Comfortable Fiber

Abstract

A method for manufacturing a filament is disclosed. The method includes extruding material for the core of the filament and material for the sheath of the filament using one or more extruders, routing the extruded material from the one or more extruders using core and sheath portions of a die head, and cooling the material to form a filament during or after use of the die head. Methods and apparatus for post-processing 3D printed products using at least one of laser irradiation and plasma treatment are also disclosed. Also disclosed are core / sheath structures that comprise build materials or objects produced from the build materials. The core / sheath structures include a core and a sheath, and the sheath includes one or both of fibers and particles, and at least one of a soluble material, an antimicrobial material, a UV protection material, an odor management material, and a moisture management material.

Description

[Technical Field]

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 486,385, filed February 22, 2023, the entire contents of which are incorporated herein by reference.

[0002] The present disclosure relates to core / sheath structures, methods of making flock products, and flock products, which are filaments that can be made or formed (e.g., woven) into textiles (fabrics) having desired properties. [Background technology]

[0003] This section is intended to introduce various aspects of technology related to exemplary embodiments of the present disclosure. This discussion is believed to help provide a framework that may facilitate a better understanding of certain aspects of the present disclosure. As such, this section is intended to facilitate understanding of the present disclosure and is not intended as an admission of prior art.

[0004] US Patent Application Publication No. 2017 / 0268133 discloses a consumable filament. The consumable filament is melted and extruded in an additive manufacturing system. The consumable filament comprises a core portion and a sheath portion surrounding the core portion. The core portion comprises a matrix of a first base polymer and particles dispersed in the matrix. The sheath portion comprises a second base polymer. The particles in the core portion are selected from metal particles, non-metal particles, magnetic particles, and combinations thereof, and may be ferrite particles (see paragraph

[0005] ) The particles in the core portion do not penetrate the outer surface of the sheath portion (paragraph

[0074] ). Summary of the Invention [Problem to be solved by the invention]

[0005] The objects manufactured using the consumable filament disclosed in U.S. Patent Application Publication No. 2017 / 0268133 have a rubbery or plastic-like feel, and are not comfortable to the touch. [Means for solving the problem]

[0006] In one or some embodiments, a method for manufacturing a filament is disclosed, the method including: extruding, using one or more extruders, a first set of materials for a core of the filament and a second set of materials for a sheath of the filament, the second set of materials including one or both of fibers and particles; using core and sheath portions of at least one die head to route the first and second sets of materials, respectively, extruded from the one or more extruders; and cooling the first and second sets of materials during or after use of the core and sheath portions of the at least one die head to form the filament.

[0007] In one or more embodiments, a method of treating a 3D printed object is disclosed, the method including receiving the 3D printed object and, after receiving the object, subjecting the object to at least one of a laser irradiation treatment and a plasma treatment.

[0008] In one or more embodiments, an apparatus configured to process a 3D printed object is disclosed, the apparatus including at least one of a laser irradiation device and a plasma treatment device configured to receive a 3D printed object from at least one 3D printer, and at least one control device configured to control the at least one of the laser irradiation device and the plasma treatment device to apply laser irradiation or plasma treatment to the object.

[0009] In one or more embodiments, a core / sheath structure is disclosed that comprises a build material or a built object produced from the build material, the core / sheath structure including a core comprising at least one thermoplastic polymer and having a linear shape and an outer peripheral surface, and a sheath at least partially covering the outer peripheral surface, the sheath including (i) one or both of fibers and particles, and (ii) at least one of a soluble material, an antimicrobial material, a UV protection material, an odor management material, and a moisture management material.

[0010] The present invention is further described in the detailed description by way of non-limiting examples of illustrative embodiments with reference to several drawings, in which like reference numerals refer to like parts throughout the figures unless otherwise specified. In this regard, the accompanying drawings illustrate only exemplary embodiments and therefore should not be considered limiting in scope. The present disclosure permits other equally effective embodiments and applications. [Brief explanation of the drawings]

[0011] [Figure 1] FIG. 2 is a perspective view schematically illustrating a modeling material according to the first embodiment. [Figure 2] FIG. 2 is a cross-sectional view schematically illustrating the molding material of the first embodiment. [Figure 3] 1 is a photograph of a cross section of a prototype of the modeling material of the first embodiment. [Figure 4] FIG. 4 is a cross-sectional view schematically illustrating a modeling material according to a modified example of the first embodiment. [Figure 5] FIG. 10 is a plan view schematically illustrating a shaped object according to a second embodiment. [Figure 6] FIG. 10 is a cross-sectional view schematically illustrating a linear body provided in a shaped object of a second embodiment. [Figure 7] 10 is a scanning electron microscope (SEM) photograph of the entire cross section of a linear body provided in a prototype of a shaped object of a second embodiment. [Figure 8] 10 is an SEM photograph of the periphery of a cross section of a linear body provided in a prototype of a shaped object of a second embodiment. [Figure 9]FIG. 10 is an enlarged cross-sectional view schematically illustrating a shaped object of a second embodiment and the vicinity of the interface between the shaped object and human skin in contact with the shaped object. [Figure 10] 10 is an SEM photograph of a cross section of a prototype of a molded object according to a second embodiment. [Figure 11] 10 is an SEM photograph of a cross section of a prototype of a molded object according to a second embodiment. [Figure 12] This is an SEM photograph of the cross section of a prototype of a molded object manufactured using monofilament. [Figure 13] This is an SEM photograph of the cross section of a prototype of a molded object manufactured using monofilament. [Figure 14] This is an SEM photograph of the top surface of a prototype object manufactured using monofilament. [Figure 15] This is an SEM photograph of the top surface of a prototype object manufactured using monofilament. [Figure 16] 10 is an SEM photograph of a prototype of a molded object manufactured using a molding material according to a modified example of the first embodiment. [Figure 17] 1 is a micrograph of a polyester monofilament. [Figure 18] 1 is a micrograph of a polyester multifilament. [Figure 19] FIG. 10 is a side view schematically illustrating a three-dimensional (3D) printer used to manufacture a modeled object according to a second embodiment. [Figure 20] FIG. 10 is a plan view schematically illustrating a flock product according to a third embodiment. [Figure 21] FIG. 10 is an enlarged cross-sectional view schematically illustrating the vicinity of the interface between the flocked product of the third embodiment and human skin in contact with the flocked product. [Figure 22] FIG. 10 is a perspective view schematically illustrating an electrostatic deposition apparatus used in the production of the flock product of the third embodiment. [Figure 23] FIG. 10 is a flow chart showing the flow of manufacturing a flock product according to a third embodiment. [Figure 24] 10 is a photograph of a prototype of a main body to be provided in the flock product of the third embodiment. [Figure 25]10 is a photograph of a prototype of the flock product of the third embodiment. [Figure 26] 1 is a comparative cross-sectional view of comfort fiber and the current filament. [Figure 27A] FIG. 1 is a cross-sectional view of a comfort fabric with particles inter-loaded within an associated sheath layer. [Figure 27B] FIG. 1 is a cross-sectional view of a comfort fiber with a high particle loading within the associated sheath layer. [Figure 28] FIG. 1 is a flow diagram of a comfort fiber and a process for making garments from the comfort fiber. [Figure 29] FIG. 1 shows a TPU-based monofilament. [Figure 30] FIG. 1 shows a core / sheath filament with cotton powder in the sheath layer. [Figure 31] 1A-1C are enlarged views of the outer surface of a core / sheath filament with cotton particles in the sheath layer at different scales. [Figure 32] FIG. 1 shows a core / sheath filament with wool particles within the sheath layer. [Figure 33] FIG. 1 is a close-up view of the outer surface of a core / sheath filament with wool particles within the sheath layer. [Figure 34] FIG. 1C is a cross-sectional view of a 3D printed fabric based on core / sheath filaments (e.g., comfort fibers) with cotton particles within the sheath layer. [Figure 35] FIG. 1C is a cross-sectional view of a 3D printed fabric based on core / sheath filaments (e.g., comfort fibers) with cotton particles within the sheath layer. [Figure 36] FIG. 1 shows a 3D printed fabric based on TPU monofilament. [Figure 37] FIG. 37 is a cross-sectional view of a 3D printed fabric based on the TPU monofilament illustrated in FIG. 36. [Figure 38] FIG. 1 illustrates a final product (e.g., 3D printed fabric) based on core / sheath filaments (e.g., comfort fibers) with cotton particles within the sheath layer. [Figure 39]1 is a table summarizing tensile test results at 100%, 200%, and 300% elongation under standard conditions (23° C., 50% relative humidity). [Figure 40] 1 is a table summarizing tensile test results for chemical resistance to seawater and chlorine water, taking into account the modulus of elasticity (recorded stress) at 100%, 200%, and 300% elongation as a measure of chemical resistance. [Figure 41] 1 is a table showing moisture levels of different comfort fabrics at different exposure times. [Figure 42] FIG. 1 is a block diagram of an exemplary system for filament production. [Figure 43] FIG. 1 illustrates an exemplary flow diagram for filament manufacturing. [Figure 44] FIG. 1 is a block diagram of an exemplary system for applying laser illumination. [Figure 45] FIG. 1 illustrates an exemplary flow diagram of laser ablation. [Figure 46] FIG. 1 is a block diagram of an exemplary system for plasma processing. [Figure 47] FIG. 1 is an exemplary flow diagram of a plasma process. [Figure 48] FIG. 1 illustrates an exemplary computer system that may be utilized to implement the methods described herein. DETAILED DESCRIPTION OF THE INVENTION

[0012] The methods, devices, systems, and other configurations described below can be embodied in several different forms. Not all of the components described are required, but some embodiments can include additional, different, or fewer components than those described in this disclosure. Variations in the type and arrangement of components can be made without departing from the scope and spirit of the claims set forth below. Furthermore, variations in the processes described below, including additions, deletions, or ordering and reordering of logical operations, can be made without departing from the scope and spirit of the claims set forth below.

