Three-dimensional printing method and system for fabric

Abstract

This relates to a method and system for three-dimensional printing on fabric. [Solution] The three-dimensional printing system comprises a nozzle array for dispensing construction material, a work tray (12 / 360), and a jig (402) configured to attach a fabric (420) to the work tray. A computerized controller operates at least the nozzle array to dispensing construction material onto the attached fabric in a construction pattern corresponding to the shape of the object.

Description

Technical Field

[0001] This application claims the benefit of priority of U.S. Provisional Patent Application No. 63 / 056,759, filed on July 27, 2020, the content of which is incorporated herein by reference in its entirety.

[0002] The present invention relates in some embodiments to three-dimensional printing, and more specifically, but not limited thereto, to methods and systems for three-dimensional printing on fabrics.

Background Art

[0003] Additive manufacturing (AM) is a technology that enables the fabrication of structures having a shape directly from computer data through additional forming steps. The basic operation of any AM system consists of slicing a three-dimensional computer model into thin cross-sectional parts, converting the result into two-dimensional position data, and supplying that data to a control device that fabricates the three-dimensional structure layer by layer.

[0004] Additive manufacturing involves many different approaches to fabrication methods, such as three-dimensional (3D) printing like 3D inkjet printing, electron beam melting, stereolithography, selective laser sintering, thin film lamination, and fused deposition modeling.

[0005] Some 3D printing processes, such as 3D inkjet printing, are performed by inkjet depositing construction materials layer by layer. Thus, construction materials are ejected from a discharge head having a set of nozzles and deposited layer by layer on a support structure. Depending on the construction material, the layer can then be cured or solidified using an appropriate device.

[0006] Various three-dimensional printing technologies exist, for example, disclosed in U.S. Patents 6,259,979, 6,569,373, 6,658,314, 6,850,334, 6,863,859, 7,183,335, 7,209,797, 7,225,045, 7,300,619, 7,500,846, 9,031,680, 9,227,365, U.S. Published Patent Application No. 20060054039, and International Publication WO2016 / 009426, all by the same assignee, and are incorporated herein by reference in their entirety.

[0007] U.S. Patent No. 8,993,061 discloses a method for direct 3D printing onto footwear. A 3D pattern for printing is designed. The footwear is placed substantially flat on a tray of a 3D printing system, and the 3D material is printed directly onto the fabric of the footwear using the designed pattern. [Prior art documents] [Patent Documents]

[0008] [Patent Document 1] U.S. Publication No. 6,259,979 [Patent Document 2] U.S. Publication No. 6,569,373 [Patent Document 3] U.S. Publication No. 6,658,314 [Patent Document 4] U.S. Publication No. 6,850,334 [Patent Document 5] U.S. Publication No. 6,863,859 [Patent Document 6] U.S. Publication No. 7,183,335 [Patent Document 7] U.S. Publication No. 7,209,797 [Patent Document 8] U.S. Publication No. 7,225,045 [Patent Document 9] U.S. Publication No. 7,300,619 [Patent Document 10] U.S. Publication No. 7,500,846 [Patent Document 11] U.S. Publication No. 9,031,680 [Patent Document 12] U.S. Publication No. 9,227,365 [Patent Document 13] U.S. Published Patent Application No. 20060054039 [Patent Document 14] International Publication WO2016 / 009426 Specification [Patent Document 15] U.S. Publication No. 8,993,061 [Overview of the project]

[0009] According to one aspect of several embodiments of the present invention, a three-dimensional printing system is provided. The system comprises a nozzle array for dispensing construction material, a work tray, a jig configured for attaching fabric to the work tray, and a computerized controller configured to operate at least the nozzle array on the attached fabric to dispensing construction material in a construction pattern corresponding to the shape of an object.

[0010] According to some embodiments of the present invention, the jig is configured to stretch the fabric.

[0011] According to some embodiments of the present invention, the system further includes a robotic mechanism configured to be connected to a jig and to position the jig on a tray.

[0012] According to some embodiments of the present invention, the robotic mechanism is configured to reverse the orientation of the jig with respect to the horizontal plane.

[0013] According to some embodiments of the present invention, the computerized controller is configured to operate at least a nozzle array to dispense the construction material onto a tray, and to operate a robotic mechanism to position the jig on the tray after the construction material has been dispensed onto the tray and before the construction material has been dispensed onto the attached fabric.

[0014] According to some embodiments of the present invention, the system includes a position tracking system configured to determine the position of the jig with respect to the work tray, and a computerized controller is configured to execute an alignment procedure based on the position and operate the nozzle array in response to the alignment.

[0015] According to some embodiments of the present invention, the jig includes a mark, and the mark is identifiable by the position tracking system to determine the position.

[0016] According to some embodiments of the present invention, the system includes a radiation source, and the work tray has a reflectivity of at least 50% with respect to the radiation emitted from the radiation source.

[0017] According to some embodiments of the present invention, the work tray includes a fluid flow path, and the system includes a fluid delivery system configured to generate a fluid flow within the fluid flow path.

[0018] According to one aspect of some embodiments of the present invention, a three-dimensional printing system is provided. The system includes a nozzle array that discharges a construction material, a radiation source that emits radiation for solidifying the discharged construction material, a work tray characterized by a reflectivity of at least 50% with respect to the radiation, and a computerized controller configured to operate at least the nozzle array to discharge the construction material onto a fabric in a configuration pattern corresponding to the shape of an object.

[0019] According to one aspect of some embodiments of the present invention, a three-dimensional printing system is provided. The system includes a nozzle array that discharges a construction material, a work tray having a fluid flow path, a fluid delivery system configured to generate a fluid flow within the fluid flow path, and a computerized controller configured to operate at least the nozzle array to discharge the construction material onto a fabric in a configuration pattern corresponding to the shape of an object.

[0020] According to some embodiments of the present invention, the system comprises an additive dispensing system that fluidly communicates with a container containing additives other than the building material for three-dimensional printing and dispenses the additives onto a fabric surface.

[0021] According to one aspect of several embodiments of the present invention, a three-dimensional printing system is provided. The system comprises a nozzle array for dispensing construction material, a work tray, a computerized controller configured to operate at least the nozzle array to dispensing the construction material onto a fabric in a construction pattern corresponding to the shape of an object, and an additive dispensing system which is in fluid communication with a container containing additives other than construction material for three-dimensional printing and dispensing the additives onto the fabric.

[0022] According to some embodiments of the present invention, the computerized controller is configured to operate the additive dispensing system.

[0023] According to some embodiments of the present invention, the array and the additive dispensing system are mounted on the same printing block.

[0024] According to some embodiments of the present invention, the array and additive dispensing system are configured to move independently along the horizontal direction.

[0025] According to some embodiments of the present invention, the array and the additive dispensing system are configured to move independently along the vertical direction.

[0026] According to one aspect of several embodiments of the present invention, a three-dimensional printing system for fabric is provided. The system comprises a printing chamber having a nozzle array for dispensing construction material and a work tray inside it; a computerized controller configured to operate at least the nozzle array to dispensing construction material onto the fabric in a construction pattern corresponding to the shape of an object; and a fabric unwinding device for unfolding a roll of fabric and supplying the unfolded fabric to the printing chamber.

[0027] According to some embodiments of the present invention, the system includes a cutting device for cutting the unfolded fabric into sections.

[0028] According to some embodiments of the present invention, the system includes a fabric winding device for winding up the fabric after it has been discharged.

[0029] According to some embodiments of the present invention, a fabric winding device receives fabric from a fabric unwinding device via a printing chamber, thereby providing a continuous fabric roll on which a three-dimensional object is printed.

[0030] According to one aspect of several embodiments of the present invention, a system for three-dimensional printing is provided. The system comprises a nozzle array for ejecting construction material, a work tray, an imaging system positioned to image a fabric placed on the work tray, and a computerized controller that receives image data from the imaging system, processes the image data to identify patterns on the fabric, and operates at least the nozzle array to eject construction material in a construction pattern corresponding to the shape of an object at selected positions relative to the identified features on the fabric.

[0031] According to some embodiments of the present invention, the imaging system comprises a pixelated image sensor.

[0032] According to some embodiments of the present invention, the imaging system includes a scanner.

[0033] According to some embodiments of the present invention, the work tray is operationally coordinated with a radiation source configured to emit radiation upward to solidify the extruded construction material from below.

[0034] According to some embodiments of the present invention, the system comprises a stationary platform surrounding a work tray, and the jig comprises a frame configured to attach a cloth to the platform at the periphery of the work tray.

[0035] According to some embodiments of the present invention, at least one of the platform and the frame is provided with a protruding element or a rough surface. According to some embodiments of the present invention, both the platform and the frame are provided with complementary protruding elements or rough surfaces.

[0036] According to some embodiments of the present invention, the edge of the top surface of the tray is at least one of a fillet cut and a chamfer.

[0037] According to some embodiments of the present invention, the system comprises a ramp structure that can be mounted or positioned on the work tray to define the upper space of the work tray, the upper surface of the ramp structure is configured to support the horizontal portion of the fabric, the space is configured to receive the hanging portion of the fabric, and a computerized controller controls a nozzle array to discharge the construction material only onto the upper surface.

[0038] According to some embodiments of the present invention, a computerized controller is configured to adjust the vertical position of the work tray to compensate for the height of the ramp structure above the work tray.

[0039] According to one aspect of several embodiments of the present invention, a system for three-dimensional printing is provided. This system includes applying a curable material to a fabric and operating a nozzle array to extrude the construction material onto the fabric in a configuration pattern corresponding to the shape of an object.

[0040] According to some embodiments of the present invention, the application of the curable substance includes applying the curable substance to the same side of the fabric from which the construction material is extruded.

[0041] According to some embodiments of the present invention, the application of the curable substance includes applying the curable substance to the opposite side of the fabric from which the construction material is extruded.

[0042] According to some embodiments of the present invention, the application of a curable substance includes placing a sheet containing the curable substance on a fabric and heating the sheet.

[0043] According to some embodiments of the present invention, the application of a curable substance includes placing a sheet containing the curable substance under a fabric and heating the sheet.

[0044] According to some embodiments of the present invention, the operation of the nozzle array includes operating a three-dimensional printing system comprising a nozzle array and a work tray, and the application of a curable substance includes placing a sheet containing the curable substance on a tray, placing a cloth on top of the sheet, and heating the tray.

[0045] According to some embodiments of the present invention, the curable substance is an oily substance.

[0046] According to some embodiments of the present invention, the curable substance includes wax.

[0047] According to one aspect of several embodiments of the present invention, a system for three-dimensional printing is provided. This method includes operating a first nozzle array to extrude a first construction material onto a fabric to form an adhesive area on the fabric, and operating a second nozzle array to extrude a second construction material onto the adhesive area in a configuration pattern corresponding to the shape of an object.

[0048] According to some embodiments of the present invention, the fabric is on a work tray, and the method includes acquiring alignment data regarding the position of the fabric relative to the work tray, and aligning the dispensing position of the construction material based on the alignment data.

[0049] According to some embodiments of the present invention, the second building material generally includes a colorless and transparent building material.

[0050] A three-dimensional printing system is provided according to one aspect of several embodiments of the present invention. This method includes extruding at least one construction material onto a receiving surface to form a fixed element thereon, placing a fabric on the fixed element, extruding at least one construction material onto the fabric to form a penetrating element that penetrates the fabric and connects to the fixed element, and extruding at least one construction material onto the penetrating element in a configuration pattern corresponding to the shape of an object.

[0051] According to one aspect of several embodiments of the present invention, a system for three-dimensional printing is provided. This method includes extruding at least one construction material onto a receiving surface in a construction pattern corresponding to the shape of an object, placing a fabric on the object, extruding at least one construction material onto the fabric to form a penetrating element that penetrates the fabric and connects to the object, and extruding at least one construction material onto the penetrating element to form another object.

[0052] According to some embodiments of the present invention, this other object is a fixed element.

[0053] According to some embodiments of the present invention, another object is a decorative object.

[0054] According to some embodiments of the present invention, at least one of the object and another object is a thermal protection object.

[0055] According to some embodiments of the present invention, this method comprises extruding at least one construction material onto a work tray to form a sacrificial structure, wherein the receiving surface is the sacrificial structure.

[0056] According to some embodiments of the present invention, extruding at least one construction material to form a through element generally includes extruding a colorless and transparent construction material.

[0057] According to some embodiments of the present invention, this method includes dispensing at least one construction material to form a penetrating element, penetrating the fabric while the penetrating element is in a liquid state, and then irradiating the construction material by solidification irradiation.

[0058] According to some embodiments of the present invention, this method includes extruding at least one construction material to form a sacrificial layer on the exposed portion of the fabric, and non-selectively irradiating all the extruded construction material by solidification irradiation.

[0059] According to some embodiments of the present invention, this method includes acquiring alignment data regarding the position of the fabric relative to the work tray and aligning the dispensing position of the construction material based on the alignment data.

[0060] According to one aspect of several embodiments of the present invention, a method for manufacturing clothing is provided. This method includes extruding a construction material onto a first element of fabric to form a female snap connector, extruding the construction material onto a second element of fabric to form a male snap connector, connecting the female snap connector to the male snap connector, and thereby manufacturing clothing.

[0061] According to one aspect of several embodiments of the present invention, a method for manufacturing a garment is provided. This method includes extruding a construction material onto a fabric element to form a female snap connector and a male snap connector offset laterally from the female snap connector, folding the fabric element to align with the connectors, connecting the female snap connector to the male snap connector, thereby manufacturing a garment.

[0062] According to some embodiments of the present invention, this method includes applying at least one additive other than the construction material for three-dimensional printing to the fabric before the extrusion of the construction material and / or after the extrusion of the construction material.

[0063] According to one aspect of several embodiments of the present invention, a three-dimensional printing method is provided. This method involves operating a nozzle array to extrude a construction material onto a fabric in a construction pattern corresponding to the shape of an object, and applying at least one additive other than the construction material for three-dimensional printing to the fabric before and / or after the extrusion of the construction material.

[0064] According to some embodiments of the present invention, at least one additive comprises a primer selected from the group consisting of adhesive solutions and pore size adjusting solutions, and the application of the primer is performed before dispensing.

