of the material inside the tank. This opens up the possibility of controlling the fill level even more precisely.
[0059] Another part of the invention is a sporting goods product manufactured according to the method.
[0060] The invention according to the method is suitable for the manufacture of sporting goods, since these often require the materials and manufacturing processes that use the aforementioned parameters. 4. Brief description of the characters
[0061] Preferred embodiments of the disclosure are disclosed below with reference to the accompanying figures. Fig. Figure 1 illustrates the inventive method with a horizontally movable construction platform in a schematic view. Fig. Figure 2 illustrates the inventive method with a pressure vessel in a schematic view. Fig. Figure 3 shows the inventive method with a rotatable disk in a schematic view. Fig. Figure 4 illustrates a conventional method for printing a three-dimensional object with a high fill level. Fig. Figure 5 illustrates the inventive method with a lower fill level. Fig. Figure 6 shows the method according to the invention with an overflow dam. Fig. Figure 7 illustrates a studded shoe printed using a method according to the invention. Fig. Figure 8 illustrates a shin guard printed using a method according to the invention. Fig. Figure 9 shows a shoe printed using a method according to the invention. Fig. Figure 10 illustrates a shoe sole printed by a method according to the invention. Fig. Figure 11 illustrates a vertically integrated shoe sole printed by a method according to the invention. Fig. Figure 12 shows a method according to the invention, wherein a build platform passes a cleaning tank after a first printing step in a schematic view. Fig. 13: illustrates the procedure of Fig. 12, where the build platform passes the cleaning tank after a second pressure step in a schematic view. Fig. Figure 14 illustrates a method according to the invention, wherein the build platform passes through an ultrasonic cleaning tank in a schematic view. 5. Detailed description of the figures
[0062] The following sections provide a detailed description of the invention, with reference to the accompanying figures for clarity. The descriptions are examples only and are not intended to limit the scope of the invention. Identical reference numerals in the figures and in the text denote the same components. The figures may not be true to size or scale; their dimensions, proportions, and representations of elements may have been enhanced for better understanding and visual convenience.
[0063] Fig. Figure 1 illustrates a printing device according to the invention for printing a three-dimensional object 1. The build platform 100 is movable in the horizontal and vertical directions. The printed three-dimensional object 1 is printed on the underside of the build platform 100. A first material tank 10 and a second material tank 20 are provided, the first material tank 10 containing a first printing material (not shown) and the second material tank 20 containing a second printing material (not shown). The build platform 100 can easily switch between the first material tank 10 and the second material tank 20 to print a three-dimensional object from different materials.
[0064] The build platform 100 can seamlessly switch between these two tanks 10 and 20, enabling the integration of different materials into the three-dimensional object 1. This capability is particularly useful for creating complex objects that require different material properties (e.g., hardness, flexibility, color, and the like) at various sections of the final product. Such a setup allows for improved product functionality and aesthetic qualities by integrating multiple materials into a single object without requiring manual intervention or post-printing assembly. This can significantly streamline the manufacturing process for multi-material articles, allowing material properties to be optimized for specific functional zones within the object. In this embodiment, the printing materials could be liquid photopolymer resin. The printing process could utilize Digital Light Processing (DLP).Printing could also be carried out by photopolymerization, and photopolymerization could be made possible by UV light.
[0065] Fig. Figure 2 illustrates another printing device according to the invention for printing a three-dimensional object 1. The build platform 200 is movable in the vertical direction. A pressure vessel 30 is arranged below the build platform 200. The first printing material 11 and the second printing material 21 can be introduced into the pressure vessel 30, depending on which printing material is to be used for printing a layer of the three-dimensional printed object.
[0066] The pressure vessel 30 is designed to accommodate both the first printing material 11 and the second printing material 21. These materials can be alternately introduced into the vessel based on the specific requirements of each layer of the three-dimensional object 2 being printed. This method enables efficient switching between materials during the printing process, facilitating the creation of complex multi-material objects without the need to pause, manually change, or mix materials. Such a setup could be particularly advantageous for producing layers with different material properties in a continuous printing process.
[0067] In Fig. The build platform 300 is vertically movable and arranged above a rotatable disk 300. The disk 302 can rotate clockwise and contains a first material tank 310, a second material tank 320, a third material tank 330, and a cleaning tank 340. Depending on the rotational position of the disk 300, a different tank can be used for printing.