[0013] It is understood that the present disclosure is not limited to any particular device or method, as such may vary. Terms used herein are for the purpose of describing particular embodiments only and are not intended to be limiting. The singular forms used herein (the articles "a," "an," and "the") include both singular and plural referents unless the context clearly dictates otherwise. Furthermore, as used throughout this specification, the term "can" is used in its permissive (i.e., possible) sense and not its mandatory (i.e., not necessarily) sense. The term "include" and its derivatives mean "including, but not limited to." The term "connect" means directly or indirectly connected. The term "exemplary" as used herein means "as an example, instance, or illustration." Features described herein as "exemplary" are not necessarily construed as preferred or advantageous over other features. The term "uniform" means that each subcomponent is substantially equivalent within a variance of about ±10%. The term "substantially" means within about ±10% variation, such as within about ±9% variation, within about ±8% variation, within about ±7% variation, within about ±6% variation, within about ±5% variation, within about ±4% variation, within about ±3% variation, within about ±2% variation, and within about ±1% variation.

[0014] As used herein, "obtaining" data generally refers to any method or combination of methods of acquiring, collecting, or accessing data, including, for example, directly measuring or detecting a physical property, receiving transmitted data, selecting data from a group of physical sensors, identifying data within a data record, and retrieving data from one or more data libraries.

[0015] As used herein, the terms "continuous" and "continuous" generally refer to a process that occurs repeatedly over time, independent of an external trigger that causes subsequent repetitions. In some instances, a continuous process repeats in real time and has minimal periods of inactivity between repetitions. In some instances, periods of inactivity are inherent in a continuous process.

[0016] If there is a discrepancy in the use of a word or term in this specification and one or more patents or other documents incorporated by reference, the definition used consistently in this specification should prevail for purposes of understanding the present disclosure.

[0017] 3D printing can be performed in one of a variety of ways. In one method, 3D printing can include an extrusion printing process. For example, Fused Deposition Modeling (FDM) can use filaments such as the consumable filaments disclosed in U.S. Patent Application Publication No. 2017 / 0268133, which is described in the background of the present disclosure.

[0018] When a shaped object is produced using a consumable filament such as that disclosed in U.S. Patent Application Publication No. 2017 / 0268133, the shaped object has a rubbery, plastic-like, or other unpleasant feel. In this regard, one or more embodiments disclose a shaped object or flock product that has a pleasant feel.

[0019] In one or more embodiments, a build material (e.g., a filament for a 3D printer) is disclosed that includes a core and one or more sheaths (e.g., one or more shells). In one or more embodiments, the sheath includes one or both of fibers and particles. As described in more detail below, the fibers and / or particles in the sheath may be separated and / or separated layers and / or may protrude from the outer surface of the core, thereby being closer to the core than the user's skin and imparting properties to the build material. Thus, in one or more embodiments, the one or more sheaths may include at least one material (e.g., fibers and / or particles) that is different from the material in the core. Alternatively, one or more materials in the sheath may be included in the core.

[0020] In one or more embodiments, the build material is then used to create a build object. As described in more detail below, the build object is generated from the build material by one of a variety of methods, such as 3D printing using the build material as a filament to generate the object, braiding, weaving, and / or stitching the build material. In other examples, the build object generally maintains the core / sheath structure of the underlying build material. For example, in 3D printing, the build object may include one or more layers (replaceable printed layers), where the one or more layers generally maintain the core / sheath structure, but may have some variation. In one particular variation, one or more layers may have a different diameter than the build material (e.g., the diameter of one or more layers may be smaller than the diameter of the build material. See Figures 27A and 27B, where the diameter of the build material is reduced from 1.75 mm to 0.4 mm, effectively a quarter-fold reduction). In certain other variations, the outer surface of one or more layers can be different from the outer surface of the build material (e.g., one or more materials within the sheath layer, such as fibers and / or particles, can protrude from the outer surface of the sheath layer (see Figures 27A and B), thereby providing a benefit to the user of the build). Thus, the build can be comprised of one or more layers having a core / sheath structure, as described further below.

[0021] In one or more embodiments, the material in the sheath of the build material can be a variety of materials, similarly affecting the build. In one example, the sheath can be the same or a different type of thermoplastic polymer as the thermoplastic polymer in the core. In another example, the core can contain fibers and / or particles, which can be (i) the same or a different type as the fibers and / or particles in the sheath, or (ii) the same or a different concentration as the fibers and / or particles in the sheath. In this regard, in one embodiment, the sheath, which is formed separately from the core and contains fibers and / or particles, can impart desired properties to the build material that differ from the properties imparted by the core itself. Alternatively, the sheath can be formed with fibers and / or particles protruding from the core.

[0022] Thus, various methods are possible for providing fibers and / or particles within the sheath. In one or several embodiments, the fibers and / or particles can be contained within a material separate from the core (e.g., disposed on the outer surface of the core). For example, the core can include at least one thermoplastic polymer (e.g., a single thermoplastic polymer), and one or more sheaths can include fibers and / or particles within or on at least one thermoplastic polymer at least partially surrounding the core (e.g., a single sheath at least partially surrounding the core and including a thermoplastic polymer and both or one of fibers and particles). In one embodiment, the at least one thermoplastic layer in the core is the same as the at least one thermoplastic layer in the sheath. Alternatively, the at least one thermoplastic layer in the core differs from the at least one thermoplastic layer in the sheath in one or more properties (e.g., different Shore A values). Regardless, some of the fibers and / or particles in the sheath provide different qualities from the thermoplastic elastomer in the core.

[0023] Alternatively, or in addition, the fibers and / or particles in the sheath may be directly disposed on the surface of the fibers and / or particles contained within a material separate from the core (disposed on the outer surface of the core). In one example, the fibers and / or particles may be sprayed onto the outer surface of the core with an adhesive. In this case, the sheath consists of the fibers and / or particles (and optionally the adhesive) disposed on the outer surface of the core, without an intermediate material (such as a thermoplastic layer) in which the fibers and / or particles are suspended. In a specific, non-limiting example, flock fibers may be applied (e.g., flocked) to the outer surface of the core emerging from the die head with an adhesive, such as a thermoplastic emulsion, used to adhere the fibers until printing. In another example, the fibers and / or particles may be sprayed onto the outermost surface of the sheath with an adhesive. In this manner, the fibers and / or particles may come into contact with the user's skin, thereby imparting a different quality to the core and / or any intermediate sheath.

[0024] Thus, in one or more embodiments, the sheath can be comprised of any one, any combination, or all of: (i) a plastic polymer (e.g., a thermoplastic polymer), (ii) fibers and / or particles, (iii) a soluble material (e.g., a water-soluble material such as a water-soluble synthetic polymer (polyvinyl alcohol (PVA))), (iv) an antimicrobial material (any one, any combination, or all of antibacterial, antifungal, and antiviral materials), (v) sun or ultraviolet protection factor (UPF) protection (e.g., zinc oxide), (vi) odor management (e.g., zinc oxide, coffee grounds), and (vii) moisture management (e.g., coffee grounds). Because the various components (i) through (vii) are contained within the sheath (and, in one embodiment, only within the sheath), less of each component may be required to achieve acceptable effectiveness than if the component were contained within the core, which can be particularly beneficial, especially for more expensive materials (e.g., wool).

[0025] In one example, the sheath can be comprised of a plastic polymer, fibers and / or particles, and a soluble material. In another example, the sheath can be comprised of a plastic polymer and a soluble material. In either example, the sheath includes at least a portion of a soluble material, such as a water-soluble material, and after 3D printing the object, the object is subjected to a post-treatment to remove at least a portion of the soluble material.

[0026] Various ratios of TPU (thermoplastic polyurethane) and fibers / particles are contemplated. In one or some embodiments, the ratio of TPU may be greater than the ratio of fibers / particles. In one example, the ratio of TPU may be at least two times, at least three times, at least four times, or at least five times the ratio of fibers / particles.

[0027] For sheaths with water-soluble material, post-processing of the object can include exposing the object to water (e.g., rinsing the object with water). When rinsing is performed, some or all of the water-soluble material is removed from the sheath, thereby increasing the amount of fibers and / or particles in the sheath and making the effect of the fibers and / or particles on the skin more noticeable (softer feeling).