[0065] According to some embodiments of the present invention, at least one additive comprises a radiation protection solution and a finishing liquid selected from the group consisting of a glossy finishing liquid and a matte finishing liquid, and the application of the finishing liquid is performed after the dispensing.

[0066] According to some embodiments of the present invention, at least one additive comprises a masking solution, and the application of the masking solution is performed selectively on a location not occupied by an object, prior to dispensing.

[0067] According to some embodiments of the present invention, at least one additive is an in-situ activatable inactive formulation, and the method comprises applying the formulation to a fabric and then activating the formulation.

[0068] According to some embodiments of the present invention, activation is performed by irradiation.

[0069] According to some embodiments of the present invention, activation is performed by heating.

[0070] According to some embodiments of the present invention, activation is achieved by a chemical reaction between the additive and one or more building materials.

[0071] According to some embodiments of the present invention, the application of the additive includes applying an aerosol of the additive to a fabric.

[0072] According to some embodiments of the present invention, the application of the additive includes depositing droplets of the additive at discrete, addressable locations on the fabric.

[0073] According to some embodiments of the present invention, there are at least two additives, and the application of the additives involves overlapping and depositing droplets of the additives at discrete addressable locations on the fabric.

[0074] According to some embodiments of the present invention, there are a first additive and a second additive, the first and second additives chemically react with each other upon contact, and the application of the additives involves separating and depositing the additives on a fabric surface so as to later induce the reaction between them.

[0075] According to one aspect of several embodiments of the present invention, a three-dimensional printing method is provided. This method includes receiving data relating to the properties of a fabric via a user interface, receiving data relating to the properties of an object to be printed on the fabric, accessing a computer-readable medium that stores a library having multiple entries, each having a fabric properties library, an object properties library, and a set of printing parameters, searching the library for the entry best suited to the received properties, and operating a three-dimensional printing system according to the set of printing parameters of the entry to form the object on the fabric.

[0076] According to some embodiments of the present invention, the characteristics of the fabric include at least one characteristic selected from the group consisting of the type of fabric, the size of the pores in the fabric, and the weave pattern of the fabric.

[0077] According to some embodiments of the present invention, the properties of an object include at least one property selected from the group consisting of the thickness of the object, the shape of the object, and the rigidity of the object.

[0078] According to some embodiments of the present invention, the set of printing parameters includes at least one of (i) the application sequence of the primer, (ii) the building material, (iii) the dispensing sequence of the building material, and (iv) the application sequence of the finish liquid.

[0079] According to some embodiments of the present invention, this method includes receiving a scan of an individual's body or an external body part thereof and selecting at least one characteristic of the object based on the scan.

[0080] According to some embodiments of the present invention, the object is selected from the group consisting of a lens or prism object, an object that reflects visible light, an object that is transparent to visible light but reflects non-visible light, a fluorescent object, and a waveguide.

[0081] According to some embodiments of the present invention, an object can change its optical, mechanical, and / or geometric properties in response to environmental changes.

[0082] According to some embodiments of the present invention, the environmental change includes at least one change selected from the group consisting of temperature changes, humidity changes, and changes in the electromagnetic content of the environment.

[0083] According to some embodiments of the present invention, the object includes a drug.

[0084] According to some embodiments of the present invention, the agent is selected from the group consisting of antibacterial agents and antiviral agents.

[0085] According to some embodiments of the present invention, the object includes cosmetics.

[0086] According to some embodiments of the present invention, the object includes a heating element.

[0087] According to some embodiments of the present invention, the object includes a cooling element.

[0088] According to some embodiments of the present invention, the object includes a circuit.

[0089] According to some embodiments of the present invention, the object includes a cavity for receiving foreign matter.

[0090] According to some embodiments of the present invention, the object includes a female or male part of a snap connector.

[0091] According to some embodiments of the present invention, this method involves folding the fabric over a lamp structure, mounting or positioning the lamp structure on a work tray, such that the horizontal portion of the fabric is supported on the upper surface of the lamp structure, and the suspended portion of the fabric is folded into the space below the upper surface and above the work tray, with dispensing only on the upper surface.

[0092] According to some embodiments of the present invention, this method includes adjusting the vertical position of the work tray to compensate for the height above the work tray on the top surface of the ramp structure.

[0093] According to one aspect of several embodiments of the present invention, a three-dimensional printing system is provided. The system comprises a nozzle array for ejecting a construction material, a work tray operationally coupled with a radiation source configured to emit radiation upward to solidify the ejected construction material from below, and a computerized controller configured to operate at least the nozzle array to eject the construction material in a construction pattern corresponding to the shape of an object, and to operate the radiation source after ejection.

[0094] According to some embodiments of the present invention, a computerized controller is configured to spatially select and operate a radiation source.

[0095] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those generally understood by those skilled in the art to which the present invention pertains. Similar or equivalent methods and materials to those described herein may be used in carrying out or trying out embodiments of the present invention, but exemplary methods and / or materials are described below. In case of any conflict, the specification of the present invention, including definitions, shall prevail. Furthermore, the materials, methods and examples are illustrative and not necessarily intended to be restrictive.

[0096] Implementation of the methods and / or apparatus of embodiments of the invention may include performing or completing selected tasks manually, automatically, or in combination thereof. Furthermore, according to actual instrumentation and equipment of embodiments of the methods and / or apparatus of the invention, some selected tasks can be performed by hardware, or by software or firmware and / or a combination thereof using an operating system.

[0097] For example, hardware for performing a selected task according to embodiments of the present invention can be implemented as a chip or circuit. With respect to software, a selected task according to embodiments of the present invention can be implemented as a set of software instructions executed by a computer using any suitable operating system. In exemplary embodiments of the present invention, one or more tasks according to exemplary embodiments of the method and / or apparatus described herein are performed by a data processor, such as a computing platform that executes a set of instructions. Optionally, the data processor includes volatile memory for storing instructions and / or data, and / or non-volatile storage devices for storing instructions and / or data, such as magnetic hard disks and / or removable media. Optionally, network connectivity is also provided. A display and / or user input devices such as a keyboard and mouse are also optionally provided.

[0098] Several embodiments of the present invention are described herein only as illustrative, with reference to the accompanying drawings. Herein, with detailed and specific reference to the drawings, it is emphasized that the details shown are illustrative and intended to illustrate embodiments of the present invention. In this regard, the description made in conjunction with the drawings will make it clear to those skilled in the art how embodiments of the present invention may be carried out. [Brief explanation of the drawing]

[0099] [Figure 1A] This is a schematic diagram of an additive manufacturing system according to several embodiments of the present invention. [Figure 1B]This is a schematic diagram of an additive manufacturing system according to several embodiments of the present invention. [Figure 1C] This is a schematic diagram of an additive manufacturing system according to several embodiments of the present invention. [Figure 1D] This is a schematic diagram of an additive manufacturing system according to several embodiments of the present invention. [Figure 1E] This is a schematic diagram of a work tray for an additive manufacturing system in an embodiment of the present invention, the work tray including or associated with a radiation source. [Figure 1F] This is a schematic diagram of a work tray for an additive manufacturing system in an embodiment of the present invention, the work tray including or associated with a radiation source. [Figure 1G] This is a schematic diagram of a work tray for an additive manufacturing system in an embodiment of the present invention, the work tray including or associated with a radiation source. [Figure 2A] This is a schematic diagram of a print head according to several embodiments of the present invention. [Figure 2B] This is a schematic diagram of a print head according to several embodiments of the present invention. [Figure 2C] This is a schematic diagram of a print head according to several embodiments of the present invention. [Figure 3A] This is a schematic diagram illustrating coordinate transformations according to several embodiments of the present invention. [Figure 3B] This is a schematic diagram illustrating coordinate transformations according to several embodiments of the present invention. [Figure 4A] This is a schematic diagram of a jig suitable for several embodiments of the present invention. [Figure 4B] This is a schematic diagram of a jig suitable for several embodiments of the present invention. [Figure 4C] This is a schematic diagram of a jig suitable for several embodiments of the present invention. [Figure 4D] This is a schematic diagram of a jig suitable for several embodiments of the present invention. [Figure 4E] This is a schematic diagram of a jig suitable for several embodiments of the present invention. [Figure 4F]This is a schematic diagram of a jig suitable for several embodiments of the present invention. [Figure 5A] This is a schematic diagram of a robotic mechanism connected to a printing chamber or system housing for three-dimensional printing, according to some embodiments of the present invention. [Figure 5B] This is a schematic diagram of a robotic mechanism connected to a printing chamber or system housing for three-dimensional printing, according to some embodiments of the present invention. [Figure 5C] This is a schematic diagram of a jig storage cabinet accessed by a robotic mechanism according to some embodiments of the present invention. [Figure 6A] This is a schematic diagram of a sequence of operations suitable for a double-sided printing method for fixing an object to a fabric, according to some embodiments of the present invention. [Figure 6B] This is a schematic diagram of a sequence of operations suitable for a double-sided printing method for fixing an object to a fabric, according to some embodiments of the present invention. [Figure 6C] This is a schematic diagram of a sequence of operations suitable for a double-sided printing method for fixing an object to a fabric, according to some embodiments of the present invention. [Figure 6D] This is a schematic diagram of a sequence of operations suitable for a double-sided printing method for fixing an object to a fabric, according to some embodiments of the present invention. [Figure 6E] This is a schematic diagram of a sequence of operations suitable for a double-sided printing method for fixing an object to a fabric, according to some embodiments of the present invention. [Figure 7] This is a schematic diagram of an object, according to some embodiments of the present invention, that is printed upside down by double-sided printing and fixed to a fabric. [Figure 8A] This is a schematic diagram of a printed object fixed to a fabric without performing double-sided printing, according to some embodiments of the present invention. [Figure 8B] This is a schematic diagram of a printed object fixed to a fabric without performing double-sided printing, according to some embodiments of the present invention. [Figure 9] This is a schematic diagram of a system suitable for unfolding a roll of fabric and printing on the unfolded fabric, according to several embodiments of the present invention. [Figure 10]This is a flowchart of a method suitable for printing three-dimensional objects onto fabric, according to several embodiments of the present invention. [Figure 11A] This is a schematic diagram of a method suitable for producing garments from two or more fabric elements, according to some embodiments of the present invention. [Figure 11B] This is a schematic diagram of a method suitable for producing garments from two or more fabric elements, according to some embodiments of the present invention. [Figure 11C] This is a schematic diagram of a method suitable for producing garments from two or more fabric elements, according to some embodiments of the present invention. [Figure 12A] This is a schematic diagram of a method suitable for producing folded clothing, according to some embodiments of the present invention. [Figure 12B] This is a schematic diagram of a method suitable for producing folded clothing, according to some embodiments of the present invention. [Figure 13] This is a flowchart of a method suitable for printing a three-dimensional object onto fabric, in an embodiment of the present invention in which the system determines the printing protocol. [Figure 14] This is a schematic diagram of a library of characteristics and printing parameters according to some embodiments of the present invention. [Figure 15A] This is a schematic diagram of a configuration in which fabric is arranged on a lamp structure according to several embodiments of the present invention. [Figure 15B] This is a schematic diagram of a configuration in which fabric is arranged on a lamp structure according to several embodiments of the present invention. [Figure 15C] This is a schematic diagram of a configuration in which fabric is arranged on a lamp structure according to several embodiments of the present invention. [Modes for carrying out the invention]

[0100] In some embodiments, the present invention relates to three-dimensional printing, and more specifically, to a method and system for printing an object onto a fabric, though not limited thereto.

[0101] Before describing in detail at least one embodiment of the present invention, it should be understood that the application of the present invention is not necessarily limited to the details of the structure, arrangement and / or method of its components presented in the following description and / or shown in the drawings and / or examples. Other embodiments of the present invention are possible and can be carried out or implemented in various ways.

[0102] The method and system of this embodiment manufacture a three-dimensional object layer by layer by forming multiple layers with a configuration pattern corresponding to the shape of the object based on computer object data. The computer object data may be any known format, including, but is not limited to, Standard Tessellation Language (STL) or Stereolithography Contour (SLC) format, OBJ file format (OBJ), 3D Manufacturing Format (3MF), Virtual Reality Modeling Language (VRML), Additive Manufacturing File (AMF) format, Drawing Exchange Format (DXF), Polygon File Format (PLY), or any other format suitable for computer-aided design (CAD).

[0103] As used herein, the term “object” refers to the whole or a part of an object.

[0104] Each layer is formed by an additive manufacturing apparatus that scans and patterns a two-dimensional surface. During scanning, the apparatus moves to multiple target locations on the two-dimensional layer, i.e., the surface, and for each target location or group of target locations, it determines whether or not each target location or group of target locations should be covered with building material, and what type of building material should be delivered to them. The decision is made according to a computer image of the surface.

[0105] In preferred embodiments of the present invention, AM comprises three-dimensional printing, more preferably three-dimensional inkjet printing. In these embodiments, a build material is ejected from a printhead having one or more nozzle arrays, depositing the build material in layers on a receiving surface. The AM apparatus thus ejects the build material to target positions to be covered with it, leaving other target positions empty. The apparatus typically includes multiple nozzle arrays, each of which can be configured to eject a different build material. This is usually achieved by providing a printhead having multiple fluid channels that are separated from each other and not fluidly communicating with one another. Each channel receives a different build material through a separated inlet, which is then delivered to a separate nozzle array.

[0106] Therefore, it is possible to occupy different target locations with different construction materials. Construction materials are broadly classified into two types: shaping materials and support materials. Typically, construction materials are solvent-free (e.g., do not contain water or any organic solvents) and / or extruded at temperatures above 40°C, 50°C, or 60°C. Support materials function as a support matrix or structure to support an object or part of an object during the manufacturing process and / or for other purposes, such as providing a hollow or porous object. Support structures may also include additional shaping material elements, for example, to increase support strength.

[0107] Modeling materials are generally compounds formulated for use in additive manufacturing, capable of forming three-dimensional objects on their own, that is, without the need for mixing or combining them with any other substances.

[0108] The final three-dimensional object is made from a molding material, a combination of multiple molding materials, a molding material and a support material, or a deformed version thereof (e.g., after curing). All of these operations are well known to those skilled in the field of solid free forming.