[0068] The rotating disk 302 enhances the operational flexibility of the setup, allowing the build platform 300 to access different materials or perform cleaning operations simply by rotating the disk to the desired position. This means that during the printing process, the build platform can align itself with one of the material tanks to deposit different materials, as required by the design of a printed three-dimensional object, or align itself with the cleaning tank to ensure that the printed object or the platform itself is free of residue before applying a new material. Such a configuration is suitable for manufacturing processes where products require the integration of multiple materials with different properties.Furthermore, incorporating a cleaning tank into the same structure prevents cross-contamination between different material layers.
[0069] In this embodiment, the tanks are arranged on a rotatable disc.
[0070] Fig. Figure 4 illustrates a conventional printing process for a three-dimensional object 4. A build platform 400 contains the three-dimensional object 4, which is almost completely immersed in the printing material 401 within the printing material tank 410. A layer of material is printed onto the object 4 near the bottom 412 of the printing material tank 410. Here, more than half of the object is covered by the printing material.
[0071] Object 4 is built upside down, and each new layer is cured by a light source (not shown) at the bottom of the tank. Meanwhile, the build platform 400 gradually raises Object 4, exposing the newly solidified layer and immersing the next layer in the material 401, such as liquid resin for printing. This immersion in the printing material makes it difficult to clean the object in a second printing step using a different material, as all the material must be cleaned from the object to avoid cross-contamination.
[0072] Fig. Figure 5 illustrates a printing method according to the invention. A build platform 500 contains the three-dimensional object 5, which is barely immersed in the printing material 501 within the printing material tank 510. A printing layer is printed onto the object 5 near the bottom 512 of the printing material tank 510. Here, only a small part of the object is covered by the printing material, and there is just enough printing material to print one layer. This reduces the cleaning effort, as only as much material as is required to print one layer is in contact with the object. The fill level of the printing material in the material tank can be controlled by a control device to maintain a constant fill level. This could be achieved using an estimate of a tank refill volume based on the volume of a printing layer.The fill level of the printing material in the material tank can be controlled by a control device to maintain it within the range of 0.5 mm to 4 mm, preferably within the range of 1 mm to 2 mm. The fill level of the printing material in the material tank can also be controlled by a control device to maintain it at the minimum volume required to print a layer. The control device could also include a non-contact level sensor, while the sensor could include an ultrasonic transducer and / or a laser. The control device could also include a weight sensor, for example, to use the mass of the printed material.
[0073] This approach offers several advantages, particularly in reducing the cleaning required between layers and after printing. By limiting the immersion depth, less of the object comes into contact with the potentially viscous printing material, thus minimizing residue and potentially reducing imperfections caused by excess material adhering to the object. Furthermore, this method can improve material usage efficiency, as only the necessary amount for each layer is in contact with the object, minimizing waste. Such a method is beneficial for manufacturing processes where minimizing cleaning effort after or during processing is desirable. This setup not only supports a cleaner and more efficient printing process but also contributes to sustainability by reducing material waste.
[0074] Fig. Figure 6 illustrates another printing method according to the invention. A build platform 600 contains the three-dimensional object 6, which is barely immersed in the printing material 601 within the printing material tank 610. A printing layer is printed onto the object 6 near the bottom 612 of the printing material tank 610. Printing material 601 is stored in a printing material reservoir 622, from where it is transferred into the material tank 610 by a material transfer unit 620. An overflow dam 630 keeps the fill level in the tank 610 constant, as excess material flows over the overflow dam 630 into the reservoir 622.
[0075] Here, only a small portion of the object is covered by the printing material. This reduces cleaning effort, as only the amount of material required to print a layer is in contact with the object. This is particularly advantageous because it ensures a constant supply of fresh material without overfilling the tank, thus maintaining the quality of each printed layer. The minimal immersion of the object in the printing material, combined with the overflow dam and material recycling, significantly reduces cleaning effort and improves process efficiency. Such a setup would be beneficial in scenarios where material consistency is critical. The controlled environment also reduces the risk of contamination and ensures that only the necessary amount of material is in contact with the object, thus maintaining high cleanliness and accuracy.This process not only optimizes material usage but also contributes to a more sustainable and cost-effective manufacturing process.
[0076] In Fig. Figure 7 illustrates a studded shoe 700 printed using the inventive method. The shoe upper 701 and the studded sole 702 are printed with different materials.
[0077] Specific design and material properties can be tailored to different sports or user preferences, providing improved performance characteristics such as enhanced shock absorption, better traction, or increased comfort.