[0028] Various ratios of TPU, PVA, and fibers / particles are contemplated. In one or some embodiments, the ratio of TPU may be greater than the respective ratios of PVA and fibers / particles. Alternatively, the ratio of TPU may be greater than the sum of the ratio of PVA and the ratio of fibers / particles. Alternatively, the ratio of TPU may be equal to (or less than) the ratio of fibers / particles. Depending on the selected ratios, the shaped object may be, for example, more or less durable, more or less brittle, or more or less elastic.

[0029] As one example, in one or more embodiments, the sheath can include a thermoplastic polymer, fibers and / or particles, and a PVA material. After 3D printing, the part is exposed to water to decompose some or all of the PVA in the sheath, further enhancing the effect of the fibers and / or particles in the sheath on the wearer's skin when the PVA is removed.

[0030] As described above, the build material can be utilized in one of a variety of 3D printing and / or non-3D printing methods to generate a built object. For example, in one or more embodiments, the build material (e.g., a filament having a core / sheath) can be directly introduced into a 3D printer to 3D print the object. Thus, the built object can be comprised of one or more layers (interchangeable 3D printing layers) including at least one, at least some, or all of the one or more layers having a core / sheath structure (including one, some, or all of the core and / or sheath features described herein). In doing so, the 3D printer can use the build material to generate the object in the layer having the core / sheath structure, thereby providing the benefits of the core / sheath structure. As one example, a core / sheath structure allows for the inclusion of various materials, such as fibers and / or particles, within the sheath, thereby allowing for the use of fewer fibers and / or particles (because the fibers and / or particles are not included in the core or are included in a lower percentage within the core) while still allowing for the benefits of the fibers and / or particles (e.g., the fibers and / or particles can contact the skin). Thus, in one or some embodiments, a build object can be 3D printed entirely from a build material having a core / sheath structure, such that all layers of the build object have a core / sheath structure. Alternatively, a build object can be 3D printed from a first build material having a core / sheath structure and a second build material having a core structure (without a sheath), such that one or some layers of the build object (e.g., an outer layer that contacts the skin) have a core / sheath structure and other layers of the build object (e.g., an inner layer that does not contact the skin) have a core structure.

[0031] As another example, a build object can be formed using build materials without 3D printing (e.g., by braiding, weaving, etc. filaments). The build materials used in such methods can be held together (e.g., braiding or weaving different filaments) in one of a variety of ways, such as by applying heat and / or adhesive. As above, the build object can be entirely made from build materials having a core / sheath structure, such that all layers of the build object have a core / sheath structure. Alternatively, the build object can be made from a first build material having a core / sheath structure and a second build material having a core structure (without a sheath), such that one or some layers of the build object (e.g., an outer layer that contacts the skin) have a core / sheath structure, and other layers of the build object (e.g., an inner layer that does not contact the skin) have a core structure. Regardless, the build object (similar to a 3D printed object) can have a core / sheath structure in one or more layers.

[0032] In one or some embodiments, after the creation of the object (whether 3D printed or non-3D printed), one or more additional steps or treatments can be performed, including any one, any combination, or all of flocking, laser irradiation (e.g., laser ablation), or plasma treatment.

[0033] Thus, in one or more embodiments, flocking can be performed, and flock (e.g., fibers) can be attached or secured to the surface of a shaped object. For example, the flock can be secured to a surface containing an adhesive by contacting and / or piercing the flock into the surface of the shaped object. In contacting and / or piercing, an external force can be applied, such as via an electrostatic deposition device.

[0034] In one or some embodiments, a laser irradiation process (e.g., laser ablation) can be used to process a built object (e.g., after 3D printing or after braiding and / or weaving filaments). In particular, the built object can include one or more layers, such as an outer layer (e.g., an outer surface that contacts the user's skin) and an inner layer (e.g., no surface contacts the user's skin). In one or some embodiments, one or more layers can be used to apply laser irradiation (e.g., perform laser ablation), and laser irradiation is applied to one or more layers. As one example, laser irradiation can be applied to one or both outer surfaces of the outer layer (that contact the user's skin) or to one or more portions of the outer layer, such as the interior of the outer layer. In particular, laser irradiation (e.g., laser ablation) can be applied to the surface of the outer layer (e.g., the surface of the sheath of the outer layer in a core / sheath structure of the built object, or the surface of the core of the outer layer in a core (sheath-free) structure of the built object) to ablate a pattern or other markings on the surface of the outer layer. Alternatively, or in addition, in other examples, laser radiation (e.g., laser ablation) can be applied to the interior of the outer layer (e.g., within the sheath of the outer layer in a core / sheath structure of the object, within the core of the outer layer in a core / sheath structure of the object, or within the core of the outer layer in a core structure (without a sheath) of the object), and the laser radiation can modify the interior of the outer layer in one of a variety of ways (e.g., ablation or removal of material such as TPU within the sheath and / or core to highlight other material such as fibers / particles within the sheath and / or core, and / or activation of material within the sheath and / or core using laser radiation).

[0035] Alternatively, or in addition, in other examples, laser radiation can be applied to one or more portions of an inner layer of a built object, such as the interior of the inner layer or one or both of the outer surfaces of the inner layer. In particular, laser radiation (e.g., laser ablation) can be applied to the interior of the inner layer (e.g., within the sheath of the inner layer in a core / sheath structure of the built object, within the core of the inner layer in a core / sheath structure of the built object, or within the core of the inner layer in a core (sheath-less) structure of the built object), which can be used to modify the interior of the inner layer in one of a variety of ways (e.g., ablation or removal of material, such as TPU, within the sheath and / or core to highlight other material, such as fibers / particles, within the sheath and / or core, and / or activation of material within the sheath and / or core using laser radiation). In this manner, laser radiation can be used to modify properties of the built object, such as moisture management (e.g., wicking and moisture absorption) and drapeability.

[0036] In one or more embodiments, plasma treatments can be used to modify the built object (after 3D printing or after braiding and / or weaving filaments), particularly to clean the surface (e.g., to remove contaminants) and functionalize the surface, modify the surface properties of the built object, such as surface energy, etc.

[0037] First embodiment 1. Overview of modeling materials Fig. 1 is a perspective view that schematically illustrates the molding material of the first embodiment. Fig. 2 is a cross-sectional view that schematically illustrates the molding material of the first embodiment. Fig. 3 is a photograph of a cross section of a prototype of the molding material of the first embodiment.

[0038] The first embodiment of the build material 1, illustrated in FIGS. 1, 2, and 3, is used to produce a shaped object. Various shaped objects are contemplated. As one example, the shaped object can be in a flat shape, similar to a piece or bolt of fabric. In such a shape, the shaped object is subjected to further processing, such as additional cutting or knotting (e.g., joining with other fabrics formed from the build material 1 or other fabrics not formed from the build material), thereby transforming the object into a resale item (e.g., a shirt, pants, handbag, etc.). As another example, the shaped object can include a final product for sale (e.g., a shirt, pants, handbag, etc.), or a semi-final product for sale (e.g., subjected to additional processing, including flocking, laser irradiation, etc.). In this case, the shaped object can be one of a variety of shapes and can be utilized at various steps in the manufacturing process.

[0039] When a molded object is produced using the molding material 1, the molding material 1 is melted, a shape is given to the molten molding material, and the shaped molding material is hardened. In one or some embodiments, this produces a molded object that is a molten and hardened product of the molding material 1. Therefore, the molding material 1 may include consumables that are consumed to produce the molded object.

[0040] In one or some embodiments, the modeling material 1 is used to manufacture a modeled object using, for example, a three-dimensional (3D) printer, such as a fused filament fabrication (FFF) method or a fused deposition modeling (FDM) method. However, in alternative embodiments, the modeling material 1 may be used to manufacture a modeled object using a modeling device other than a 3D printer, or may be used to manufacture a modeled object using a modeling method other than an FFF method or an FDM method.

[0041] In one or some embodiments, the building material 1 has a linear shape and is thermoplastic. In one or some embodiments, when the building material 1 is used to manufacture a model, the building material 1 is heated while being fed lengthwise. This melts the building material 1. In one or some embodiments, the building material 1 is flexible and elastic. A building material 1 having these characteristics is also called a filament. In one or some embodiments, when the building material 1 is used to manufacture a model using a 3D printer, the building material 1 has a circular cross-sectional shape and a diameter compatible with the 3D printer. The diameter is, for example, 1.75 mm or 2.85 mm. In FIGS. 27A and 27B, the diameter of the building material is shown as 1.75 mm. However, the building material 1 may have a cross-sectional shape other than a circular cross-sectional shape and a diameter other than 1.75 mm or 2.85 mm. In one example, the circular cross-sectional shape may be smaller than 1.75 mm. In other embodiments, the circular cross-section may be greater than 2.85 mm. In yet other embodiments, the circular cross-section may be between 1.75 mm and 2.85 mm.

[0042] In one or several embodiments, the majority of the build material 1 has thermoplastic properties, which allows the build material 1 to be melted and separated into multiple components, and allows new build materials or other types of products to be produced from the build material 1. Thus, the build material 1 is recyclable.

[0043] In one or some embodiments, the building material 1 can be sold directly in the do-it-yourself (DIY) market to consumers who build their own objects. Alternatively, or additionally, objects produced using the building material 1 can be sold to regular consumers in regular stores and regular markets.