[0109] In some exemplary embodiments of the present invention, an object is manufactured by extruding two or more different molding materials, each material being extruded from a different nozzle array (of the same or different print heads) of the AM device. In some embodiments, two or more such nozzle arrays extruding different molding materials are all located on the same print head of the AM device. In some embodiments, the nozzle arrays extruding different molding materials are located on separate print heads. For example, a first nozzle array extruding a first molding material is located on a first print head, and a second nozzle array extruding a second molding material is located on a second print head.

[0110] In some embodiments, both the nozzle array for ejecting the build material and the nozzle array for ejecting the support material are located on the same print head. In some embodiments, the nozzle array for ejecting the build material and the nozzle array for ejecting the support material are located on separate print heads.

[0111] Figure 1A shows a representative and non-limiting example of a system 110 suitable for AM of an object 112, according to several embodiments of the present invention. The system 110 comprises an additive manufacturing apparatus 114 having an ejection unit 16 with a plurality of print heads. Each head preferably comprises one or more nozzle arrays 122, typically mounted on an orifice plate 121 as shown in Figures 2A to 2C below, through which a liquid building material 124 is ejected.

[0112] Preferably, but not required, the apparatus 114 is a three-dimensional printing apparatus, in which case the print head is a print head and the building material is ejected via inkjet technology. This is not necessarily required, because in some applications, additive manufacturing apparatuses do not need to use three-dimensional printing technology. Typical examples of additive manufacturing apparatuses intended by various exemplary embodiments of the present invention include, but are not limited to, fused deposition modeling apparatuses and fused material deposition apparatuses.

[0113] Each print head is optionally and preferably supplied via one or more build material tanks, which may optionally include a temperature control unit (e.g., a temperature sensor and / or heating device) and a material level sensor. To eject the build material, a voltage signal is applied to the print head, as in piezoelectric inkjet printing technology, for example, to selectively deposit droplets of the material through the print head nozzles. Another example is a thermal inkjet print head. In this type of head, there is a heater element that is in thermal contact with the build material, and by activating the heater element with a voltage signal, the build material is heated and gas bubbles are formed therein. The gas bubbles generate pressure within the build material, causing droplets of the build material to be ejected through the nozzles. Piezoelectric and thermal print heads are known to those skilled in the art of solid free-form molding. With respect to any type of inkjet print head, the ejection speed of the head depends on the number of nozzles, the type of nozzles, and the applied voltage signal rate (frequency).

[0114] Preferably, but not required, the total number of ejection nozzles or nozzle arrays is selected such that half of the ejection nozzles are for ejecting the support material and the other half are for ejecting the build material. That is, the number of nozzles ejecting the build material is the same as the number of nozzles ejecting the support material. In a typical example, Figure 1A shows four print heads 16a, 16b, 16c, and 16d. Each head 16a, 16b, 16c, and 16d has a nozzle array. In this example, heads 16a and 16b may be for build material, and heads 16c and 16d may be for support material. Thus, head 16a can eject one build material, head 16b can eject another build material, and both heads 16c and 16d can eject support material. In an alternative embodiment, for example, heads 16c and 16d can be combined to form a single head with two nozzle arrays for depositing support material. In a further alternative embodiment, any one or more print heads may have two or more nozzle arrays for depositing two or more materials. For example, two nozzle arrays for two different build materials, or two nozzle arrays for one build material and one support material, where each formulation is deposited through a different array or a different number of nozzles.

[0115] However, it should be understood that this is not intended to limit the scope of the present invention, and that the number of print heads (build heads) for the build material and the number of print heads (support heads) for the support material may differ. Generally, the number of nozzle arrays for ejecting the build material, the number of nozzle arrays for ejecting the support material, and the number of nozzles in each array are selected to give a predetermined ratio a between the maximum ejection speed of the support material and the maximum ejection speed of the build material. The value of the predetermined ratio a is preferably selected such that the height of the build material and the height of the support material are equal in each layer formed. Typical values ​​of a are from about 0.6 to about 1.5.

[0116] As used throughout this specification, the term “approximately” refers to ±10%.

[0117] For example, when a=1, if all nozzle arrays are operating, the total extrusion rate of the support material is approximately equal to the total extrusion rate of the build material.

[0118] The apparatus 114 may comprise, for example, M build heads, each having m nozzle arrays of p nozzles, and S support heads, each having s nozzle arrays of q nozzles, where M × m × p = S × s × q. Each of the M × m build arrays and S × s support arrays can be fabricated as a separate physical unit and can be assembled and disassembled from a group of arrays. In this embodiment, each such array optionally and preferably comprises its own temperature control unit and material level sensor, which receive individually controlled voltages for their operation.

[0119] The apparatus 114 further comprises a solidification apparatus 18. This may include any apparatus configured to emit light, heat, or the like, which can solidify the deposited material. For example, the solidification apparatus 18 may include one or more radiation sources. Depending on the material being molded, these may be, for example, ultraviolet, visible light, or infrared lamps, or other electromagnetic radiation sources, or electron beam sources. In some embodiments of the present invention, the solidification apparatus 18 performs the function of curing or solidifying the material being molded.

[0120] In addition to the coagulation apparatus 18, apparatus 114 optionally and preferably includes an additional radiation source 328 for evaporating the solvent. The radiation source 328 optionally and preferably generates infrared radiation. In some embodiments of the present invention, the coagulation apparatus 18 includes a radiation source that generates ultraviolet radiation, and the radiation source 328 generates infrared radiation.

[0121] In some embodiments of the present invention, the apparatus 114 includes one or more cooling devices 134, such as fans.

[0122] The print head(s) and radiation source are preferably mounted on a frame or block 128 and reciprocate on a tray 360 which preferably acts as a work surface. In some embodiments of the present invention, the radiation source is mounted on a block and follows the trajectory of the ejection head to at least partially harden or solidify the material just ejected by the print head. The tray 360 is positioned horizontally. Following common practice, an XYZ Cartesian coordinate system is selected such that the XY plane is parallel to the tray 360. The tray 360 is preferably configured to move vertically (along the Z direction), usually downward. In various exemplary embodiments of the present invention, the apparatus 114 further includes one or more leveling devices 32, e.g., rollers 326. The leveling device 326 acts to straighten, flatten, and / or determine the thickness of a newly formed layer before the next layer is formed on it. The leveling device 326 preferably includes a waste collection device 136 for collecting excess material generated during flattening. The waste collection device 136 may include any mechanism for delivering the material to a waste tank or waste cartridge.

[0123] In the schematic diagram of Figure 1A, the edges of the tray 360 are straight corners. However, this is not always necessary, and in some applications, especially when the tray 360 is in contact with the fabric on which the object is printed, it may be desirable for the corners of the top surface of the tray 360 to be formed as fillet corners and / or chamfers (see chamfers 411 in Figures 4E and 4F).

[0124] During use, the print heads of unit 16 move in a scanning direction, which is referred to herein as the X direction, and selectively eject the build material in a predetermined configuration as they pass over the tray 360. The build material typically includes one or more support materials and one or more build materials. Following the passage of the print heads of unit 16, the build material is cured by the radiation source 126. Additional build material may be ejected according to a predetermined configuration during the reverse movement of the heads back to the starting point of the layer that has been deposited. The layers thus formed can be corrected by the leveling device 326 during the forward or reverse movement of the print heads. This is preferably along the path of the print heads during the forward and / or reverse movement. When the print heads return to their starting points along the X direction, the print heads can move to another position along the indexing direction, which is referred to herein as the Y direction, and continue building the same layer by reciprocating motion along the X direction. Alternatively, the print heads may move in the Y direction between forward and reverse movements, or after two or more forward-reverse movements. A series of scans performed by the print head to complete a single layer is referred to herein as a single scan cycle.

[0125] Once that layer is complete, the tray 360 is lowered in the Z direction to a predetermined Z level, depending on the desired thickness of the next layer to be printed. This procedure is repeated until the three-dimensional object 112 is formed layer by layer.

[0126] In another embodiment, the tray 360 may be displaced in the Z direction within the layer during the forward and reverse passage of the print head of unit 16. Such Z displacement is performed to bring the leveling device and the surface into contact in one direction and not in the opposite direction.

[0127] System 110 optionally includes a supply system 330 which includes a container or cartridge of construction material and supplies a plurality of construction materials to the manufacturing apparatus 114.

[0128] The controller 20 controls the manufacturing apparatus 114 and, optionally and preferably, the supply system 330. The controller 20 typically includes electronic circuitry configured to perform control operations. The controller 20 preferably communicates with a data processor 154, which transmits digital data relating to manufacturing instructions based on computer object data, such as CAD configurations represented on a computer-readable medium in a format such as Standard Tessellation Language (STL) format. Typically, the controller 20 controls the voltage applied to each print head or each nozzle array, and the temperature of the construction material in each print head or each nozzle array.

[0129] Once the manufacturing data is loaded into the controller 20, the controller can operate without user intervention. In some embodiments, the controller 20 receives additional input from the operator, for example, using a data processor 154 or a user interface 116 that communicates with the controller 20. The user interface 116 may be any type known in the art, such as a keyboard or touchscreen, but is not limited to these. For example, the controller 20 may receive as additional input one or more types of construction materials and / or attributes such as, for example, color, characteristic strain and / or transition temperature, viscosity, electrical properties, magnetic properties, etc. Other attributes and attribute groups are also conceivable.

[0130] Another representative and non-limiting example of system 10 suitable for AM of objects according to some embodiments of the present invention is shown in Figures 1B to 1D. Figures 1B to 1D show a plan view (Figure 1B), a side view (Figure 1C), and an isometric view (Figure 1D) of system 10.

[0131] In this embodiment, the system 10 comprises a tray 12 and a plurality of inkjet print heads 16, each having one or more nozzle arrays, each having one or more isolated nozzles. The material used for three-dimensional printing is supplied to the heads 16 by a construction material supply system 42. The tray 12 may be disc-shaped or annular. Non-circular shapes are also possible, as long as they are rotatable about a vertical axis. In the schematic diagram of Figure 1C, the edges of the tray 12 are straight corners. However, in some applications, such as the tray 360 described above, especially when the tray 12 is in contact with the fabric on which the object is printed, it may be desirable for the corners of the top surface of the tray 12 to be formed as fillet and / or chamfered.

[0132] The tray 12 and the head 16 are optionally, and preferably, mounted to allow relative rotational motion between the tray 12 and the head 16. This can be achieved by (i) a configuration in which the tray 12 rotates relative to the head 16 about a vertical axis 14, (ii) a configuration in which the head 16 rotates relative to the tray 12 about a vertical axis 14, or (iii) a configuration in which both the tray 12 and the head 16 rotate about a vertical axis 14, but at different rotational speeds (e.g., in opposite directions). In the following, several embodiments of the system 10 will be described with particular emphasis on configuration (i), which is a rotating tray configured to rotate relative to the head 16 about a vertical axis 14, but it should be understood that this application also intends configurations (ii) and (iii) with respect to the system 10. Any embodiment of the system 10 described herein can be adapted to be applicable to either configuration (ii) or configuration (iii), and the manner of such adaptation will be apparent to those skilled in the art given the details described herein.

[0133] In the following explanation, the direction parallel to tray 12 and outward from axis 14 will be called the radial direction r, the direction parallel to tray 12 and perpendicular to radial direction r will be called the azimuth direction φ, and the direction perpendicular to tray 12 will be called the vertical direction z.

[0134] The radial direction r of system 10 defines the indexing direction y of system 110, and the azimuth direction φ defines the scanning direction x of system 110. Therefore, the radial direction is interchangeably referred to as the indexing direction in this specification, and the azimuth direction is interchangeably referred to as the scanning direction in this specification.

[0135] As used herein, the term "radial position" refers to a position on or above the tray 12 at a specific distance from the axis 14. When used in relation to a print head, the term refers to a position of the head at a specific distance from the axis 14. When used in relation to a point on the tray 12, the term corresponds to any point that belongs to the locus of a circle whose radius is at a specific distance from the axis 14 and whose center is on the axis 14.

[0136] As used herein, the term "azimuth position" refers to a position on or above the tray 12 that is at a specific azimuth angle with respect to a predetermined reference point. Therefore, the radial position refers to any point that belongs to the locus of points that form a straight line making a specific azimuth angle with respect to the reference point.

[0137] As used herein, the term "vertical position" refers to a position on a plane that intersects the vertical axis 14 at a specific point.

[0138] Tray 12 functions as a build platform for three-dimensional printing. The work area on which one or more objects are printed is usually smaller than the total area of ​​tray 12, but not necessarily. In some embodiments of the present invention, the work area is annular. The work area is indicated by reference numeral 26. In some embodiments of the present invention, tray 12 rotates continuously in the same direction during the formation of an object, and in some embodiments of the present invention, the tray reverses its direction of rotation at least once (e.g., to vibrate) during the formation of an object. Tray 12 is optionally and preferably removable. Removal of tray 12 can be done for maintenance of system 10 or, if desired, to replace the tray before printing a new object. In some embodiments of the present invention, system 10 is provided with one or more different replacement trays (e.g., a kit of replacement trays), and two or more trays are designated for different types of objects (e.g., different weights), different operating modes (e.g., different rotation speeds), etc. Replacement of tray 12 can be manual or automatic, as desired. When automatic replacement is used, the system 10 includes a tray changer 36 configured to remove the tray 12 from its position below the head 16 and replace it with a replacement tray (not shown). In the representative figure of Figure 1B, the tray changer 36 is shown as a drive unit 38 having a movable arm 40 configured to pull the tray 12, but other types of tray changers are also possible.

[0139] Exemplary embodiments of the print head 16 are shown in Figures 2A to 2C. These embodiments are not limited to those described above and can be used in any AM system including system 110 and system 10.

[0140] Figures 2A and 2B show a print head 16 having one (Figure 2A) and two (Figure 2B) nozzle arrays 22. The nozzles in the arrays are preferably arranged linearly along a straight line. In embodiments in which a particular print head has two or more linear nozzle arrays, the nozzle arrays may optionally and preferably be parallel to each other. When a print head has two or more nozzle arrays (for example, Figure 2B), all arrays in the head may be supplied with the same building material, or at least two arrays in the same head may be supplied with different building materials.