[0078] Fig. Figure 8 illustrates a shin guard 800 printed using the inventive method. The inner layer 801 is printed with a different material than the outer layer 802.
[0079] The inner layer 801, which is in direct contact with the wearer's skin, can be printed using a softer, more flexible material to ensure comfort and impact absorption. Ideally, this material would be lightweight and able to conform to the contours of the user's leg, providing a snug fit that maximizes protection while maintaining comfort. Conversely, the outer layer 802 is designed to absorb and distribute the force of impacts during sports or other activities. For this purpose, a harder, stiffer material is used to resist punctures and scratches, ensuring that the shin guard remains effective over time under harsh usage conditions. This dual-material printing technique illustrates the process's ability to produce complex, multifunctional sports equipment in a single, streamlined process.By integrating different material properties within the same article, the shin guard is optimized for both protection and comfort, without requiring additional assembly processes.
[0080] In Fig. Figure 9 illustrates a shoe 900 printed using the inventive method. The upper part 901 and the sole 902 are printed with different materials.
[0081] The upper (901), which encloses the foot, can be printed from a material that offers flexibility, breathability, and comfort. This could be a soft material that conforms to the shape of the wearer's foot, providing a comfortable fit while also allowing airflow to keep the foot cool and dry. The sole (902), in contrast, is printed from a more durable and robust material that can withstand the wear and tear of walking or running. This material must provide sufficient traction and support, potentially incorporating different densities and textures to optimize grip and cushioning, thereby improving the shoe's performance and longevity.This method of using different materials for various parts of the shoe demonstrates the advanced capabilities of the 3D printing process, enabling extensive customization and optimization of the product. By precisely controlling the material properties, the shoe can be tailored to specific activities or user preferences, providing an excellent fit, targeted support, and optimal comfort. One of the materials could have a Shore A hardness in the range of 70 to 80, an elongation at break in the range of 240% to 360%, and / or a tensile strength in the range of 20 to 30 kN / m. The other material could have a Shore D hardness in the range of 68 to 74, a tensile modulus in the range of 1000 MPa to 1200 MPa, and / or an elongation at break of more than 50%.
[0082] Fig. Figure 10 illustrates a sole 1000 printed using the inventive method. It comprises different materials: a first sole material 1001, a second sole material 1002, and a third sole material 1003.
[0083] The first sole material, 1001, could be designed to provide cushioning and shock absorption, ideal for areas of the sole that bear the brunt of impacts during activities like walking or running. This material could be a soft, elastic polymer that compresses under pressure but quickly returns to its original shape. The second sole material, 1002, could be used for its durability and wear resistance, suitable for the outer perimeter of the sole, which comes into frequent contact with the ground. This could be a harder, more abrasion-resistant material that withstands long-term use without degradation. The third sole material, 1003, could be selected for its grip and traction properties, particularly in areas of the sole that require anti-slip characteristics to ensure safety and performance on various surfaces.This method of using different materials within a single sole illustrates the versatility and precision of advanced 3D printing techniques. It allows each section of the sole to be tailored to specific functional requirements, optimizing the overall performance of the footwear. By segmenting the sole into zones with tailored material properties, the product can offer enhanced comfort, durability, and safety, all essential for high-performance footwear.
[0084] In Fig. Figure 11 illustrates a shoe 1100 printed using the inventive method. The shoe upper 1101 and the sole 1102 are printed with different materials. The shoe upper 1101 and the sole 1103 are not only horizontally connected, but also vertically interlocked.
[0085] This vertical engagement incorporates a form of interlocking design, where elements of the sole and upper interlock or fit together, similar to puzzle pieces, enhancing the strength and durability of the connection. This could be achieved through complementary ribs and grooves, snap closures, or other mechanical fasteners printed directly into the materials. This type of connection ensures that the upper and sole not only adhere to each other but are structurally integrated, which can significantly improve the overall stability and durability of the shoe. Such a design enhances the shoe's integrity and performance by ensuring that the two parts can effectively distribute and withstand the stresses and strains encountered during wear.The integrated structure can better absorb shocks, provide improved support, and reduce the likelihood of separation or wear at the joint, which is often a weak point in conventionally manufactured footwear.