[0044] 2. Cross-sectional structure and material of the molding material As shown in Figures 1, 2, and 3, the building material 1 has a two-layer structure and is composed of a core / sheath structure 101 including a core 111 and a sheath 112. The sheath 112 is also called a shell. The core / sheath structure 101 is also called a core / shell structure. Alternatively, the building material 1 may have a multi-layer structure of three or more layers. A building material 1 having a multi-layer structure of two or more layers (such as a three-layer structure, a four-layer structure, a five-layer structure, etc.) is also called a multifilament. In contrast to a multifilament, a building material having a single-layer structure is called a monofilament.

[0045] As one example, a three-layer structure can include a core (such as core 111), a first sheath, and a second sheath, where the first sheath is coaxially disposed between the core and the second sheath. As another example, a four-layer structure can include a core (such as core 111), a first sheath, a second sheath, and a third sheath, where the first sheath is coaxially disposed between the core and the second sheath, and the second sheath is coaxially disposed between the core and the third sheath.

[0046] In one or some embodiments, the core 111 has a linear shape. Furthermore, in one or some embodiments, the core 111 is flexible. In one aspect, the core 111 can be flexible and include a material with a lower Young's modulus and / or lower hardness (e.g., 75 Shore A or less, 70 Shore A or less, 65 Shore A or less, 60 Shore A or less, etc.). As illustrated in FIGS. 1 and 2 , the core 111 has a circular cross-sectional shape. Alternative cross-sectional shapes (e.g., elliptical, oval, etc.) are also contemplated. In this case, the core 111 may have a cross-sectional shape other than a circular cross-sectional shape. In one or some embodiments, the sheath 112 covers the outer peripheral surface 111S of the core 111. Thus, the sheath 112 is an outer layer disposed radially outward of the core 111 and is the outermost layer disposed radially outward of the molding material 1. At this time, the sheath 112 at least partially covers the outer peripheral surface 111S of the core 111. At this time, in one or some embodiments, the sheath 112 can cover the entire outer peripheral surface 111S (for example, 100% of the entire outer peripheral surface 111S). Alternatively, the sheath 112 can cover at least a portion (but not all) of the outer peripheral surface 111S (e.g., at least 50% of the outer peripheral surface 111S, at least 60% of the outer peripheral surface 111S, at least 70% of the outer peripheral surface 111S, at least 75% of the outer peripheral surface 111S, at least 80% of the outer peripheral surface 111S, at least 85% of the outer peripheral surface 111S, at least 90% of the outer peripheral surface 111S, at least 95% of the outer peripheral surface 111S, at least 96% of the outer peripheral surface 111S, at least 97% of the outer peripheral surface 111S, at least 98% of the outer peripheral surface 111S, at least 99% of the outer peripheral surface 111S).

[0047] As shown in FIG. 2 , the core 111 includes a first thermoplastic polymer 121. The sheath 112 includes a second thermoplastic polymer 122 and one or both of fibers and particles (hereinafter referred to as fibers / particles 123). Thus, in one or some embodiments, the fibers and particles can include different morphologies. In one or some embodiments, the fibers can be characterized in one of a variety of ways based on shape, etc. For example, the fibers can include strands of material in an elongated cylindrical shape having a relatively small diameter (D) (or width) and a higher length (L), thus resulting in a high L / D ratio (e.g., at least 5, at least 10, at least 15, etc.). In one or some embodiments, the particles can be characterized by shapes such as spherical, cubic, rectangular, or irregular. In one or some embodiments, the sheath 112 includes only particles. Alternatively, the sheath 112 includes only fibers. Further alternatively, both particles and fibers are contained within sheath 112. Moreover, in one or some embodiments, the fibers can include (or consist of) natural materials, synthetic materials, or both natural and synthetic materials. Similarly, in one or some embodiments, the particles can include (or consist of) natural materials, synthetic materials, or both natural and synthetic materials. In one or some embodiments, the material of one or both of the fibers and particles is selected based on the final desired feel of the final product (e.g., whether the final product is a fabric, or whether the final product is a wearable product such as a shirt, skirt, pants, handbag, etc.).

[0048] In one or some embodiments, the second thermoplastic polymer 122 serves as a matrix. The fibers / particles 123 are dispersed within the second thermoplastic polymer 122, which serves as a matrix. In one or some embodiments, the dispersion and / or distribution of the fibers / particles 123 within the second thermoplastic polymer 122 depends on one or more aspects of the extrusion / mixing process. In one or some embodiments, the fibers / particles 123 are uniformly dispersed and / or evenly distributed throughout the second thermoplastic polymer 122. Alternatively, the fibers / particles 123 are randomly dispersed and / or randomly distributed throughout the second thermoplastic polymer 122. In one or some embodiments, the fibers / particles 123 can be at least partially embedded or contained within the second thermoplastic polymer 122 at one end, with the opposite end of the fibers / particles 123 protruding from the second thermoplastic polymer 122. This allows the fibers / particles 123 to form protrusions on the surface of the manufactured object, providing a pleasant feel to the manufactured object. Additionally, the portion of the fibers / particles 123 contained or embedded within the second thermoplastic polymer 122 can contribute to the moisture management properties associated with the second thermoplastic polymer 122.

[0049] In one or more embodiments, the first thermoplastic polymer 121 and the second thermoplastic polymer 122 are the major components of the core 111 and the sheath 112, respectively.

[0050] In one or some embodiments, the first thermoplastic polymer 121 and the second thermoplastic polymer 122 can be the same type of thermoplastic polymer. Alternatively, the first thermoplastic polymer 121 and the second thermoplastic polymer 122 can be different types of thermoplastic polymer. Thus, in one or some embodiments, the first thermoplastic polymer 121 and the second thermoplastic polymer 122 are composed of the same polymer (e.g., the same type of polymer). In particular, in one or some embodiments, the first thermoplastic polymer 121 and the second thermoplastic polymer 122 can be identical in all characteristics. Alternatively, certain, but not all, properties of the first thermoplastic polymer 121 and the second thermoplastic polymer 122 can be identical, such as any one, any combination, or all of the same type, same grade, same structure, same hardness, same mechanical properties, same density, same flow properties, same crystallinity, etc.

[0051] Alternatively, the first thermoplastic polymer 121 and the second thermoplastic polymer 122 can comprise different polymers (e.g., different types of polymers). In particular, in one or some embodiments, the first thermoplastic polymer 121 and the second thermoplastic polymer 122 can differ in all characteristics. Alternatively, certain, but not all, properties of the first thermoplastic polymer 121 and the second thermoplastic polymer 122 can differ, such as any one, any combination, or all of the following: different type, different grade, different structure, different hardness, different mechanical properties, different density, different flow properties, different crystallinity, etc.

[0052] In one or some embodiments, each of the first thermoplastic polymer 121 and the second thermoplastic polymer 122 can be one type of thermoplastic polymer. Alternatively, one or both of the first thermoplastic polymer 121 and the second thermoplastic polymer 122 can be a blend of two or more types of thermoplastic polymers.

[0053] In one or some embodiments, one, some, or each thermoplastic polymer can include, for example, one or both of a rigid component and a flexible component. Thus, in one embodiment, each of first thermoplastic polymer 121 and second thermoplastic polymer 122 can include a flexible component. Alternatively, in one or some embodiments, the thermoplastic polymer can include a more rigid component and a less rigid component (alternatively, a more flexible component and a less flexible component).

[0054] In one or some embodiments, the more rigid component (e.g., the rigid component) can include, for example, a thermoplastic resin. Various thermoplastic resins are contemplated. For example, the thermoplastic resin can include any one, any combination, or all of acrylonitrile butadiene styrene (ABS), polylactic acid (PLA), polyethylene terephthalate (PET) and other polyester derivatives, polycarbonate (PC), polyvinyl alcohol (PVA), polyamide (PA), styrene-based polymers, polyvinyl chloride (PVC), acrylic-based polymers, and polyolefins such as polyethylene, polypropylene, copolymers, and combinations thereof.

[0055] In one or some embodiments, the less rigid component (e.g., the flexible component) comprises, for example, a thermoplastic elastomer. In one or some embodiments, a thermoplastic elastomer (e.g., a thermoplastic rubber) can include a class of copolymers or physical mixtures of polymers (e.g., at least one plastic and at least one rubber and / or elastomer) consisting of materials that have both thermoplastic and elastic properties.

[0056] By including a thermoplastic elastomer in one or both of the core 111 and the sheath 112, the flexibility and elasticity of the core 111 or the sheath 112 are improved, respectively, thereby improving the flexibility and elasticity of the molding material 1. Furthermore, the flexibility and elasticity of the core or the sheath provided in the manufactured object are improved, respectively, thereby improving the flexibility and elasticity of the manufactured object.

[0057] In one or some embodiments, the thermoplastic elastomer can include, for example, any one, any combination, or all of an olefin-based thermoplastic elastomer (TPO) (e.g., a thermoplastic polyolefin elastomer), a styrenic thermoplastic elastomer (TPS) (e.g., a styrenic block copolymer), a vinyl chloride-based thermoplastic elastomer (TPVC) (e.g., a thermoplastic vulcanizate), an amide-based thermoplastic elastomer (TPAE) (e.g., a thermoplastic polyamide), an ester-based thermoplastic elastomer (TPEE) (e.g., a thermoplastic copolyester), a urethane-based thermoplastic elastomer (TPU) (e.g., a thermoplastic polyurethane), an unclassified thermoplastic elastomer (TPZ), and an acrylic-based elastomer, and can include a TPU.