[0141] When a system similar to system 110 is used, all print heads 16 are optionally and preferably oriented along the indexing direction, and their positions along the scanning direction are offset from one another.

[0142] When a system similar to system 10 is used, all print heads 16 are optionally and preferably oriented radially (parallel to the radial direction), and their azimuth positions are offset from one another. Thus, in these embodiments, the nozzle arrays of different print heads are not parallel to each other, but rather form an angle with each other. This angle is approximately equal to the azimuth offset between the respective heads. For example, one head may be radially oriented and positioned at azimuth position φ1, and another head may be radially oriented and positioned at azimuth position φ2. In this example, the azimuth offset between the two heads is φ1-φ2, and the angle between the linear nozzle arrays of the two heads is also φ1-φ2.

[0143] In some embodiments, it is possible to combine two or more print heads into a single print head block. In this case, the print heads in the block are usually parallel to each other. A block containing multiple inkjet print heads 16a, 16b, 16c is shown in Figure 2C.

[0144] In some embodiments, the system 10 includes a stabilization structure 30 located below the head 16, with the tray 12 between the stabilization structure 30 and the head 16. The stabilization structure 30 can function to prevent or reduce vibrations of the tray 12 that may occur when the inkjet print head 16 is operating. In a configuration in which the print head 16 rotates around an axis 14, the stabilization structure 30 preferably also rotates so that the stabilization structure 30 is always directly below the head 16 (the tray 12 is between the head 16 and the tray 12).

[0145] The tray 12 and / or print head 16 are optionally and preferably configured to move along the vertical z-direction parallel to the vertical axis 14 to change the vertical distance between the tray 12 and the print head 16. In a configuration where the vertical distance is changed by moving the tray 12 along the vertical direction, the stabilization structure 30 also preferably moves vertically with the tray 12. In a configuration where the vertical position of the tray 12 is fixed and the vertical distance along the vertical direction is changed by the head 16, the stabilization structure 30 is also held in a fixed vertical position.

[0146] Vertical movement can be performed by the vertical drive device 28. Once a layer is completed, the vertical distance between the tray 12 and the head 16 can be increased by a predetermined vertical interval depending on the desired thickness of the next layer to be printed (for example, by lowering the tray 12 relative to the head 16). This procedure is repeated to form a three-dimensional object layer by layer.

[0147] The operation of the inkjet print head 16, and optionally, and preferably, the operation of one or more other components of the system 10, such as the movement of the tray 12, are controlled by the controller 20. The controller may have an electronic circuit and a non-volatile storage medium readable by the circuit, which stores program instructions that cause the circuit to perform control operations, as further detailed below, when read by the circuit.

[0148] The controller 20 can also communicate with a host computer 24 that transmits digital data relating to manufacturing instructions based on computer object data. The digital data may be, for example, Standard Tessellation Language (STL) or Stereolithography Contour (SLC) format, Virtual Reality Modeling Language (VRML), Additive Manufacturing File (AMF) format, Drawing Exchange Format (DXF), Polygon File Format (PLY), or any other format suitable for computer-aided design (CAD). The object data format is typically structured according to the Cartesian coordinate system. In such cases, the computer 24 preferably performs a procedure to convert the coordinates of each slice in the computer object data from the Cartesian coordinate system to the polar coordinate system. The computer 24 optionally, and preferably, transmits the manufacturing instructions in the converted coordinate system. Alternatively, the computer 24 may transmit the manufacturing instructions in the original coordinate system provided by the computer object data. In this case, the coordinate transformation is performed by the controller 20's circuitry.

[0149] Coordinate transformation enables three-dimensional printing on a rotating tray. In a non-rotating system with a fixed tray, the print head typically reciprocates along a straight line on the fixed tray. In such a system, assuming a uniform ejection speed of the head, the print resolution is the same at every point on the tray. In system 10, unlike the non-rotating system, not all nozzles at the head point travel the same distance on the tray 12 in the same amount of time. The coordinate transformation is performed, optionally and preferably, so that the excess material is equal at different radial positions. Representative examples of coordinate transformations according to some embodiments of the present invention are shown in Figures 3A and 3B. These represent three slices of an object (each slice corresponding to a manufacturing instruction for a different layer of the object), with Figure 3A showing the slices in Cartesian coordinates and Figure 3B showing the same slices after applying the coordinate transformation procedure to each slice.

[0150] Typically, the controller 20 controls the voltage applied to each component of the system 10 based on manufacturing instructions and instructions from the stored program described below.

[0151] Generally, the controller 20 controls the print head 16 while the tray 12 is rotating to eject droplets of construction material in layers, thereby printing a three-dimensional object on the tray 12.

[0152] System 10 optionally and preferably comprises one or more solidification devices 18. These may include, for example, one or more radiation sources, depending on the material used, but not limited to, ultraviolet, visible light, or infrared lamps, or other electromagnetic radiation sources, or electron sources. The radiation sources may include any type of radiation emitter, but not limited to, light-emitting diodes (LEDs), digital photoprocessing (DLP) systems, resistance heating lamps, etc. The radiation sources 18 play a role in curing or solidifying the material. In various exemplary embodiments of the present invention, the operation of the radiation sources 18 is controlled by a controller 20, which starts and stops the radiation sources 18 and optionally also controls the amount of radiation emitted by the radiation sources 18.

[0153] In some embodiments of the present invention, the system 10 further comprises one or more leveling devices 32, which may be manufactured as rollers or blades. The leveling devices 32 serve to straighten a newly formed layer before forming the next layer on top of it. In some embodiments, the leveling device 32 has the shape of a conical roller, with its axis of symmetry 34 inclined with respect to the surface of the tray 12 and positioned so that its surface is parallel to the surface of the tray. This embodiment is shown in a side view of the system 10 (Figure 1C).

[0154] The conical roller may be in the shape of a cone or a frustocone.

[0155] The opening angle of the conical roller is preferably selected such that the ratio between the radius of the cone at any position along its axis 34 and the distance between that position and the axis 14 is constant. In this embodiment, the roller 32 can efficiently level the layers because, while the roller rotates, any point p on the roller surface has a linear velocity proportional to (e.g., identical to) the linear velocity of the tray at a point directly below point p. In some embodiments, the roller has a frustoconical shape with height h, radius R1 at the position closest to the axis 14, and radius R2 at the position furthest from the axis 14, where the parameters h, R1, and R2 satisfy the relationship R1 / R2=(Rh) / h, and R is the furthest distance of the roller from the axis 14 (e.g., R may be the radius of the tray 12).

[0156] The operation of the leveling device 32 is optionally and preferably controlled by the controller 20. The controller starts and stops the leveling device 32 and optionally controls its position along the vertical (parallel to the axis 14) and / or radial (parallel to the tray 12, in a direction toward or away from the axis 14).

[0157] In some embodiments of the present invention, the print head 16 is configured to reciprocate relative to the tray along a radial direction r. These embodiments are useful when the length of the nozzle array 22 of the head 16 is shorter than the radial width of the work area 26 on the tray 12. The radial movement of the head 16 is optionally and preferably controlled by a controller 20.

[0158] Figures 1E to 1G are schematic diagrams of a work tray 12 / 360 in an embodiment of the present invention. Here, the work tray includes or is associated with a radiation source 19 that emits radiation 17 to irradiate the construction material from below. Depending on the material used, the radiation source 19 can emit any type of radiation 17, including but not limited to electromagnetic radiation (e.g., ultraviolet, visible light, infrared, etc.), electron beam radiation, etc. The radiation 17 emitted by the radiation source 19 serves to solidify the construction material from below. The radiation source 19 can include, but not limited to, any device capable of emitting radiation 17, such as one or more LEDs, a digital light projector (DLP), a laser device, an electron source, etc. The radiation source 19 is controllable by a controller 20, which can also control the amount and / or cross-sectional area of ​​the radiation 17 by starting, stopping, and optionally selecting its operation.

[0159] In the schematic diagram of Figure 1E, the radiation source 19 is located beneath the work tray, in which case the work tray 12 / 360 is preferably transparent to the radiation 17 emitted from the source 19. In the schematic diagram of Figure 1F, the radiation source 19 is embedded within the tray 12 / 360, in which case the portion of the work tray above the source 19 is transparent to the radiation 17. In the schematic diagram of Figure 1G, the radiation source 19 is mounted on the side of the tray 12 / 360, in which case the radiation 17 is coupled to the tray 12 / 360 and guided through the tray 12 / 360 and exits upward. The radiation 17 is guided by the material of the work tray 12 / 360 (e.g., by internal total internal reflection) and exits upward by a reorientation element 21 (e.g., a mirror or diffraction grating). The radiation 17 may also be guided by one or more waveguides (not shown) embedded in the work tray 12 / 360.

[0160] In some embodiments, the radiation source 19 is activated by the controller 20 only when the bottom layer(s) of the building material is extruded (e.g., the first 1, 2, 3, 4, or 5 layers), and then deactivated. Alternatively, the building material extruded to form the bottom layer may be transparent to radiation 17, allowing the radiation 17 to penetrate the bottom layer and solidify the layers above it. In some embodiments, it is assumed that a material that absorbs radiation 17 is selected as the building material for the bottom layer, thereby shielding the layers above it from radiation 17.

[0161] In some embodiments, the radiation source 19 is activated spatially, causing certain areas on the tray to emit radiation while other areas do not. For example, the radiation source 19 is activated spatially, irradiating only the area on the work tray where the construction material is being dispensed. Spatially selected irradiation can be achieved, for example, by providing the radiation source 19 as an LED array and selectively activating individual LEDs.

[0162] In some embodiments, it is envisioned that an object is manufactured by ejecting different materials from different nozzle arrays (belonging to the same or different print heads). These embodiments, in particular, provide the function of selecting materials from a predetermined number of materials and defining a desired combination of the selected materials and their properties. According to these embodiments, the spatial locations in which each material is deposited in layers are defined by either having different materials occupy different three-dimensional spatial locations, or by placing two or more different materials in substantially the same three-dimensional location or adjacent three-dimensional locations, and then spatially mixing the materials within the layer after deposition to form a composite material at each of the single or multiple locations.

[0163] Any combination or mixture of materials after deposition is possible. For example, after a particular material is extruded, it may retain its original properties. However, if it is extruded simultaneously with another material or other extruded material at the same or nearby location, a composite material may be formed that has one or more properties different from those of the extruded materials.

[0164] In some embodiments of the present invention, the system extrudes a digital material into at least one of multiple layers.

[0165] As used herein and in the art, the term “digital material” refers to a combination of two or more materials at the pixel or voxel level such that pixels or voxels of different materials intersect with each other in a given area. Such digital materials can exhibit novel properties influenced by the choice of material types and / or the ratio and relative spatial distribution of the two or more materials.

[0166] As used herein, a “voxel” of a layer refers to the physical three-dimensional element volume within the layer, corresponding to a single pixel in the bitmap describing the layer. The dimensions of a voxel are approximately equal to the dimensions of the area formed by the construction material after it has been extruded, flattened, and solidified at the locations corresponding to individual pixels.

[0167] Thus, this embodiment enables the deposition of a wide range of material combinations and allows for the creation of objects in which different parts can be composed of combinations of multiple different materials, depending on the characteristics required to characterize each part of the object.

[0168] Further details of the principles and operation of the AM system suitable for this embodiment are described in U.S. Published Patent Application No. 20100191360, the contents of which are incorporated herein by reference.

[0169] In some embodiments of the present invention, system 10 and / or system 110 are configured to print one or more objects onto a fabric.

[0170] As used herein, “textile” encompasses any manufactured product made, at least in part, from natural or artificial fiber materials. Examples of types of textiles include, but are not limited to, clothing, shoes, toys, textile products, carpets, cloth hats, cloth bags, socks, towels, and curtains.

[0171] This embodiment assumes printing on woven or nonwoven fabrics.

[0172] As used herein, the term “woven fabric” means, in accordance with ASTMD123-03, a structure made of at least two sets of twisted yarns intersecting each other, for example at right angles, according to a predetermined interlacing pattern, with at least one set parallel to an axis along the length of the fabric.

[0173] As used herein, the term “nonwoven fabric” means, in accordance with ASTM D123-03, a woven fabric structure produced by binding or entangling fibers by mechanical, chemical, thermal or solvent means or a combination thereof.

[0174] Preferably, though not necessarily, the leveling device 32 is not used when the printing system (e.g., system 10 or system 110) is used to print an object onto a fabric. In these embodiments, each layer of the building material extruded onto the fabric is solidified (e.g., cured) after extrusion without planarization of the layers.

[0175] Preferably, though not necessarily so, when the printing system (e.g., system 10 or system 110) is used to print an object onto a fabric, the height of the printed object is less than 10 cm, more preferably less than 9 cm, more preferably less than 8 cm, more preferably less than 8 cm, more preferably less than 7 cm, more preferably less than 6 cm, more preferably less than 5 cm, more preferably less than 4 cm, more preferably less than 3 cm, more preferably less than 2 cm, and more preferably less than 1 cm.

[0176] In some embodiments of the present invention, the work tray of the system (e.g., tray 12 or tray 360) has a reflectivity of at least 50%, at least 60%, at least 70%, at least 80%, or more to radiation emitted by the radiation source of the solidification device 18. The advantage of making the work tray reflective or partially reflective is that reflected radiation reaching the fabric from below can solidify the construction material beneath the fabric and can penetrate the pores of the fabric to solidify droplets of construction material within these pores, thereby improving the adhesion of printed objects to the fabric.

[0177] This embodiment also envisions the provision of one or more fluid channels 52 in the work tray. A fluid delivery system 54 can generate a fluid flow within the fluid channels 52. The fluid can be optionally and preferably at a controlled temperature, thereby controlling the temperature of the work tray. When the fluid delivery system 54 generates a fluid flow that is lower in temperature than the temperature of the extruded construction material, the fluid absorbs heat from the construction material. The fluid delivery system 54 can also generate a fluid flow that is higher in temperature than the fabric, facilitating the smoothing of wrinkles in the fabric before the construction material is extruded onto the fabric. The inventors also envision combinations of these embodiments, where the fluid is hot before the construction material is extruded and at a reduced temperature during the construction of the object. The fluid may be in gaseous or liquid phase (e.g., air, helium, water, oil, etc.). Preferably, the fluid delivery system 54 is controlled by a controller 20.