[0086] Fig. Figure 12 illustrates the method for printing a three-dimensional object 12 with the following steps: providing a first printing material 1211 and a second printing material 1221, which are separated in a first material tank 1210 and a second material tank 1220; providing a build platform 1200; a first printing step of printing the object 12 at least partially onto the build platform 1200 with the first printing material 1211. A cleaning step of cleaning the object 12 is shown: After printing the object 12 partially onto the build platform 1200, the build platform 1200 with the object 12 moves to the right in the direction of the second material tank 1220. On its way, it passes the cleaning solution tank 1240, which includes a first standing washing wave 1244 of cleaning solution and an air knife 1242. In this embodiment, the at least one cleaning tank is arranged between the printing material tanks.
[0087] The stationary wash shaft 1244 effectively removes any remaining first printing material or residue from the object 12, ensuring a clean surface for the next material application layer. The air knife 1242 is positioned to dry the object by blowing off any remaining cleaning solution and preparing it for further processing. This process integrates cleaning directly into the printing line and improves the quality of the printed object by ensuring clean material layers free from contamination from previous steps. Such a setup could be extremely advantageous in high-precision manufacturing environments where material purity and layer adhesion are critical.
[0088] Fig. Figure 13 shows a subsequent step in the printing of the three-dimensional object 12. Fig. Figure 12 shows that after the first cleaning step of object 12, the following occurs: After a second printing step of at least partially printing object 12 onto the build platform 1200 with the second printing material 1221 from the second material tank 1220, the build platform 1200 with object 12 is moved to the left. The build platform 1200 with object 12 passes the cleaning solution tank 1240, which includes a second standing washing wave 1246 of cleaning solution and an air knife 1242.
[0089] As the build platform 1200 moves, it passes the cleaning solution tank 1240 again. This time, the object 12 is exposed to a second stationary wash wave 1246 of cleaning solution, designed to remove any excess material or particles of the second printing material, ensuring that the object's surface remains clean and prepared for further processing steps. The air knife 1242, which was used in the first cleaning step of Fig. If the cleaning solution matches step 12, it is reused to quickly dry the object, removing any remaining liquid or particles from the cleaning solution. This sequential and systematic cleaning and drying process, embedded within the material printing workflow, improves the consistency and reliability of the printing process.
[0090] Fig.Figure 14 illustrates the process for printing a three-dimensional object 14 with the following steps: providing a first printing material 1411 and a second printing material 1421, which are separated in a first material tank 1410 and a second material tank 1420; providing a build platform 1400; a first printing step of printing the object 14 at least partially onto the build platform 1400 with the first printing material 1411. A cleaning step of cleaning the object 14 is shown: After printing the object 14 partially onto the build platform 1400, the build platform 1400 with the object 14 moves to the right towards the second material tank 1420. On its way, it passes the ultrasonic cleaning tank 1440, which includes an air knife 1442. The platform 1400 is moved vertically into the ultrasonic cleaning tank 1440, so that the object 14 is immersed in the cleaning solution inside the ultrasonic cleaning tank.After an ultrasonic cleaning step, platform 1400 is moved upwards so that object 14 exits the ultrasonic cleaning tank 1440. Platform 1400 is then moved to the right towards the second printing material tank 1420. On its way, it passes the air knife 1442.
[0091] The build platform 1400, carrying the partially printed object 14, moves to the right towards the second material tank 1420 for subsequent printing. During this transition, the platform passes the ultrasonic cleaning tank 1440, which is equipped with an air knife 1442. The platform 1400 lowers the object 14 into the ultrasonic cleaning tank and immerses it in a cleaning solution. The ultrasonic cleaning process uses high-frequency sound waves to agitate the fluid, creating microcavitation bubbles. These bubbles effectively remove any residue, residual printing material, or contaminants from the object's surface, providing a deep clean that is highly effective for intricate designs and complex geometries. Once the ultrasonic cleaning process is complete, the build platform 1400 is raised, lifting the object 14 out of the cleaning solution.As the platform continues its movement toward the second material tank, it passes under the air knife 1442. The air knife directs a high-velocity airflow onto the object, effectively drying it by removing any remaining moisture or cleaning fluid residue. This step is crucial because it prepares the object's surface for the application of the second printing material, ensuring proper adhesion of subsequent layers. In this embodiment, the build platform is movable both vertically and horizontally. Such a feature of a vertically and horizontally movable platform could also be implemented using a Stewart platform. Reference symbol list: 1, 2, 4, 5, 6, 12, 14 three-dimensional object 100, 200, 300, 400, 500, 600, 1200, 1400 building platform 10, 310, 1210, 1410 first material tank 11, 1211, 1411 first printed material 20, 320, 1220, 1420 second material tank 21, 1221, 1421 second printed material 30 pressure vessels 302 rotating disc 330 third material tank 340, 1240 cleaning tank 401, 501, 601 Printing material 410, 510, 610 Printing material tank 412, 512, 612 Floor 620 transfer units 622 Material reservoir 630 Overflow dam 700 studded shoe 701 shoe upper 702 studded sole 800 shin guards 801 Inner layer 802 Outer layer 900 shoes 901 shoe upper 902 sole 1000 soles 1001 first sole material 1002 second sole material 1003 third sole material 1100 shoes 1101 Shoe upper 1102 sole 1242, 1442 Air gauge 1244 first washing wave 1246 second wash wave 1440 Ultrasonic cleaning tank