[0058] In one or some embodiments, the fibers / particles 123 can include one or both of natural and synthetic materials (e.g., compounds). Synthetic materials (such as synthetic fibers) are created by humans through chemical synthesis, while natural materials (such as natural fibers, natural powders, and mineral powders) can be obtained directly from living organisms (such as plants (e.g., wool or cotton)). A variety of natural materials are contemplated. Examples of natural powders and fibers include ramie, cotton, wool, silk, chitosan, and the like. Examples of mineral powders include chalk and calcium carbonate. Other examples are also contemplated.

[0059] At least one of the core 111 and the sheath 112 may include a reinforcing component. The inclusion of a reinforcing component in the core 111 or the sheath 112 improves one or more properties, such as the strength of the core 111 or the sheath 112, thereby affecting the build material 1 (e.g., improving the strength of the build material 1). Thus, in one or some embodiments, the reinforcing component affects one or more properties, such as any one, any combination, or all of strength, hardness, stiffness, density, UV resistance, optical properties, or chemical resistance. In one particular example, the strength of the core or sheath included in the manufactured object is improved, thereby improving the strength of the manufactured object. Various reinforcing components are contemplated. For example, the reinforcing component may include a filler. In one or some embodiments, the filler may include one, any combination, or all of fibers, particles, fine powders, nanoparticles, nanofibers, and similar additives. Furthermore, the filler may include, for example, one or both of natural and synthetic materials.

[0060] Furthermore, in one or more embodiments, one or both of the core 111 and the sheath 112 may include a liquid additive in addition to a plasticizer. Additionally or alternatively, one or both of the core 111 and the sheath 112 may include an additive for forming pores. By including an additive for forming pores in the core 111 or the sheath 112, multiple pores are formed in the core or sheath, respectively, of the manufactured shaped object, thereby improving the flexibility, elasticity, and breathability of the core or sheath of the manufactured shaped object. In one or more embodiments, the additive for forming pores includes, for example, one or both of a foaming agent and a blowing agent. A filament having a foamed core / sheath structure, in which either the core or the sheath is foamed but the other layer is not, has higher strength than a filament having a fully foamed structure due to the high strength and consistency of the unfoamed layer.

[0061] In one or some embodiments, the core 111 may include any one, any combination, or all of the particles, additives, mixtures, etc. that do not fall under the above-mentioned components. In one or some embodiments, any one, any combination, or all of the particles, additives, mixtures, etc. are dispersed in the first thermoplastic polymer 121 that serves as the matrix. Alternatively or additionally, the sheath 112 may include any one, any combination, or all of the particles, additives, mixtures, etc. that do not fall under the above-mentioned components. Furthermore, in one or some embodiments, any one, any combination, or all of the particles, additives, mixtures, etc. are dispersed in the second thermoplastic polymer 122 that serves as the matrix (e.g., a primary polymer component in a material that includes a base material mixed with other ingredients). In this case, one or both of the first thermoplastic polymer 121 and the second thermoplastic polymer 122 may have any one, any combination, or all of the particles, additives, mixtures, etc. dispersed therein.

[0062] In a first example, the first thermoplastic polymer 121 is a TPU having a hardness of 70 Shore A. The second thermoplastic polymer 122 is a TPU having a hardness of 60 Shore A. In this first example, the first thermoplastic polymer 121 has a higher hardness (e.g., greater resistance to indentation) than the second thermoplastic polymer 122. In this case, the first thermoplastic polymer 121 and the second thermoplastic polymer 122 can be the same type (e.g., TPU). In one embodiment, other characteristics of the first thermoplastic polymer 121 and the second thermoplastic polymer 122 can be the same (e.g., the same Shore A) or different (e.g., different Shore A).

[0063] In a second example, the first thermoplastic polymer 121 is TPU, the second thermoplastic polymer 122 is PVA, and the fibers / particles 123 are natural fibers. In this case, the first thermoplastic polymer 121 and the second thermoplastic polymer 122 can be different types (e.g., TPU and PVA).

[0064] In a third example, the first thermoplastic polymer 121 is TPU. The second thermoplastic polymer 122 is a mixture of TPU and PVA. The sheath 112 includes a foaming agent. In this case, the first thermoplastic polymer 121 and the second thermoplastic polymer 122 may include at least one common material (e.g., TPU). In one or some embodiments, both the first thermoplastic polymer 121 and the second thermoplastic polymer 122 may include an additional material that is not included in the other of the first thermoplastic polymer 121 and the second thermoplastic polymer 122 (e.g., PVA that is not included in the first thermoplastic polymer 121 but is included in the second thermoplastic polymer 122).

[0065] In a fourth example, the second thermoplastic polymer 122 is TPU and the fibers / particles 123 are natural fibers.

[0066] In a fifth example, the first thermoplastic polymer 121 and the second thermoplastic polymer 122 are TPU, and the fibers / particles 123 are ramie fibers.

[0067] Various outer diameters (and corresponding ratios) of the core 111 and the sheath 112 are contemplated. The ratio of the outer diameter of the sheath 112 to the diameter of the core 111 reflects the composition or mass fraction of the materials constituting the core 111 and the sheath 112, and can be controlled within a wide range from 1:1.01 to 1:10 (e.g., greater than 1:1 (e.g., 1:1.01), greater than 1:2 (e.g., 1:2.01), greater than 1:3 (e.g., 1:3.01), greater than 1:4 (e.g., 1:4.01), greater than 1:5 (e.g., 1:5.01)). It may also be greater than 1:10 (e.g., 1:10.01).

[0068] 3. Manufacturing method of molding material Build material 1 can be manufactured in one of a variety of ways. In one method, build material 1 can be manufactured by co-extruding the materials comprising core 111 and sheath 112 using an appropriate feedblock and nozzle. In one or more embodiments, the same manufacturing method can be applied, even when build material 1 comprises layers other than core 111 and sheath 112. Alternatively, a different manufacturing method can be used.

[0069] For example, when manufacturing the build material 1, the material constituting the core 111 and the material constituting the sheath 112 are co-extruded in a co-extrusion line. In one or some embodiments, the co-extrusion line includes two extruders, a feedblock / multi-manifold die head, and a nozzle. The two extruders respectively form two feeds containing (or consisting of) the material constituting the core 111 and the material constituting the sheath 112. The feedblock / multi-manifold die head converges the two formed feeds. The nozzle co-extrudes the build material 1 using the converged feeds.

[0070] 4. Variations FIG. 4 is a cross-sectional view schematically illustrating a modeling material according to a modified example of the first embodiment.

[0071] In the first embodiment of the molding material 1 shown in FIGS. 1, 2, and 3, the core 111 is solid. Alternatively, the core may be non-solid. For example, in a modified molding material 1M of the first embodiment shown in FIG. 4, the core 111 is porous. Therefore, in the molding material 1M, a large number of pores are formed in the core 111. This can improve any one, any combination, or all of the flexibility, flexibility, elasticity, and breathability of the core 111, and can improve any one, any combination, or all of the flexibility, flexibility, elasticity, and breathability of the molding material 1M. Furthermore, it can improve any one, any combination, or all of the flexibility, flexibility, elasticity, and breathability of the core provided in the manufactured object, and can improve any one, any combination, or all of the flexibility, flexibility, elasticity, and breathability of the manufactured object. In one or some embodiments, the porous core 111 simulates a multifilament.

[0072] Second embodiment 1. Overview of the sculpture 5 is a plan view schematically illustrating a shaped object according to a second embodiment. The shaped object 2 according to the second embodiment illustrated in FIG. 5 is manufactured using the shaped material 1 according to the first embodiment. Therefore, the shaped object 2 is a melt-hardened product of the shaped material 1. Alternatively, the shaped object may be manufactured using any other shaped material disclosed herein. As illustrated, the shaped object 2 may be composed of multiple layers (e.g., at least two layers, at least three layers, at least four layers, at least five layers, at least six layers, at least seven layers, at least eight layers, at least nine layers, or at least ten layers).

[0073] In one or several embodiments, the shaped object 2 is a new type of textile (cloth) or fabric (cloth product). The shaped object 2 constitutes, for example, clothing that can be worn on the body continuously. Various types of clothing are possible, such as clothes, hats, gloves, socks, footwear, and accessories. Alternatively, the shaped object 2 may constitute an item other than clothing.

[0074] Whether it is clothing or an item other than clothing, the object 2 may be a homemade product made by a consumer, a custom-made product made for a specific consumer, or a ready-made product made for unspecified consumers. However, the production of the object 2 using a 3D printer is suitable for homemade and custom-made products.

[0075] The structure 2 can be sold to ordinary consumers in ordinary stores and ordinary markets.

[0076] In one or more embodiments, the main portion of the shaped object 2 has thermoplastic properties, which allows the shaped object 2 to be melted and separated into multiple components, and allows new objects or other types of products to be manufactured from the shaped object 2. Thus, the shaped object 2 can be recycled after use.