[0178] In some embodiments of the present invention, system 10 and / or system 110 includes a jig 402 configured to attach the fabric 420 to a predetermined position on the system's work tray (e.g., tray 12 or tray 360) and in a predetermined direction relative to the system's nozzle array (e.g., array 122). In some embodiments of the present invention, the jig 402 is also configured to stretch the fabric 420.

[0179] Fixture 402 is shown in detail in Figures 4A to 4F. Figures 4A and 4B show an embodiment of fixture 402 comprising a frame 403 and one or more magnetic or metallic elements 405. The elements 405 are preferably permanently mounted on a tray 360 / 12 or adjacent to it, for example, on a stationary platform 361 surrounding the tray 360 / 12. At least one tray 360 / 12 and element 405 include a permanent magnet to ensure mutual magnetic attraction between element 405 and frame 403. The frame 403 may be made entirely of magnetic material or metal, or it may include metallic or magnetic elements (not shown in Figures 4E and 4F) at lateral positions corresponding to the positions of the elements 405 on its periphery. Figure 4A shows the open fixture 402 before the fabric 420 is placed on the work tray 360 / 12, and Figure 4B shows the closed fixture 402 with a frame 403 magnetically attached to an element 405 (not shown in Figure 4B) to attach the fabric 420 to the work tray 360 / 12 and stretch it, optionally and preferably. The fixture 402 may consist of a pair of frames 403 that are magnetically attached to each other. In this case, the fabric 420 is stretched between the frames of the fixture before being placed on the work tray 360 / 12. In these embodiments, the element 405 is not required.

[0180] Figures 4E and 4F show side views of the jig 402. In the embodiment shown in the figures, the frame 403 includes magnetic or metallic elements 407 mounted laterally to coincide with the positions of the peripheral elements 405. Elements 407 and 405 may be flat as shown in Figure 4E, or they may be protruding elements 409 or rough surfaces as shown in Figure 4F. The protruding elements or rough surfaces may be on the frame 403, the platform 361, or metallic or magnetic elements mounted on both the frame 403 and the platform 361. If the entire frame 403 is made of metal or magnetic material and no other metallic or magnetic elements 407 are mounted on it, the protruding elements 409 or rough surfaces may be formed laterally to coincide with the positions of the elements 405 on the frame 403.

[0181] Figures 4C and 4D show an embodiment in which the jig 402 includes a rotatable frame 406 and a flat fabric holder 408. Here, the frame 406 is sized and shaped such that when the frame 406 rotates and engages with the surface of the fabric holder 408, the frame 406 surrounds the fabric holder 408 and captures the fabric 420 between the frame 406 and the fabric holder 408. The fabric holder 408 may be a continuous surface or a frame. If the fabric holder 408 is a continuous surface, once the fabric 420 is placed on the fabric holder 408 and optionally, and preferably, stretched, the fabric 420 is accessible from only one side (typically the top). If the fabric holder 408 is a frame, once the fabric 420 is placed on the fabric holder 408 and optionally, and preferably, stretched on the holder, the fabric 420 is accessible from both sides. Figure 4C shows the open state of the jig 402, which is capable of receiving the fabric 420, and Figure 4D shows the closed state of the jig 402 with the fabric 420 attached to the tray 12 / 360.

[0182] The advantage of having a jig equipped with a flat fabric holder 408 is that the jig 402 can receive the fabric 420 either when the jig 402 is placed on the work tray 12 / 360 (as shown in Figures 4C and 4D) or before the jig 402 is placed on the work tray 12 / 360 (as shown in Figures 5A to 5C, which will be described later).

[0183] Figures 15A to 15C are schematic diagrams of a configuration in which the fabric 420 is placed on a ramp structure 450 which includes a flat ramp 452 and one or more spacer beams 454, and which holds the ramp 452 perpendicularly separated from the work tray 12 / 360. The ramp structure 450 may be placed on the tray 12 / 360, or may be connected to the tray 12 / 360 by connectors (not shown), such as snap connectors. When the ramp structure 450 is connected to the tray, the connectors are preferably located outside the printing area of ​​the AM system so as not to interfere with the printing process when the AM system is operating without the ramp 450. The fabric 420 can be attached using any of the techniques described above, except when the fabric is attached to the ramp structure 450 rather than the tray 12 / 360.

[0184] The advantage of using the lamp structure 450 is that it allows printing of three-dimensional objects on fabric larger than the work tray. When in use, the fabric 420 is attached to the top surface of the lamp 452. If the dimensions of the fabric 420 are larger than the dimensions of the lamp structure, the fabric 420 is folded at the edge of the lamp structure 450, as shown in Figure 15A, so that the horizontal portion 420a of the fabric 420 is supported on the top surface of the lamp 452 and the hanging portion 420b of the fabric 420 is folded under the lamp 452 into the space above the work tray 12 / 360. Preferably, the fabric 420 is attached to the lamp structure 450 before being placed on or connected to the work tray 12 / 360. However, embodiments in which the fabric 420 is attached to the lamp 452 while the lamp structure 450 is on the work tray 12 / 360 are also conceivable.

[0185] Once the fabric 420 is attached to the work tray 12 / 360 (Figures 4A-4F) or the ramp 452 (Figures 15A-15C), the computerized controller 20 (Figures 1A and 1B) operates the nozzle array 122 (Figures 2A-2C) to dispense the construction material onto the attached fabric 420 according to a configuration pattern corresponding to the object shape. In embodiments where a ramp structure 450 is used, the computerized controller 20 controls the nozzle array 122 to terminate all dispensing when the nozzles are over the gap between the ramp structure 450 and the platform 361. This ensures that droplets of the construction land only on the horizontal portion 402a of the fabric 420.

[0186] When the ramp structure 450 is used, the vertical position of the ramp 452 in the Z-axis direction is found to be higher than the position of the work tray 12 / 360. In this case, the computerized controller 20 adjusts the vertical position of the work tray 12 / 360 to compensate for the height of the ramp structure 452 above the work tray 12 / 360. This adjustment process is shown in Figures 15A to 15C. The initial vertical position of the work tray 12 / 360 is preferably selected so that the top surface of the ramp 452 is at the vertical position that the work tray 12 / 360 would take if the ramp structure were not used. For example, as shown in Figure 15C, the initial vertical position of the work tray 12 / 360 can be selected so that the top surface of the ramp 452 is at the same vertical position as the top surface of the platform 361. After the initial vertical position is adjusted, the printing process continues layer by layer as further detailed herein, where, upon completion of each layer, the work tray 12 / 360 is lowered in the Z-direction according to the desired thickness of the subsequent layer.

[0187] In some embodiments of the present invention, the system 10 / 110 includes a robotic mechanism 410 (e.g., a multi-axis robotic arm, a gantry robot, etc.) configured to be connected to a jig 402 and to position the jig 402 on a tray 360 or tray 12. For example, the robotic mechanism 410 may be connected to the jig 402 at its distal end and to the printing chamber or housing of the printing system 10 or printing system 110 at its proximal end. Figures 5A and 5B show the printing chamber or housing 412 of the system 110 (Figure 5A) and system 10 (Figure 5B) connected to the proximal end of the robotic mechanism 410.

[0188] Preferably, a computerized controller 20 also controls the robotic mechanism 410. The controller 20 controls the robotic mechanism 410 to introduce the jig 402 into the printing chamber or housing 412 and position it on the tray 12 or tray 360 before extruding the construction material onto the fabric 420. Optionally, and preferably, the jig can then be removed from the printing chamber or housing 412 after forming the object or part thereof based on a pre-programmed three-dimensional printing protocol. A suitable three-dimensional printing protocol will be described later. The advantage of using a computerized controller to control the robotic mechanism 410 is that the jig 402 can be precisely positioned in a predetermined location on the work tray 12 or work tray 360 and in a predetermined direction relative to the nozzle array 122.

[0189] The robotic mechanism 10 can grip the jig 402 by any gripping technique known in the art, such as gripping jaws, suction, or magnetic attachments, but is not limited to these.

[0190] In some embodiments of the present invention, a robotic mechanism 410 is controlled by a controller 20 to access a jig storage unit, grasp and retrieve one jig from the storage unit, and place the retrieved jig on a work tray. These embodiments are schematically shown in Figure 5C, which shows a storage unit of multiple jigs 402 accessible by the robotic mechanism 410. In the depiction in Figure 5C, the storage unit 430 is in the form of a static shelf, but other types of static or movable storage units (e.g., rotatable wheels, conveyors, etc.) are also conceivable. Preferably, one or more jigs 402, more preferably each of the jigs 402 in the storage unit 430, holds a fabric portion 420 and optionally, and preferably, stretches it. In these embodiments, when the robotic mechanism 410 grasps one of the jigs 402 in the storage unit 430, it retrieves each jig with the fabric portion still held in the jig and places the jig together with the stretched fabric on a work tray (not shown; see Figures 5A and 5B).

[0191] In some embodiments of the present invention, the robotic mechanism 410 is optionally and preferably configured to invert the orientation of the jig 402 with respect to a horizontal plane (e.g., the plane engaged by the tray 12 or tray 360) in response to a signal received from the controller 20. These embodiments are particularly useful when the fabric holder 408 is in the shape of a frame, as this allows for a series of printing operations to print objects on both sides of the fabric 420. For example, the fabric can be stretched on the jig 402 and one object can be printed on one side of the fabric. Then, with the fabric still stretched therein, the jig 402 can be inverted to print one object on the opposite side of the fabric.

[0192] In this embodiment, it is also assumed that printing may be performed on both sides of the fabric without reversing the jig 402. In these embodiments, the nozzle array 122 and optionally the solidification device 18 are also operated by the controller 20 to form an object on a tray or some receiving surface placed on the tray. The robotic mechanism 410 then introduces the jig 402, which holds the fabric and optionally and preferably stretches it, into the printing chamber or printing housing 412 and onto the previously formed object so that one side of the fabric is in contact with the object. The nozzle array 122 and optionally the solidification device 18 are then operated again to form another object on the opposite side of the fabric.

[0193] When double-sided printing is used in any of the above embodiments, objects printed on different sides of the fabric may have different properties and functions. For example, if the fabric is intended to be part of a garment, objects having desired aesthetic properties or giving the garment a desired appearance (e.g., lens-shaped, prism-shaped, or occludable or fluorescent objects, or objects with selective optical reflectivity, or waveguides, etc.) may be printed on the outer surface of the fabric, and objects having desired functions (e.g., pharmaceuticals or cosmetics, or objects having heating or cooling elements, etc.) may be printed on the inner surface of the fabric.

[0194] Double-sided printing is also useful for securely fixing the printed object to the fabric. This will be explained below with reference to Figures 6A to 6E. These figures are schematic diagrams of a suitable operating sequence for double-sided printing according to several embodiments of the present invention. This method optionally and preferably prints a base structure 502 on a receiving surface such as a work tray 12 or work tray 360 using an array 122 (Figure 6A). The base 502 optionally and preferably facilitates the removal of the printed object from the printing tray and can therefore help prevent deformation due to manual or mechanical damage. The base 502 can also improve the accuracy of the object in the Z direction (height) and / or the XY direction. The base 502 forms a sacrificial layer and is therefore composed of a support material. Preferably, the support composition is soluble in a liquid, such as water. In various exemplary embodiments of the present invention, the base 502 consists of a combination of a support material and a molding material.

[0195] This method also prints the fixing elements 504 on the receiving surface (Figure 6B). If a base structure 502 is formed, the fixing elements 504 are preferably printed on the base structure 502. Otherwise, the fixing elements 504 can be printed on other receiving surfaces, such as, but not limited to, the work tray 12 or 360. Unlike the base structure 502, the fixing elements 504 are preferably not a sacrificial layer, and therefore at least partially made of the molding material, optionally and preferably of an insoluble molding material. Preferably, the building material used to form the fixing elements 504 is usually transparent to visible light (e.g., a transmittance of at least 50% to visible light, e.g., about 50% to about 99%, or about 55% to about 95%).

[0196] The lateral dimensions of the fixed element 504 are preferably approximately the same as the lateral dimensions of the object to be printed, however, this embodiment also assumes fixed elements 504 in which at least one lateral dimension (indexing direction and / or scanning direction) is larger or smaller than that of the object. The advantage of printing fixed elements 504 having lateral dimensions that are approximately the same as or smaller than the lateral dimensions of the object to be printed is that such a configuration saves on the amount of material used, making it economical in terms of the total weight of the final product and efficient in terms of printing time.

[0197] Following the printing of the fixing element 504, the fabric 420 is placed on the fixing element 504 as shown in Figure 6C. Figure 6C is a magnified view of a portion of the fabric 420, showing the pores 422 between the fibers forming the fabric and the protruding fuzzy fibers 424. The fabric 420 can be placed on the fixing element 504 while stretched on a jig 402 (not shown in Figures 6A to 6D). The advantage of using the jig 402 is that stretching expands the pores 422, resulting in a stronger bond between the printed object and the fabric. The placement of the fabric 420 on the fixing element 504 can be done by activating a robotic mechanism 410. This method then extrudes construction material onto the fabric 420 to form one or more through-elements 506 that penetrate the pores 422 of the fabric 420 and connect to the fixing element 504 below the fabric 420 (Figure 6C). The through-elements 506 are preferably made of the construction material, at least partially. Preferably, the construction material used to form the fixed element 504 is generally transparent to visible light.

[0198] The penetration of element 506 through pore 422 is optionally and preferably ensured by carefully controlling the time interval Δt between the time the building material forming element 506 is dispensed and the time the solidification device 18 allows it to solidify. Specifically, the time interval Δt is selected to be long enough to ensure that element 506 is in contact with element 504 while the building material forming element 506 is still in a liquid state.

[0199] The length Δt can be controlled in several ways. In some embodiments of the present invention, the solidification device 18 is stopped during a delay time selected such that the time length between the time the elements 506 are ejected and the time they are solidified is Δt. For example, when system 110 is used, the block 128 can be stationary, for example, outside the tray 360, and when system 10 is used, the solidification device 18 can be stopped while the tray 10 continues to rotate.