Claims
[1] Method for printing a three-dimensional object comprising at least the following steps: Providing at least one first and one second printed material, which are separated into at least one first and one second material tank; Provide a construction platform; a first printing step of the object printing at least partially onto the build platform with the first printing material; a cleaning step of cleaning the object of the first and / or second printing material; and a second printing step of printing the object at least partially onto the build platform with the second printing material. [2] The method of claim 1, wherein the cleaning step comprises at least the following steps: Providing one or more cleaning tanks containing a cleaning solution; Providing one or more air meters; and Providing one or more standing waves of cleaning solution; Cleaning the object by exposing it to one or more standing waves of cleaning solution; and Drying the cleaned object by exposing it to one or more air knives. [3] The method of claim 1, wherein the cleaning step comprises at least the following steps: Providing one or more cleaning tanks containing a cleaning solution, wherein at least one of the cleaning tanks is an ultrasonic cleaning tank configured and dedicated for ultrasonic cleaning; and Providing one or more air meters; Cleaning the object by immersing it in the ultrasonic cleaning tank; and Drying the cleaned object by exposing it to one or more air knives. [4] Method according to any of the preceding claims, wherein at least one of the material tanks and / or at least one of the cleaning tanks is horizontally movable. [5] Method according to one of the preceding claims, wherein the tanks are arranged on a rotatable disk. [6] Method according to any one of claims 2-5, wherein at least one cleaning tank is arranged between the printing material tanks. [7] Method according to any of the preceding claims, wherein the construction platform is movable vertically and horizontally. [8] Method according to the preceding claim 7, wherein the construction platform comprises a Stewart platform. [9] Method according to any of the preceding claims, wherein at least one of the printing materials is a liquid photopolymer resin. [10] Method according to any of the preceding claims, wherein the printing uses Digital Light Processing (DLP). [11] Method according to any of the preceding claims, wherein the printing is carried out by photopolymerization. [12] Method according to claim 11, wherein the photopolymerization is enabled by UV light. [13] Method according to any of the preceding claims, wherein the first and the second printing material differ in their mechanical properties. [14] Method according to the preceding claim 13, wherein the first material has a Shore A hardness in the range of 70 to 80. [15] Method according to any one of the preceding claims 13 to 14, wherein the first material has an elongation at break in the range of 240% to 360%. [16] Method according to any one of the preceding claims 13 to 15, wherein the first material has a tensile strength in the range of 20 to 30 kN / m. [17] Method according to any one of the preceding claims 13 to 14, wherein the second material has a Shore D hardness in the range of 68 to 74. [18] Method according to any one of the preceding claims 13 to 17, wherein the second material has a tensile modulus in the range of 1000 MPa to 1200 MPa. [19] Method according to any one of the preceding claims 13 to 18, wherein the second material has an elongation at break of more than 50%. [20] Method according to one of the preceding claims, wherein the fill level of the printing material in the material tank is controlled by a control means to maintain a constant fill level. [21] Method according to claim 20, wherein the method comprises an estimation of a tank refill volume based on a volume of a pressure layer. [22] Method according to claim 20 or 21, wherein the fill level of the printing material in the material tank is controlled by a control means such that it is in the range of 0.5 mm to 4 mm, preferably in the range of 1 mm to 2 mm. [23] Method according to one of claims 20 to 22, wherein the fill level of the printing material in the material tank is controlled by a control means such that it is at the minimum volume required to print a layer. [24] Method according to any one of claims 20 to 23, wherein the control means comprises an overflow dam. [25] Method according to any one of claims 20 to 24, wherein the control means comprises a non-contact level sensor, wherein the sensor comprises an ultrasonic transducer and / or a laser. [26] Method according to any one of claims 20 to 25, wherein the control means comprises a weight sensor. [27] Sporting goods manufactured according to a method according to any of the preceding claims.