[0077] The properties of the object 2 can be adjusted by any one, any combination, or all of the following: the material constituting the object 2, the structure of the object 2, the process parameters used to manufacture the object 2, etc. Various structures of the object can be considered to meet specific design and functional requirements, including any one, any combination, or all of solid, hollow, honeycomb packing, spiral packing, lattice packing, triangular packing, sparse packing, concentric packing, linear packing, support structures, and textured surfaces. Additionally, separate from but in combination with the various structures, various process parameters are contemplated to adjust or select the quality and / or characteristics of the printed object, such as any one, any combination, or all of the following: layer height (e.g., 0.05 mm or more and / or 0.8 mm or less, at least 0.1 mm and / or 0.6 mm, 0.15 mm to 0.25 mm, or 0.2 mm), number of layers (e.g., at least 2 layers, at least 5 layers), print speed (e.g., 4 mm / s or more and / or 120 mm / s or less, at least 150 mm / s, at least 160 mm / s, at least 200 mm / s, at least 300 mm / s), nozzle temperature (e.g., 190° C. or more and / or 260° C. or less, depending on the filament material), bed temperature (e.g., 25° C. or more and / or 100° C. or less), packing density (e.g., 5% or more and / or 100% or less), and wall thickness (e.g., 0.4 mm or more and / or 1.2 mm or less). The adjustments are made to improve the manufacturability of the shaped object 2 as well as any one, any combination, or all of the flexibility, softness, strength, and breathability of the shaped object 2 .

[0078] 2. Planar shape of the object As shown in FIG. 5, in one or some embodiments, the shaped object 2 includes a first linear body 201 and a second linear body 202 .

[0079] Each first linear body 201 extends in a meandering manner in a first direction D1. The first linear bodies 201 are arranged in a second direction D2. FIG. 5 illustrates a lattice structure as an example. Other lattice structures, including zigzag, anti-zigzag, wavy fill, linen, or wide waves (with vertical or horizontal lines between them), are also possible. Gaps 203 exist between adjacent first linear bodies 201. Each second linear body 202 extends in a meandering manner in the second direction D2. The second linear bodies 202 are arranged in the first direction D1. Gaps 204 exist between adjacent second linear bodies 202. The characteristics of the object 2, such as its thickness and / or cross section, can be varied by various features of the 3D printer, such as the printing nozzle of the 3D printer. Therefore, the object 2 can be modified to reflect design freedom.

[0080] In one or some embodiments, the second direction D2 is perpendicular to the first direction D1. Directions other than perpendicular, including parallel directions or directions at angles other than 90 degrees, are also possible. As a result, the first linear body 201 intersects with the second linear body 202 in a planar view. Furthermore, the object 2 has a lattice-like planar shape. Alternatively, the object 2 may have a structure different from that illustrated in FIG. 5.

[0081] In one or more embodiments, the second linear body 202 is positioned on top of the first linear body 201 in one of a variety of ways. In one method, a 3D printer can build an object layer by layer by extruding a filament through a heated nozzle and depositing and solidifying it in thin horizontal sections, thereby building the object 2 depicted in FIG. 5 . Alternatively, instead of 3D printing, different filaments can be placed on top of or woven together, and then heated to bind the various filaments together. In either case, the second linear body 202 and the first linear body 201 are bound together.

[0082] 3. Cross-sectional structure and material of the linear body Fig. 6 is a cross-sectional view schematically illustrating a linear body provided in a shaped object of the second embodiment. In Fig. 6, the shaping material is illustrated by a dashed line so that the size of the shaping material in the first embodiment can be compared with the size of the linear body provided in a shaped object of the second embodiment. Various dimensions of the shaping material are possible.

[0083] 6 may be the first linear body 201 and the second linear body 202 described above (illustrated in FIG. 5). Thus, in one or some embodiments, a reference to the linear body 210 may include the first linear body 201 and the second linear body 202.

[0084] In one or some embodiments, the linear body 210 can be comprised of a core (without a sheath). Alternatively, the linear body 210 can be comprised of a sheath. In this case, the linear body 210 is formed by longitudinally stretching the shaping material 1. This is illustrated in FIG. 6, where the linear body 210 is comprised of a core / sheath structure 221 including a core 231 and a sheath 232. In one or some embodiments, the diameter of the linear body 210 is smaller than the diameter of the shaping material 1. Alternatively or additionally, the diameter of the core 231 is smaller than the diameter of the core 111. Furthermore, alternatively or additionally, the thickness of the sheath 232 is thinner than the thickness of the sheath 112.

[0085] In one or some embodiments, the core 231 and the sheath 232 provided in the linear body 210 are derived from the core 111 and the sheath 112, respectively, provided in the molding material 1. Therefore, the core 231 has a linear shape. The sheath 232 can at least partially cover the outer peripheral surface 231S of the core 231 (for example, can entirely cover the outer peripheral surface 231S of the core 231). Alternatively, the sheath 232 can cover at least a portion (but not all) of the outer circumferential surface 231S of the core 231 (e.g., the sheath 232 can cover 50% or more of the outer circumferential surface 231S, the sheath 232 can cover 60% or more of the outer circumferential surface 231S, the sheath 232 can cover 70% or more of the outer circumferential surface 231S, the sheath 232 can cover 75% or more of the outer circumferential surface 231S, the sheath 232 can cover 80% or more of the outer circumferential surface 231S, the sheath 232 can cover 85% or more of the entire outer peripheral surface 231S, sheath 232 can cover 90% or more of the entire outer peripheral surface 231S, sheath 232 can cover 95% or more of the entire outer peripheral surface 231S, sheath 232 can cover 96% or more of the entire outer peripheral surface 231S, sheath 232 can cover 97% or more of the entire outer peripheral surface 231S, sheath 232 can cover 98% or more of the entire outer peripheral surface 231S, and sheath 232 can cover 99% or more of the entire outer peripheral surface 231S).

[0086] In one or some embodiments, the core 231 comprises a first thermoplastic polymer 121. In one or some embodiments, the sheath 232 comprises a second thermoplastic polymer 122 and fibers / particles 123. As noted above, in one or some embodiments, the first thermoplastic polymer 121 may be the same as the second thermoplastic polymer 122. Alternatively, the first thermoplastic polymer 121 may be at least partially different from the second thermoplastic polymer 122. In one or some embodiments, the fibers / particles 123 are dispersed within the second thermoplastic polymer 122. As one example, the fibers / particles 123 are dispersed within the second thermoplastic polymer 122 by combining the fibers / particles 123 with the second thermoplastic polymer 122 using a two-stage screw compounding or similar melt-mixing process. In one or some embodiments, the core 231 and the sheath 232 included in the linear body 210 may contain the components that the core 111 and the sheath 112 included in the modeling material 1 may contain. The core 231 may be a porous body.

[0087] Further, in one or more embodiments (as illustrated in FIG. 6), sheath 112 completely covers core 111. Alternatively, sheath 112 covers at least a portion (but not all) of the outer periphery of core 111 (e.g., at least 50%, 60%, 70%, 75%, 80%, 85%, 90%, 95%, 96%, 97%, 98%, or 99% of the outer periphery of core 111).

[0088] Fig. 7 is a scanning electron microscope (SEM) photograph of the entire cross section of a linear body provided in a prototype of the object of the second embodiment. Fig. 8 is an SEM photograph of the peripheral part of the cross section of a linear body provided in a prototype of the object of the second embodiment.

[0089] In the SEM photograph of Fig. 7, although a clear interface between the core 231 and the sheath 232 cannot be seen, the fibers / particles 123 are hardly visible in the region that will become the core 231, and dispersed fibers / particles 123 can be seen in the region at the tip of the arrow 233 that will become the sheath 232. Furthermore, in the SEM photograph of Fig. 8, although a clear interface between the core 231 and the sheath 232 cannot be seen, the fibers / particles 123 are hardly visible in the region that will become the core 231, and dispersed fibers / particles 123 can be seen inside the circle that will become the sheath 232. Therefore, it can be seen from the SEM photographs of Figs. 7 and 8 that the fibers / particles 123 are contained in the sheath 232 and are dispersed in the second thermoplastic polymer 122. It should be noted that the reason why a clear interface between the core 231 and the sheath 232 cannot be identified is that, in one embodiment, the second thermoplastic polymer 122, which is the main component of the sheath 232, is similar to the first thermoplastic polymer 121, which is the main component of the core 231, and may even be the same as the first thermoplastic polymer 121.

[0090] 9 is an enlarged cross-sectional view schematically illustrating the vicinity of the interface between the object and human skin in contact with the object according to the second embodiment. As shown in FIG. 9, linear body 210 includes linear body main body 241 and protrusion 242.

[0091] The linear body main body 241 constitutes the main portion of the linear body 210. The protrusions 242 protrude from the outer peripheral surface 241S of the linear body main body 241, forming characteristic irregular concaves and convexes on the outer peripheral surface of the linear body 210. In one or some embodiments, in the filament shape, the particles are generally uniformly dispersed within the matrix (e.g., polymer), although the dispersion may depend on any one, any combination, or all of the following: particle type (e.g., chemical structure), particle length, dispersion level, mixing intensity, particle-polymer compatibility, etc. Nevertheless, by appropriately controlling one or more of the above-mentioned characteristics, the dispersion of the particles within the matrix can be sufficiently predetermined.