[0200] Additional control of the time length Δt is achieved by providing solidification devices on both sides of the head 16 and activating the solidification devices based on the direction of relative motion between the head and the tray. Specifically, a large value of Δt can be achieved by activating a solidification device that reaches element 506 before the head (thus the return stroke is completed before element 506 is irradiated), and a small value of Δt can be achieved by activating a solidification device that reaches element 506 after the head (thus the return stroke is incomplete before element 506 is irradiated).

[0201] In some embodiments of the present invention, the relative motion speed between the tray and the solidification device 18 is selected such that the time length between the time the elements 506 are ejected and the time they are solidified is Δt. This can be done throughout the entire print job, but more preferably only during the formation of the elements 506. For example, the method can reduce the relative motion speed immediately before or after the ejection of the building material that forms the elements 506, and increase the speed after the elements 506 have solidified.

[0202] Once element 506 is extruded and solidified, this method extrudes the construction material onto the fabric 420 and the through element 506 in a construction pattern corresponding to the pre-designed shape of the object 112 (Figure 6E).

[0203] It should be understood that the printing order shown in Figures 6A to 6E is changeable, and that the object is provided on one side of the fabric, the fixing element is provided on the opposite side of the fabric, and one or more through-elements are provided that penetrate the pores of the fabric and connect the object to the fixing element. Those skilled in the art will understand from the details described herein how to adjust the described printing order according to their respective needs.

[0204] A typical example of such a modification is shown in Figure 7. In this embodiment, the selected operations shown in Figures 6A to 6E are reversed. The object 112 is printed upside down on a tray, or more preferably on a base structure 502. The fabric 420 is then placed on the printed object 112, preferably stretched on a jig 402. The placement of the fabric 420 on the object 112 can be done by activating a robotic mechanism 410. Through elements 506 are printed on the fabric 420 and connect to the object 112 through pores 422. Subsequently, fixing elements 504 are printed on the fabric 420 and connect to the through elements 506. Figure 7 also shows a support structure 510, which is preferably made at least partially of a support material and serves to support the suspension portion or thin wall of the object 112 during the manufacturing process known in three-dimensional printing technology. Although the support structure 510 is shown only in Figure 7, it should be understood that the use of the support structure 510 during the fabrication of object 112 is also conceivable when object 112 is not printed upside down (for example, in the order of operations in Figures 6A to 6E), and that support structures such as structure 510 can be printed at any stage in the fabrication of object 112.

[0205] The advantage of the embodiment shown in Figure 7 is that it can be used to create the height of most of the object on the tray before placing the fabric. This makes it possible to create relatively tall objects (for example, with a thickness of more than 10 cm, or more than 12 cm, or more than 14 cm, or more than 16 cm, or more than 18 cm, or more than 20 cm).

[0206] This embodiment also envisions the use of through-elements 506 to fix the printed object to the fabric 420 without performing double-sided printing. These embodiments are shown in Figures 8A and 8B. Figure 8A shows an embodiment in which the through-element 506 is deeply embedded in the pore 422 but does not reach the other side of the fabric 420 (e.g., embedded to a depth of about 50-80% of the pore depth), and Figure 8B shows an embodiment in which the through-element 506 is only slightly embedded in the pore 422 (e.g., embedded to a depth of less than 50% of the pore depth, e.g., 10-40%). The inventors have found that such fixation is sufficient, especially in fabrics having high-density, protruding fuzzy fibers 424, because the fuzzy fibers readily adhere to the building material of the object 112, thus further strengthening the bond between the object 112 and the fabric 420.

[0207] Referring to Figures 1A to 1C, systems 10 and 110 optionally and preferably include a position tracking system 50. In some embodiments of the present invention, the position tracking system 50 is configured to determine the position of the fixture 402 relative to the work tray 12 or work tray 360 when the fixture 402 is placed on the tray. The position tracking system 50 may include, for example, an optical scanner, an imaging device, a magnetic sensor and / or a high-frequency sensor. A computerized controller 20 receives a position tracking signal from system 50 and performs a positioning procedure based on this position tracking signal, and acts the nozzle array 122 in accordance with the positioning. An advantage of this embodiment is that the positioning procedure performed by the controller 20 ensures that the nozzles dispense the construction material to the correct position of the fabric 420, thus eliminating the need for precise positioning of the fixture 402 on the tray.

[0208] The position tracking system 50 can determine the position of the fixture 402 in several ways. In some embodiments of the present invention, the system 50 captures an image of the tray or a part thereof (for example, if the system 50 is equipped with a pixelating imager or optical scanner), performs an image processing procedure to determine the position of the fixture 402 relative to the tray. In some embodiments of the present invention, the position tracking system 50 can determine the position of the fixture 402 using a mark 414 that can be formed or attached, for example, on the frame 406 of the fixture 402, or on the fabric holder 408 as shown in Figures 4A, 4C, 4D, or on the work tray, or on the stationary platform 361 as shown in Figure 4A. The mark 414 is identifiable by the position tracking system 50 and is used by the system 50 to determine the position of the fixture 402. For example, if the system 50 is equipped with an optical scanner or imager, the mark 414 may be a printed pattern such as a barcode, or an optical signal source, such as a light-emitting diode that emits radiation that does not harden the construction material ejected by the nozzle array. If the system 50 includes a magnetic sensor or a high-frequency sensor, the mark may include, but is not limited to, a source of high frequency or magnetic field, such as a miniature coil.

[0209] The disclosure also envisions embodiments in which the position tracking system 50 is used to identify the pattern (e.g., printed pattern, woven pattern, knitted pattern) of the fabric 420 itself. In these embodiments, the controller 20 can perform alignment procedures based on the identified pattern of the fabric 420, and it is not necessary to use the tracking system 50 to determine the position of the jig 402 (although such determination is envisioned in some embodiments).

[0210] The process of fabricating a three-dimensional object on the fabric 420 optionally and preferably involves the use of one or more liquid additives other than the construction material for three-dimensional printing. Such liquid additives may include, but are not limited to, primers (e.g., curing liquids, adhesives, pore size adjusting liquids, etc.), finishing liquids (e.g., radiation protection liquids, gloss finish liquids, matte finish liquids, etc.), masking liquids, etc. Other types of additives that may be used in some embodiments of the present invention include temporary protective liquids, water-repellent liquids, waterproof liquids, hydrophobic liquids, etc.

[0211] If the additive is a primer, it is applied before the construction material is dispensed. Therefore, for example, the construction material can be dispensed after applying an adhesive to the fabric to ensure adhesion of the construction material to the fabric by the adhesive. Another example is the application of a pore-adjusting liquid to enlarge the pore size of the fabric. The construction material can then be dispensed to form through-elements (e.g., element 506) within the enlarged pores. A further example is the application of a curing substance to stabilize the fabric before dispensing.

[0212] If the additive is a finishing liquid, it is applied after the construction material has been extruded. For example, a gloss or matte finishing liquid can be applied to the extruded construction material to give it a desired appearance. Similarly, paints such as metallic paints (e.g., chromium, gold) can be applied in the form of a finishing liquid to at least a portion of an object printed with the construction material. Finishing liquids that serve to protect fabrics or printed objects from, for example, discoloration, radiation, abrasion, chemical damage, moisture absorption, etc. are also conceivable. Typical examples of such protective liquids, but not limited to, are UV-resistant materials (such as UV-resistant materials commercially available from Krylon®) and polyurethanes (such as polyurethane solutions made of Rust-Oleum).

[0213] If the additive is a masking fluid, it is preferable to apply it before the construction material is dispensed. The masking fluid serves to prevent a selected area of ​​the fabric from coming into contact with the dispensed construction material. Therefore, it is applied selectively to areas not occupied by the object being printed. The masking fluid is preferably removable, for example, washable. For example, the masking fluid may include the solution disclosed in U.S. Patent No. 5,308,647, the contents of which are incorporated herein by reference. The masking fluid may also be applied after printing rather than before finishing, if possible (if it is applied), to protect other areas of the object or fabric from the finishing fluid (if it is applied).

[0214] Furthermore, it is conceivable that the support material layer could be used as a protective coating in areas not occupied by the object to be printed on.

[0215] Any of the additives described above may optionally and preferably consist of inactive formulations that can be activated in situ, that is, while spread on the fabric. In these embodiments, the formulation is applied to the fabric and then activated. Activation can induce, for example, polymerization of monomers and / or oligomers, crosslinking of polymer chains, or modification of the optical properties of the formulation. This embodiment envisions many types of inactive formulations that can be activated in situ. In some embodiments of the present invention, activation is by radiation, such as ultraviolet or infrared optical radiation. In some embodiments, activation is by heat.

[0216] Furthermore, formulations that are activated by chemical reactions are also conceivable. Such reactions may occur between the formulation and one or more building materials, and / or between two or more coated formulations. For example, in some embodiments of the present invention, one or more building materials are extruded onto a fabric and at least partially penetrated into the pores of the fabric while it is in the liquid phase. Subsequently, a formulation that reacts with the building materials is applied. The chemical reaction between the building materials and the applied formulations alters at least one property of the building materials (e.g., mechanical properties and / or optical properties). In some embodiments, the formulations induce polymerization of the extruded building materials.

[0217] In embodiments in which two or more formulations react with each other, it is preferable to dispense them separately so that their reactions are induced on the fabric. Depending on the products of such reactions, the formulations may be dispensed before, after, or simultaneously with or intermittently with the dispensing of the building materials.

[0218] For example, when the reaction product forms an adhesive that allows the building material to adhere, and / or If the reaction product alters the size of pores (e.g., a reaction product that locally shrinks the fibers of a fabric, thereby increasing the size of the pores between fibers), and / or if the reaction product forms a mask in areas of the fabric where it is desired that the building material not come into contact with it, the compound can be dispensed before the building material is dispensed. If the reaction product alters the appearance of the building material (e.g., increases or decreases gloss, corrects color), or if the building material is covered with a (usually transparent) cover, such as a protective cover, the compound can be deposited after the building material is dispensed. If it is desirable to weave the reaction product perpendicular or transversely to the building material, for example, to strengthen the building material or to improve the flexibility of the final object, the compound can be deposited simultaneously with or intermittently with the dispensing of the building material.

[0219] Additives can be applied in two or more ways. Typically, an additive dispensing system 340 is used (Figures 1A and 1B). The additive dispensing system 340 is typically in fluid communication with a container 342 (shown only in Figure 1A) containing the additives. The additive dispensing system 340 is controllable by a controller 20. In some embodiments of the present invention, one or more additives are applied by pouring an aerosol or mist of the additive onto the fabric. In these embodiments, the system 340 takes the form of an aerosol dispenser or sprinkler that generates an aerosol or mist of the additive and pours it onto the fabric. In some embodiments of the present invention, one or more additives are applied by depositing droplets of the additive at discrete, addressable locations on the fabric. In these embodiments, one or more print heads 16 can be configured to operate as the system 340 to dispense individual additives, and one or more containers or cartridges of the supply system 330 can act as containers 342. When there are two or more additives (for example, multiple formulations that are normally inactive but react with each other in place after deposition), deposition to discrete, addressable locations on the fabric can preferably be carried out by interlacing them laterally to form interfaces between adjacent droplets of different additives.

[0220] The additive ejection system 340 can be mounted on the same printing block as the head 16, as shown in Figure 1A, and is therefore movable horizontally with the head 16. Alternatively, the system 340 can be mounted separately from the head 16 (see, for example, Figure 1B), in which case the head 16 and the system 340 can be configured to move independently. In some embodiments, the construction tray 12 / 360 or a part thereof moves beneath the stationary additive ejection system 340 (e.g., a row of sprinklers) and / or the stationary printing block 128 to which the head 16 is mounted. In some other embodiments, the tray 360 is configured to move in the Z direction, the head 16 is mounted on the printing block 128 configured to horizontally scan the surface of the tray 360 in a first direction (e.g., the X-axis), and the additive ejection system 340 is configured to horizontally scan the surface of the tray 360 in a second direction (e.g., the Y-axis). In some embodiments, both the printing block 128 and the additive ejection system 340 are configured to horizontally scan the surface of the tray 360 in the same direction (e.g., the X-axis).

[0221] This disclosure also envisions the use of non-liquid additives. For example, the additive applied may be in a solid phase. In these embodiments, the additive can be transferred from the substrate to the fabric by bringing the fabric into contact with a substrate supporting the additive and applying pressure, radiation, and / or heat to the substrate. The substrate is, but is not necessarily, in the form of a film containing the additive or a film coated with the additive. For example, if the additive includes a curable substance such as an oily substance such as wax, but is not limited thereto, a sheet containing the curable substance can be placed on the fabric and the curable substance can be transferred to the fabric by heating the sheet and pressing it against the fabric.

[0222] Solid-phase additives can be applied to the side of the fabric from which the building material is extruded, and / or to the side opposite to which the building material is extruded. While the application of solid-phase additives to the fabric is typically performed before extrusion, embodiments in which the solid-phase additives are applied after the material has formed on the fabric are also conceivable.

[0223] Contact between the substrate supporting the additive and the fabric can be established by either placing the substrate on the fabric (for example, outside the printing chamber 412) or by placing the fabric on the substrate, for example, by placing the substrate on the system's tray 12 or tray 360, or jig 402, and then placing the fabric on top of the substrate. If the substrate is placed on a tray or jig, the tray or jig is optionally and preferably heated after the fabric is placed on the substrate to induce the transfer of the solid-phase additive from the substrate to the fabric.

[0224] Refer here to Figure 9, a schematic diagram of a system 520 suitable for unfolding a roll of fabric and printing on the unfolded fabric. The system 520 comprises a printing chamber 412 having an array of nozzles for dispensing construction material, and a work tray. For example, the chamber 412 may include components of system 10 and / or system 110 as detailed above. The system 520 may also include a computerized controller, such as controller 20 as detailed above, but is not limited to this. The system 520 further comprises a fabric unwinding device 524 for unfolding a roll of fabric 526 and, after unfolding, supplying the fabric 420 to the printing chamber 412.

[0225] The fabric unwinding device 524 may be any type known in the art. In some embodiments of the present invention, the unwinding device 524 controls the advancement of the fabric roll 526 and maintains a substantially constant tension on the fabric. Preferably, the control of the unwinding device 524 over the advancement of the fabric roll 526 responds to changes in the diameter of the fabric roll 526 and also to the tension of the fabric. Preferably, the unwinding device 524 is controlled by a controller 20 (not shown in Figure 9). Typically, the unwinding device 524 moves a tension roller 528 to move the fabric toward the chamber 412. The tension roller 528 is usually biased to apply tension to the fabric. A feeder 530 receives the fabric from the tension roller 528 and feeds the fabric into the chamber 412, preferably horizontally. In embodiments in which the jig 402 is used, the feeder 530 optionally and preferably operates in conjunction with a robotic mechanism 410 (not shown in Figure 9, see Figures 4A to 5B). Here, the feeder 530 places the fabric 420 into the jig 402, and the robot mechanism 410 introduces the jig into the chamber 412 as described above.

[0226] In some embodiments of the present invention, the system 520 includes a cutting device 522 for cutting the unfolded fabric 420 into portions. For example, the cutting device 522 can cut portions to the size of a jig 402. Preferably, the cutting device 522 is located at the outlet of the feeder 530 of the unwinding device 524. In some embodiments, the system 520 includes a fabric winding device 532 for winding the fabric 420 after a three-dimensional object has been fabricated on the fabric as described herein. These embodiments are useful when it is desired to provide a continuous fabric roll 534 on which the three-dimensional object 112 is printed. This is achieved by continuously feeding the fabric into the printing chamber 412 without cutting it. The principle and operation of the fabric winding device 532 may be the same as that of the fabric unwinding device 524, except that it is configured to receive the unfolded fabric 420 from the chamber 412 and feed it to the roll 534 for winding. Therefore, the fabric winding device 532 may include a fabric receiving roller 536 that receives the unfolded fabric 420 from the chamber 412, and a winding tension roller 538 that applies tension to the fabric and supplies it to the roll 534.

[0227] Now refer to Figure 10. This is a flowchart of a method suitable for printing three-dimensional objects onto fabric, according to various embodiments of the present invention.

[0228] Unless otherwise defined, the operations described below can be performed concurrently or sequentially in many combinations or sequences of execution. In particular, the order in the flowchart should not be considered restrictive. For example, two or more operations that appear in a specific order in the description or flowchart below may be performed in a different order (e.g., in reverse order) or substantially concurrently. Furthermore, some of the operations described below are optional and may not be performed at all.

[0229] The method of this embodiment can be executed by a computerized controller (e.g., controller 20) of system 10 or system 110.

[0230] The method begins at 600 and optionally, preferably, continues to 602, where computer object data is obtained from, for example, an external source. The computer object data may include a plurality of geometric elements that define the surface of the object (e.g., a polygonal mesh, a non-uniform rational basis spline, etc.). In some embodiments of the present invention, the geometric elements are converted into a grid of voxels that define the shape of the object using a slicing procedure 603, for example, which forms a plurality of slices consisting of a plurality of voxels, each describing a layer of the 3D object. Alternatively, the method may receive the sliced ​​computer object data from an external source, for example, a computer-readable medium. In this case, the operation 603 is not required.

[0231] Since a grid of voxels and multiple geometric elements represent the same object, the term "computer object data" is used herein in relation to both a grid of voxels and multiple geometric elements. Therefore, when computer object data relates to a grid of voxels, each element of the computer object data is a voxel, and when computer object data relates to geometric elements, each element of the computer object data is a geometric element, such as a polygon or a spline.

[0232] In some embodiments of the present invention, at least a portion of the computer object data is obtained from a scan of an individual human or animal body (e.g., a three-dimensional image of the body). In these embodiments, the method receives a scan of an individual body or an external body part thereof 601. Based on this scan, the method can select at least one characteristic of the object. For example, if the system includes a cutting device 522, the dimensions of a cut piece of fabric can be selected based on the scan. Another example is the selection of the position of an object to be manufactured relative to fabric, based on the scan. For example, if the goal is to manufacture a garment with an object at a specific position relative to an individual's body, the scan data obtained in 601 can be used to convert the body coordinates to fabric coordinates so that when the garment is worn by that person, the object is aligned to the desired position.

[0233] This method follows 604, where the fabric is placed within the AM system. This can be done in several ways. In some embodiments, the fabric is placed on the fixture either before or after the fixture is introduced into the system (see Figures 4C, 4D, 5A, 5B). In some embodiments, the fabric is placed directly on the tray, and the fixture attaches the fabric to the tray (see Figures 4A, 4B, 4E, 4F). In some embodiments, the fabric is attached to the lamp structure either before or after the lamp structure is placed on or mounted on the tray (see Figures 15A-15C), and the vertical position of the tray is adjusted accordingly.

[0234] In step 605, one or more additives are applied to the fabric, and in step 606, one or more construction materials are extruded as described in detail. Operations 605 and 606 are repeatable and can be performed in any order. In addition, one or more construction materials can be extruded onto the receiving surface before introducing the fabric into the system in order to form objects on both sides of the fabric and / or to form a sacrificial pedestal structure as described in detail (see Figures 6A-6E and Figure 7).

[0235] In 607, the extruded construction material is solidified (e.g., hardened) by applying solidification radiation.

[0236] This method ends at 608.

[0237] Method 600 can be used to fabricate many kinds of objects on fabric. In some embodiments of the present invention, this method is applied to fabricate objects selected from the group consisting of lens or prism objects, objects that reflect visible light, objects that are transparent to visible light but reflect non-visible light, fluorescent objects, and waveguides. In some embodiments, the fabricated object is capable of changing its optical, mechanical, and / or geometric properties in response to environmental changes, such as temperature changes, humidity changes, and electromagnetic changes in the environment, but is not limited to these. For example, the object may be made of a photosensitive material that changes its color in response to changes in light conditions or temperature.

[0238] In some embodiments of the present invention, the method is applied to the production of objects made of pharmaceuticals and / or cosmetics, for example. For example, the pharmaceutical can be adsorbed onto the surface of an object (for example, by coating the pharmaceutical with a building material as an additive), or the object may be in the form of a capsule containing the pharmaceutical. Representative examples of pharmaceuticals that can be incorporated into an object include, but are not limited to, antibacterial agents and antiviral agents.

[0239] In some embodiments of the present invention, the method is used to manufacture an object comprising a heating element capable of releasing heat or a cooling element capable of absorbing heat. In some embodiments, the method is used to manufacture an object comprising a circuit, and in some embodiments, the method is used to manufacture an object comprising a cavity for receiving foreign objects such as an electrical circuit, a magnetic element, a light-emitting element, a chip, or a capsule containing a pharmaceutical or cosmetic product, but is not limited to these.

[0240] In some embodiments of the present invention, this method is used to manufacture female or male components of a snap connector. These embodiments are not limited to but are particularly useful for manufacturing garments such as seamless clothing. In a typical example, as shown in Figures 11A to 11C, construction material is extruded to form a female snap connector 612 (Figure 11A) on a first fabric element 610 and a male snap connector 616 (Figure 11B) on a second fabric element 614. The female snap connector 612 is then connected to the male snap connector 616 (Figure 11C), thereby connecting the two fabric elements 610 and 614. The fabric elements 610 and 614 may be parts of the same garment, such as a pocket and trousers, or a collar and shirt.

[0241] In another typical example, as shown in Figures 12A to 12B, construction material is extruded onto a fabric element 610 to form a female snap connector 612 and a male snap connector 616 offset laterally from the female snap connector 612 (Figure 12A). Then, the fabric element 610 is folded to align the connectors 612 and 614, and the female snap connector 612 is connected to the male snap connector 616 (Figure 12B). The fold is then fixed. In these embodiments, the fabric element 610 may be, for example, part of a garment such as a sleeve, sock, or seamless shirt.

[0242] In embodiments where the controller receives a scan of a body, the scan data can be used to determine the position and / or number of female and male snap connectors on the fabric element. For example, generally, larger bodies have more snap connectors printed on them compared to smaller bodies.

[0243] In some embodiments of the present invention, this method is applied to printing stitching elements that connect fabrics together. For example, a first fabric element and a second fabric element are aligned adjacent to each other on a jig, optionally within a frame, and construction material is extruded onto and between the adjacent edges of the aligned fabrics to stitch them together. Stitching elements may be formed on the fabric to create fold lines.

[0244] The three-dimensional printing protocol for performing method 600 may be selected by the system operator or automatically selected. For example, the system's user interface 116 may present the operator with one or more printing protocols, and the operator may decide whether to execute the displayed protocol, modify it at the operator's request, or use a different protocol.

[0245] Figure 13 is a flowchart of a method suitable for printing a three-dimensional object onto fabric in an embodiment of the present invention in which the system determines the printing protocol.

[0246] The method begins at 620, optionally and preferably continues to 602, and optionally continues to 603, as described in detail above. The method optionally and preferably extracts one or more geometric properties of the object to be printed from the computer object data, typically thickness, and optionally and preferably also shape. Alternatively, the method may receive these properties via the system's user interface. Combinations of these options are also conceivable. For example, geometric properties can be extracted from the computer object data, but are not limited to, non-geometric properties such as stiffness and color can be obtained via the user interface.

[0247] This method follows 621, where it receives data relating to the characteristics of the fabric via the system's user interface. Such data may include one or more items such as the type of fabric, the average size of the fabric's pores, and the weave pattern of the fabric.

[0248] This method continues to 622, where a computer-readable medium storing the library is accessed. The library typically contains multiple entries, each containing one or more libraries of fabric properties, one or more libraries of material properties, and sets of print parameters. A typical example of a library 630 suitable for this embodiment is shown in Figure 14. It contains k sets of print parameters, where the i-th (i=1,2,...,k) set of print parameters is n of fabric properties. i Values ​​and m of material properties i The values ​​correspond to the k sets of printing parameters, each defining a printing protocol which optionally and preferably includes an optimal sequence of printing operations for a particular object given one or more properties of the fabric. The set of printing parameters optionally and preferably includes at least one of (i) the application sequence of primers, (ii) the building materials, (iii) the dispensing sequence of the building materials, and (iv) the application sequence of finishes. In some embodiments of the present invention, the set of printing parameters also includes a dimensional scaling factor which allows the method to enlarge or reduce the dimensions of an object by a scaling factor.

[0249] The following are some examples of print parameter sets, but these should not be considered as limiting examples.

[0250] If the fabric properties indicate that the average size of the fabric pores is large enough to accommodate the through-elements 506 along the entire depth of the pores, the set of printing parameters will include, but is not limited to, a sequence of operations that enables double-sided printing, such as the sequence of operations described above with respect to Figures 6A to 6E and Figure 7.

[0251] If the fabric properties indicate that the fabric contains a sufficient amount of sufficiently long, protruding fuzzy fibers 424, and the object properties indicate that the object is sufficiently thin and sufficiently light in weight, the set of printing parameters may include, but is not limited to, a sequence of operations that enables single-sided printing, such as the sequence of operations described above in Figure 8A or Figure 8B.

[0252] If the properties of the fabric indicate that it is suitable for applying an adhesive to which an object will adhere, the set of printing parameters may include applying the adhesive to the fabric before the printing material is ejected.

[0253] If the fabric properties indicate a specific weave pattern, the set of printing parameters may include an operation sequence that involves aligning the fabric based on that specific weave pattern.

[0254] If the properties of the object indicate that a finishing liquid (for example, a finishing liquid that increases or reduces the gloss of the object's outer surface, or a finishing liquid that protects the object's outer surface) is required, the set of printing parameters may include the application of the finishing liquid to the construction material after the object has been formed.

[0255] If the properties of an object indicate that the object has multiple separation parts with sufficiently small gaps between adjacent separation parts, the set of printing parameters may include selectively applying a masking fluid to the gaps in the fabric before extruding the construction material. The same set of parameters can be used if the properties of the fabric indicate that it may be damaged by curing irradiation, in which case the set of printing parameters may include selectively applying a masking fluid to the fabric in areas that should not be occupied by the object before extruding the construction material.

[0256] If the object exhibits high rigidity, the set of printing parameters may include the use of a construction material that results in higher rigidity after solidification and optionally increases the physical dimensions of the object. If the object exhibits low rigidity, the set of printing parameters may include the use of a construction material that results in lower rigidity after solidification and optionally decreases the physical dimensions of the object. These embodiments are typically implemented by thresholding. Specifically, the library 630 preferably includes entries for different numerical rigidity ranges, each defined by one or two rigidity thresholds. For each such entry, the method compares the desired rigidity of the object obtained from the user interface with the rigidity threshold of each entry and selects a set of printing parameters at least partially based on this comparison.

[0257] Following 623, a library 630 is searched for an entry that best matches the characteristics of the object and the fabric. For the sake of simplicity, assume that the library 630 has a plurality of values describing the pore size of the fabric and a plurality of values describing the thickness of the object to be fabricated. For each pair of a pore size value and an object thickness value, there is a set of printing parameters. In this case, the method finds an entry having a thickness value that matches or substantially matches the thickness of the object and a pore size value that matches or substantially matches the pore size of the fabric. For example, the method searches the entire library to find all entries having a pore size value that matches or substantially matches the pore size of the fabric. Then, from these entries, it searches for an entry having a thickness value that matches or substantially matches the thickness of the object. The method can select a set of parameters from the thus detected entry.

[0258] This method proceeds to 624, where a three-dimensional printing system such as, but not limited to, system 10 or system 110 is operated to form the object on the fabric according to the set of printing parameters of the detected entry.

[0259] This method ends at 625.

[0260] Examples of suitable three-dimensional printing protocols according to some embodiments of the present invention are described in the Examples section below.

[0261] As used herein, the term "about" refers to ±10%.

[0262] As used in this specification, the term "exemplary" is used in the sense of "an example, an instance, for illustration". Any embodiment described as "exemplary" should not necessarily be construed as more suitable or advantageous than other embodiments, and / or does not exclude incorporating the features of other embodiments.

[0263] The term “optionally” is used herein to mean “provided in one embodiment and not provided in another embodiment.” Any particular embodiment of the present invention may include several “optionally” features, provided that such features do not conflict with each other.

[0264] The terms "to prepare," "prepared," "include," "included," and "to have," as well as their conjugations, all mean "to include, but not limited to."