[0092] In one or some embodiments, the fibers / particles 123 include crossing fibers / crossing particles 251 that cross the outer circumferential surface 241S of the linear body main body 241. One end of the crossing fibers / crossing particles 251 is embedded in the second thermoplastic polymer 122 that constitutes the linear body main body 241. This fixes the crossing fibers / crossing particles 251 to the linear body main body 241, preventing the crossing fibers / crossing particles 251 from falling off from the linear body main body 241. The remaining portions of the crossing fibers / crossing particles 251 protrude from the outer circumferential surface 241S of the linear body main body 241 and are covered by the second thermoplastic polymer 122 that constitutes the protrusions 242. This prevents the crossing fibers / crossing particles 251 from being exposed, preventing direct contact between the crossing fibers / crossing particles 251 and human skin 261. The protrusions 242 comprise the remainder of the crossing fibers / crossing particles 251 and the second thermoplastic polymer 122 covering the remainder of the crossing fibers / crossing particles 251. The second thermoplastic polymer 122 comprising the linear body 241 and the second thermoplastic polymer 122 comprising the protrusions 242 are continuous and integral. Alternatively, in one or some embodiments, the crossing fibers / crossing particles 251 are present within the sheath layer (e.g., outside the outer surface of the core) and are not covered by the second thermoplastic polymer 122 because the crossing fibers / crossing particles 251 protrude from the core (e.g., because the crossing fibers / crossing particles 251 were originally added to the core and then processed via an applied force, such as an electrostatic charge, as described below).

[0093] The irregular asperities formed are similar to those formed when the packing ratio of fibers / particles dispersed in a matrix is ​​high. The asperities can be described as "mountains and valleys" or "peaks and valleys." In the linear body 210, the protrusions 242 form mountains (e.g., peaks), and the spaces between adjacent protrusions 242, i.e., the regions rich in the second thermoplastic polymer 122, form valleys.

[0094] The size of the irregular asperities formed can be controlled by the shape, size, etc. of the fibers / particles 123. Thus, the roughness of the surface of the model 2 can be controlled by the shape, size, etc. of the fibers / particles 123. For example, in one or some embodiments, one or more processing parameters and / or settings of the 3D printer can also affect the roughness (e.g., peaks and valleys).

[0095] When human skin 261 comes into contact with the shaped object 2, the human skin 261 comes into contact with the protrusions 242, and gaps 262 are formed between the human skin 261 and outer peripheral surface 241S of the linear body main body 241. An air flow can be generated in the formed gaps 262. Therefore, when the human skin 261 comes into contact with the shaped object 2, the air flow generated in the gaps 262 can quickly dry the human skin 261 and effectively cool the human skin 261. Therefore, the shaped object 2 does not have a rubber-like or plastic-like feel, but has a cloth-like feel and is comfortable to the touch.

[0096] Furthermore, when the human skin 261 comes into contact with the shaped object 2, the human skin 261 can deflect the protrusions 242 with a weak force. Furthermore, the human skin 261 only weakly contacts the surface of the shaped object 2, and the frictional force generated between the human skin 261 and the shaped object 2 is small. This gives the shaped object 2 a soft feel.

[0097] 10 and 11 are SEM photographs of a cross section of a prototype of the object of the second embodiment. In the SEM photographs of Fig. 10 and Fig. 11, it can be seen that protrusions 242 protrude from sheath 112 and form irregular irregularities on the outer peripheral surface of linear body 210.

[0098] Figures 12 and 13 are SEM photographs of the cross section of a prototype of a molded object manufactured using monofilament, and Figures 14 and 15 are SEM photographs of the top surface of a prototype of a molded object manufactured using monofilament.

[0099] In the SEM photographs of Figures 12, 13, 14, and 15, it can be seen that the surfaces of the linear bodies provided on the prototypes of the objects manufactured using the monofilaments are smooth and clean, with no significant irregularities. Note that the white spots in the SEM photographs of Figures 14 and 15 are dust.

[0100] The object 2 having the above-mentioned characteristics has any one, any combination, or all of flexibility, strength, breathability, wicking properties, controlled roughness and smoothness, a cloth-like feel, and a comfortable feel. The color of the object 2 can also be changed.

[0101] Fig. 16 is an SEM photograph of a prototype of a molded object manufactured using a molding material according to a modified example of the first embodiment. Fig. 17 is a micrograph of a polyester monofilament. Fig. 18 is a micrograph of a polyester multifilament.

[0102] The polyester monofilament shown in Figure 17 is strong, hard, and stiff. For this reason, polyester monofilament cannot be used for clothing. Furthermore, when this monofilament is used, it is not possible to form irregular irregularities on the surface of a shaped object.

[0103] On the other hand, the polyester multifilament shown in Figure 18 is softer and less stiff than monofilament. For this reason, polyester multifilament can be used for clothing. Furthermore, when this multifilament is used, irregular irregularities can be formed on the surface of a model. However, when polyester multifilament is used, it is not possible to print a model using a 3D printer.

[0104] In the SEM photograph of Figure 16, it can be seen that irregular irregularities are formed on the surface of the model produced by a 3D printer using the modeling material 1M whose core 111 is porous.

[0105] 4. Manufacturing method of the object FIG. 19 is a side view schematically illustrating a 3D printer used to manufacture a modeled object according to the second embodiment. The 3D printer 271 shown in FIG. 19 prints a modeled object 2 using a modeling material 1 by one or more methods, such as the FFF method. Hereinafter, the modeling material 1 includes a filament. In this regard, the filament described below generally refers to any modeling material 1.

[0106] A filament spool 281 is attached to the 3D printer 271. The 3D printer 271 includes a print head 282, a drive mechanism 283, and a plate 284. The 3D printer 271 can further include control electronics 285 that can communicate wired and / or wirelessly (see 289) with any one, any combination, or all of the print head 282, drive mechanism 283, and plate 284. An example of the control electronics 285 is further shown in FIG. 42.

[0107] Control electronics 285 is configured to control various portions of 3D printer 271 to perform the 3D printing described herein. Control electronics 285 can include at least one processor 286 (such as CPU 4202 of FIG. 42) and at least one memory 287 (such as one or both of RAM 4206 and ROM 4208). In one or some embodiments, processor 286 can include a microprocessor, controller, PLA, etc. Similarly, memory 287 can include any type of storage device (e.g., any type of memory). Memory 287 can be a tangible, non-transitory, computer-readable storage medium that stores software, including instructions. The instructions are executed by processor 286 (functioning as part of a computer) (see FIG. 42) to perform the 3D printing described herein.

[0108] Although processor 286 and memory 287 are depicted as separate elements, they may be part of a single machine that includes a microprocessor (or other type of controller) and memory. Alternatively, processor 286 may rely on memory 287 for all of its memory needs.

[0109] Processor 286 and memory 287 are just one example of control electronics 285. Other types of control electronics are contemplated. For example, all or part of the implementation can be a circuit that includes a type of controller that includes an instruction processor, such as a central processing unit (CPU), microcontroller, or microprocessor, or an application specific integrated circuit (ASIC), programmable logic device (PLD), field programmable gate array (FPGA), or other circuit components or discrete logic that include analog circuit components, digital circuit components, or both, or a combination thereof. The circuit can include separate interconnected hardware components or can be combined into a single integrated circuit die, distributed across multiple integrated circuit dies, or implemented within a multi-chip module (MCM) of multiple integrated circuit dies within a common package, for example.

[0110] A filament spool 281 supplies filament. In one or some embodiments, the print head 282, under the control of a control electronic device 285, melts the supplied filament to generate a melt and ejects the generated melt 288. The print head 282 is positioned vertically above the upper surface 284S of the plate 284. As a result, the ejected melt 288 falls and is supplied onto the upper surface 284S of the plate 284. The melt 288 may be supplied directly onto the upper surface 284S of the plate 284, or may be supplied onto the upper surface 284S of the plate 284 over a melt already supplied onto the upper surface 284S of the plate 284 or a solidified version of that melt.

[0111] In one or more embodiments, the drive mechanism 283 includes one or more motors and, under the control of the control electronics 285, moves the print head 282 in a direction parallel to the top surface 284S of the plate 284 (e.g., the control electronics 285 can send one or more commands to the motors 294 of the drive mechanism 283 to move the print head 282), thereby moving the location where the melt 288 is dispensed. The drive mechanism 283 can position the location where the melt 288 is dispensed anywhere within the printing range.

[0112] The plate 284 supports the supplied melt 288. The supported melt 288 hardens into a molten solid. Therefore, the plate 284 supports the molten solid.

[0113] When the 3D printer 271 prints the object 2 under the control of the control electronic device 285, the drive mechanism 283 moves the print head 282 above a linear region where the linear body 210 provided on the object 2 is to be printed, while causing the print head 282 to eject the molten material 288. As a result, a linear molten material is formed above the linear region. The formed linear molten material hardens to become the linear body 210.