[0265] The term "consisting of" means "including and limited to."

[0266] The term "essentially consisting of" means that the composition, method, or structure may include additional components, steps, and / or parts, but only if such additional components, steps, and / or parts do not substantially alter the basic and novel characteristics of the claimed composition, method, or structure.

[0267] As used herein, the singular forms “a, an” and “the” also include plural references unless the context explicitly states otherwise. For example, the terms “one compound” or “at least one compound” may include multiple compounds, including mixtures thereof.

[0268] Through this application, various embodiments of the present invention may be presented in range form. It should be understood that range form descriptions are merely for convenience and simplification and should not be interpreted as a fixed and immutable limitation of the scope of the present invention. Therefore, range descriptions should be considered to specifically disclose all possible subranges, along with the individual numerical values ​​within that range. For example, a range description such as 1-6 should be considered to have specifically disclosed subranges such as 1-3, 1-4, 1-5, 2-4, 2-6, 3-6, and individual numerical values ​​within that range, such as 1, 2, 3, 4, 5, and 6. This applies regardless of the breadth of the range.

[0269] Whenever a numerical range is indicated herein, it is understood to include any cited numerical value (fraction or integer) within that range. The phrases “in the range between” the first and second designations, and “in the range from” the first designation to the second designation, are used interchangeably herein to mean the first and second designations, as well as all fractions and integers between them.

[0270] It is understood that certain features of the present invention, even if described in the context of separate embodiments for clarity, may be provided in combination in a single embodiment. Conversely, various features of the present invention described in the context of a single embodiment for brevity may be provided separately, in any suitable partial combination, or in a manner appropriate to any other described embodiment of the present invention. Certain features described in the context of various embodiments should not be considered essential features of those embodiments unless the embodiment would be unable to function without those elements.

[0271] The experimental evidence for the various embodiments and aspects of the present invention, which have been described above and are claimed in the following claims, is provided in the following examples. Examples

[0272] Next, refer to the following examples. These, in conjunction with the above description, illustrate some non-limiting embodiments of the present invention.

[0273] Example 1 Print without base

[0274] The fabric is placed on a tray, ensuring stable positioning. For example, the fabric can be placed on a jig, and the jig can be placed on a tray. Optionally, positioning marks (e.g., mark 414) are used to align the fabric to the tray. Optionally, one or more printing fluids are applied to the fabric. Next, the z-height of the printing block can be adjusted so that zero height is the height of the fabric. This operation is particularly useful in systems that automatically add the height of the base to the z-height. When printing without a base, such automatic settings are preferably readjusted. As described in detail herein, the nozzle array is then activated and through-elements or adhesive elements are printed on the fabric. Next, objects are printed on the through-elements or adhesive elements.

[0275] Example 2 Fixation by double-sided printing

[0276] A base structure is printed on the receiving surface or tray of the system. Then, fixing elements (e.g., with a thickness of 5 mm or less) are printed on the base structure. Next, optionally and preferably, printing is stopped and the fabric is placed on the tray, preferably, but not necessarily, using a jig to ensure stable positioning. Optionally, positioning marks (e.g., mark 414) are used to align the fabric on the tray. Optionally, one or more primer solutions are applied to the fabric. After the fixing elements are in place, the z-height of the printing block can then be adjusted so that the zero height is the height of the fabric. The nozzle array is then activated and, as described in detail above, through elements are printed on the fabric and connected to the fixing elements beneath the fabric. The object is then printed so that the bottom layer of the object is connected to the through elements.

[0277] Example 3 Fixation by inverted double-sided printing.

[0278] The fabric is placed on the fixture. Optionally, one or more printing liquids are applied to the fabric. The nozzle array is then activated to print a pedestal structure on the receiving surface of the system or on the tray. Thereafter, an object is printed on the pedestal structure. The printing is optionally and preferably stopped once to place the fixture on the printed object. The support material is optionally and preferably removed from the printed object. After being placed on the printed object, the z-height of the printing block can then be adjusted to set the zero height to the height of the fabric. The nozzle array is then activated again to print through-holes on the fabric to connect to the object below the fabric. Then a fixing element is printed to connect to the through-holes.

[0279] Example 4 Print an object on the opposite side of the fabric

[0280] The fabric is placed on the fixture. Optionally, one or more primer solutions are applied to the fabric. The nozzle array is then activated to print a pedestal structure on the receiving surface of the system or on the tray. Thereafter, a first object is printed on the pedestal structure. The printing is optionally and preferably stopped once to place the fixture on the first object. The support material is optionally and preferably removed from the first object. After being placed on the first object, the z-height of the printing block can then be adjusted to set the zero height to the height of the fabric. The nozzle array is then activated again to print through-holes on the fabric to connect to the first object below the fabric. A second object is then printed and connected to the through-holes.

[0281] Although the invention has been described with reference to its particular embodiments, it will be apparent to those skilled in the art that many alternatives, modifications, and variations are possible. Accordingly, it is intended to embrace all such alternatives, modifications, and variations that fall within the spirit and broad scope of the appended claims.

[0282] All publications, patents, and patent applications referenced herein are incorporated herein by reference in whole to the same extent that each individual publication, patent, and patent application is incorporated herein by reference specifically and individually. Furthermore, no citation or specification of any reference within this application should be construed as an admission that such reference is available as prior art to the present invention. Insofar as they are used as section headings, they should not necessarily be construed as restrictive.

[0283] Furthermore, any priority document of this application is incorporated herein by reference in its entirety.

Claims

1. Dispense at least one construction material onto a receiving surface to form a fixed element on the receiving surface, Place the fabric on the aforementioned fixed element, At least one construction material is extruded onto the fabric to form a penetrating element that penetrates the fabric and is connected to the fixing element. At least one construction material is extruded onto the penetrating element in a configuration pattern corresponding to the shape of the object. A three-dimensional printing method that includes the following.

2. At least one construction material is extruded onto the receiving surface in a configuration pattern corresponding to the shape of the object, Place the cloth on the object, At least one construction material is extruded onto the fabric to form a penetrating element that penetrates the fabric and is connected to the object. At least one construction material is extruded onto the penetrating element to form another object. A three-dimensional printing method that includes the following.

3. The three-dimensional printing method according to claim 2, wherein the other object is a fixed element.

4. The three-dimensional printing method according to claim 2, wherein the other object is a decorative object.

5. The three-dimensional printing method according to claim 2, wherein at least one of the aforementioned object and the other object is a thermal protection object.

6. A three-dimensional printing method according to any one of claims 1 to 5, comprising temporarily stopping the dispensing before arranging the fabric.

7. A three-dimensional printing method according to any one of claims 1 to 5, wherein the dispensing of at least one construction material to form the through-element generally includes dispensing a colorless and transparent construction material.

8. A three-dimensional printing method according to any one of claims 1 to 5, further comprising irradiating the construction material by solidification irradiation after the penetrating element has penetrated the fabric while in a liquid state.

9. The three-dimensional printing method according to claim 8, comprising discharging the construction material onto the fabric to form the penetrating element, and then delaying the irradiation for a predetermined time.

10. A three-dimensional printing method according to any one of claims 1 to 5, further comprising extruding at least one construction material to form a sacrificial layer over the exposed portion of the fabric, and non-selectively irradiating all extruded construction materials by solidification irradiation.

11. The three-dimensional printing method according to any one of claims 1 to 5, wherein the arrangement of the fabric includes attaching the fabric to the receiving surface using a jig.

12. A three-dimensional printing method according to any one of claims 1 to 5, comprising acquiring alignment data relating to the position of the fabric with respect to the receiving surface, and aligning the discharge position of the construction material based on the alignment data.

13. The aforementioned discharge includes operating the nozzle array of a three-dimensional printing system comprising a nozzle array and a work tray, A three-dimensional printing method according to any one of claims 1 to 5, further comprising dispensing at least one construction material onto a work tray to form a sacrificial structure, wherein the receiving surface is the sacrificial structure.

14. The method for three-dimensional printing according to any one of claims 1 to 5, wherein the discharge includes operating the nozzle array of a three-dimensional printing system comprising a nozzle array and a work tray, the receiving surface includes a lamp structure, and the method includes mounting or arranging the lamp structure on the work tray.

15. The three-dimensional printing method according to claim 14, comprising folding the fabric on a lamp structure, and mounting or positioning the lamp structure such that the horizontal portion of the fabric is supported on the upper surface of the lamp structure and the hanging portion of the fabric is folded into the space below the upper surface and above the work tray.

16. The three-dimensional printing method according to claim 14, further comprising adjusting the vertical position of the work tray to correct the height of the upper surface of the lamp structure above the work tray.

17. A three-dimensional printing method according to any one of claims 1 to 5, further comprising receiving a scan of an individual's body or an external body part thereof, and selecting at least one characteristic of the object based on the scan.

18. A three-dimensional printing method according to any one of claims 1 to 5, comprising applying at least one additive other than the construction material for three-dimensional printing to the fabric before the extrusion of the construction material.

19. A three-dimensional printing method according to any one of claims 1 to 5, comprising applying at least one additive other than the construction material for three-dimensional printing to the fabric after the extrusion of the construction material.

20. The three-dimensional printing method according to claim 18, wherein the at least one additive comprises a primer selected from the group consisting of adhesive solutions and pore size adjusting solutions, and the application of the primer is before the discharge.

21. The three-dimensional printing method according to claim 18, wherein the at least one additive comprises a finishing liquid selected from the group consisting of a radiation protection solution, a gloss finishing liquid, and a matte finishing liquid, and the application of the finishing liquid is after the dispensing.

22. The three-dimensional printing method according to claim 18, wherein the at least one additive comprises a masking solution.

23. The three-dimensional printing method according to claim 18, wherein the at least one additive is an inactive formulation that can be activated in situ, and the method includes applying the formulation to the fabric and then activating the formulation.

24. The three-dimensional printing method according to claim 23, wherein the activation is performed by irradiation, heating, and at least one of a chemical reaction between the additive and one or more of the construction materials.

25. The three-dimensional printing method according to claim 18, wherein the coating includes applying an aerosol of the additive to the fabric.

26. The three-dimensional printing method according to claim 18, wherein the coating includes depositing droplets of the additive at discrete addressable positions on the fabric.

27. The three-dimensional printing method according to claim 18, wherein there are at least two additives, and the coating comprises overlapping and depositing droplets of the at least two additives at discrete addressable positions on the fabric.

28. The three-dimensional printing method according to claim 18, comprising a first additive and a second additive, wherein the first additive and the second additive chemically react with each other upon contact, and the coating method includes separating and depositing the additives on the fabric surface so as to later induce the reaction between the two.

29. A three-dimensional printing system, A nozzle array for dispensing building materials, The receiving surface and, A jig configured to attach the fabric to the receiving surface, The nozzle array is operated to discharge at least one construction material onto the receiving surface. The dispensing of the construction material is temporarily stopped, and the fabric is placed and attached to the dispensed construction material using the jig. A computerized controller configured to further extrude at least one construction material in a configuration pattern onto the fabric after the fabric has been placed, A three-dimensional printing system equipped with the following features.

30. The three-dimensional printing system according to claim 29, comprising a position tracking system configured to determine the position of the jig with respect to the receiving surface, wherein the computerized controller is configured to perform an alignment procedure based on the position and to operate the nozzle array in response to the alignment.

31. The system includes an imaging system configured to image the fabric placed on the receiving surface, The three-dimensional printing system according to claim 29 or 30, wherein the computerized controller is configured to receive image data from the imaging system, process the image data to identify a pattern on the fabric, and operate the nozzle array to eject a construction material at a position selected for the identified feature.

32. Equipped with a work tray, The three-dimensional printing system according to claim 29 or 30, wherein the receiving surface comprises a lamp structure that can be attached to or positioned on the work tray.

33. The lamp structure defines the space above the work tray, The three-dimensional printing system according to claim 32, wherein the space is configured to receive the hanging portion of the fabric.

34. The three-dimensional printing system according to claim 32, wherein the computerized controller is configured to adjust the vertical position of the work tray to compensate for the height of the lamp structure above the work tray.

35. The three-dimensional printing system according to claim 29 or 30, further comprising a solidification device configured to irradiate the construction material by solidification irradiation after the penetrating element has penetrated the fabric while in a liquid state.

36. The three-dimensional printing system according to claim 34, wherein the computerized controller is configured to delay irradiation for a predetermined time after the construction material has been extruded to form a through element.

37. Equipped with two solidification devices, The three-dimensional printing system according to claim 36, wherein the computerized controller is configured to select one of the two solidification devices based on a predetermined time.

38. The three-dimensional printing system according to claim 36, wherein the computerized controller is configured to establish relative motion between the nozzle array and the receiving surface and to control the speed of the relative motion based on a predetermined time.

39. The three-dimensional printing method according to any one of claims 1 to 5, wherein the object is selected from the group consisting of a lens-shaped object, a prism object, an object that reflects visible light, an object that is transparent to visible light but reflects non-visible light, a fluorescent object, and a waveguide.

40. The three-dimensional printing method according to any one of claims 1 to 5, wherein the object is capable of changing its optical properties, mechanical properties, and / or geometric properties in response to environmental changes.

41. The three-dimensional printing method according to claim 40, wherein the environmental change includes at least one change selected from the group consisting of temperature changes, humidity changes, and changes in the electromagnetic content of the environment.

42. The three-dimensional printing method according to any one of claims 1 to 5, wherein the object includes a drug.

43. The three-dimensional printing method according to claim 42, wherein the agent is selected from the group consisting of antibacterial agents and antiviral agents.

44. The three-dimensional printing method according to any one of claims 1 to 5, wherein the object includes cosmetics.

45. The three-dimensional printing method according to any one of claims 1 to 5, wherein the object includes a heating element.

46. The three-dimensional printing method according to any one of claims 1 to 5, wherein the object includes a cooling element.

47. The three-dimensional printing method according to any one of claims 1 to 5, wherein the object includes a circuit.

48. The three-dimensional printing method according to any one of claims 1 to 5, wherein the object includes a cavity for receiving foreign matter.

49. The three-dimensional printing method according to any one of claims 1 to 5, wherein the object includes a female or male part of a snap connector.

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