[0114] The print head 282 includes a filament feeder 291, a heater 292, and a nozzle 293. Under the control of the control electronics 285, the filament supplied to the print head 282 is inserted into the filament feeder 291. The filament feeder 291 feeds the inserted filament lengthwise to insert the filament into the heater 292.

[0115] In one or some embodiments, the heater 292, under the control of the control electronics 285, heats the inserted build material 1 (e.g., a filament) to generate a melt 288, and supplies the generated melt 288 to the nozzle 293. The nozzle 293 ejects the supplied melt 288.

[0116] When the print head 282 melts the filament to generate the melt 288, the core / sheath structure is maintained. Thus, the filament 210 has a core / sheath structure 221. However, in one or some embodiments, the diameter of the filament 210 is smaller than the diameter of the filament as the filament is stretched. Furthermore, in one or some embodiments, the thickness of the sheath 232 is thinner than the thickness of the sheath 112. For example, the diameter of the filament 210 is approximately 1 / 4 of the diameter of the filament. In this case, in one or some embodiments, the diameter of the filament is, for example, at least twice the diameter of the filament 210, at least three times the diameter of the filament 210, at least four times the diameter of the filament 210, at least five times the diameter of the filament 210, or at least six times the diameter of the filament 210. Furthermore, the thickness of the sheath 232 is approximately 1 / 4 of the thickness of the sheath 112. In this case, in one or some embodiments, the thickness of sheath 112 is, for example, at least twice the thickness of sheath 232, at least three times the thickness of sheath 232, at least four times the thickness of sheath 232, at least five times the thickness of sheath 232, or at least six times the thickness of sheath 232. Therefore, in this case, a filament having a diameter of 1.75 mm results in a filament 210 having a diameter of approximately 0.40 mm. Also, a sheath 112 having a thickness of 0.2 mm results in a sheath 232 having a thickness of approximately 0.05 mm.

[0117] The size of the fibers / particles 123 contained in the sheath 112 of the filament 1, for example, the length of the fibers or the diameter of the particles, is selected to be sufficiently smaller than the thickness of the sheath 232 of the linear body 210 to be printed. Therefore, it is unlikely that the fibers / particles 123 will penetrate into the core 231 when the object 2 is printed. Therefore, most of the fibers / particles 123 remain in the sheath 232, and some of the fibers / particles 123 become intersecting fibers / intersecting particles 251 that intersect with the outer peripheral surface 111S of the linear body main body 241.

[0118] Third embodiment 1. Overview of flock products Fig. 20 is a plan view schematically illustrating a flock product of the third embodiment, and Fig. 21 is an enlarged cross-sectional view schematically illustrating the vicinity of the interface between the flock product of the third embodiment and human skin in contact with the flock product.

[0119] The flocked product 3 of the third embodiment shown in Figures 20 and 21 is a product in which a flocked object is produced using a molding material. The flocked product 3 is a new type of textile or fabric. The flocked product 3 constitutes, for example, clothing that can be worn on the body continuously. Various types of clothing are possible, such as clothes, hats, gloves, socks, footwear, and accessories. Alternatively, the flocked product 3 may constitute an item other than clothing.

[0120] The object, which is clothing or a non-clothing item, may be a homemade product made by a consumer, a custom-made product made for a specific consumer, or a ready-made product made for an unspecified consumer. However, the production of objects using a 3D printer and the production of flocked products 3 by flocking are suitable for homemade and / or custom-made products.

[0121] The flock product 3 has thermoplastic properties.

[0122] 2. Structure of flock products As shown in Figures 20 and 21, the flock product 3 includes a main body 301, an adhesive layer 302, and flock 303. The main body 301 is a molded object produced using a molding material, i.e., a molded object that is a molten and hardened product of the molding material. The molding material may be a molding material having a single layer structure, the molding material 1 of the first embodiment having a multi-layer structure, or another molding material, including a thermoplastic polymer. In one or some embodiments, the main body 301 is produced using a 3D printer. Alternatively, the main body 301 may be the molding material itself.

[0123] The adhesive layer 302 is disposed on the surface 301S of the body 301 and covers the surface 301S of the body 301. The adhesive layer 302 adheres the flock 303 to the surface 301S of the body 301, securing the flock 303 onto the surface 301S of the body 301. Various types of adhesion are contemplated. In one or some embodiments, heat may be used for curing. Alternatively, curing / drying may be performed at room temperature. In one or some embodiments, the type and / or time of curing depends on the type of adhesive used.

[0124] In one or some embodiments, the flock 303 is attached to the adhesive layer 302 in one of a variety of ways. In one or some embodiments, the flock 303 penetrates the adhesive layer 302. Alternatively, the flock 303 is attached to the adhesive layer 302 without penetrating (through contact only).

[0125] Thus, in one or some embodiments, piercing occurs only when an external force is applied. As one example, the applied force may include strong electrostatic forces generated during processing, where charged fibers experience a strong attraction toward the grounded substrate due to the opposite charge. Upon reaching the adhesive, the combination of electrostatic and adhesive forces causes the fibers to embed themselves (e.g., pierce). Thus, in one or some embodiments, the result is a dense, textured stack of fibers perpendicular to the surface or standing upright on the substrate. One end of the flock 303 is embedded in the adhesive layer 302. The remainder of the flock 303 is positioned outside the adhesive layer 302. Thus, in one or some embodiments, the flock 303 protrudes from the adhesive layer 302.

[0126] As shown in Figure 21, when human skin 311 comes into contact with the flock product 3, the human skin 311 comes into contact with the flock 303, and a gap 321 is formed between the human skin 311 and the surface of the structure consisting of the main body 301 and the adhesive layer 302. Airflow can be generated in the formed gap 321. Therefore, when the human skin 311 comes into contact with the flock product 3, the airflow generated in the gap 321 can quickly dry the human skin 311 and effectively cool the human skin 311. Therefore, the flock product 3 does not have a rubber-like or plastic-like feel, but has a cloth-like feel and is comfortable to the touch.

[0127] Furthermore, when human skin 311 comes into contact with the flock product 3, the human skin 311 can deflect the flock 303 with a weak force. Furthermore, the human skin 311 only weakly contacts the surface of the flock product 3, and the frictional force generated between the human skin 311 and the flock product 3 is small. This gives the flock product 3 a soft feel.

[0128] In one or more embodiments, the body 301 comprises a thermoplastic polymer. In one or more embodiments, the thermoplastic polymer is preferably a thermoplastic polyurethane. The properties of the body 301 can be tailored by the build material used in its manufacture.

[0129] The adhesive layer 302 can comprise (consisting of) a cured adhesive. In one or some embodiments, the adhesive is tailored to fit the body 301 and the flock 303.

[0130] In one or more embodiments, the adhesive is a thermoplastic adhesive or a thermosetting adhesive. In this regard, in one or more embodiments, a thermosetting adhesive can be used alone as the adhesive. When the adhesive is a thermosetting adhesive, the durability of the adhesive layer 302 can be improved. On the other hand, when the adhesive is a thermoplastic adhesive, electrostatic deposition of the flock 303 can be easily performed.

[0131] In one or some embodiments, the adhesive is a polymer adhesive, such as a polyurethane adhesive or an acrylic adhesive, and in particular, only a polyurethane adhesive. When the adhesive is a polyurethane adhesive, a flexible polyurethane is contained in the adhesive layer 302, which can prevent the adhesive layer 302 from impairing the flexibility of the flock product 3. The polyurethane adhesive is, for example, a water-based or solvent-based polyurethane dispersion, or liquid polyurethane.

[0132] In one or some embodiments, the flock 303 includes one or both of fibers and particles. The flock 303 includes one or both of natural and synthetic materials (e.g., compounds). Natural materials include, for example, any one, any combination, or all of cotton, wool, and viscose. Alternatively, the natural materials may include materials other than cotton, wool, and viscose. Compounds may include any one, any combination, or all of polyester, polyamide (e.g., nylon), polyurethane, polylactic acid (PLA), polyethylene, and polypropylene. Alternatively, the compounds may include materials other than polyester, polyamide, polyurethane, polylactic acid, polyethylene, and polypropylene.

[0133] The flock fibers have a length of, for example, 0.1 mm to 5 mm, e.g., 0.4 mm to 0.8 mm. If the flock fiber length is shorter than these ranges, the flock fibers may be embedded in the polymer and not protrude from the surface, which may not affect the surface feel. Also, if the protruding portion of the flock fiber is too short, the fibers may remain standing, causing a scratchy feel. If the flock fiber length is longer than these ranges, the weight of the fibers may be too great, which may result in insufficient fiber deposition during the flocking process. If the flock fiber is too long, the fibers may collapse, resulting in a loss of fluffy feel.

[0134] Flock fibers typically have a diameter of at least 1 μm and up to 100 μm or greater. Flock fibers smaller than this range generally generate large amounts of dust during manufacturing, potentially causing lung disease if they reach the lungs. End users of the product may also experience similar problems when the flock fibers adhere to the surface of the printed fabric. Furthermore, the fibers may lose strength and durability may be compromised. Flock fibers larger than this range may be difficult to fit into the sheath, making it difficult to flock (e.g., embed or disperse) the fibers in the polymer. Fibers that are too large may also feel stiff, resulting in a loss of softness and a poor tactile experience.

[0135] In the first example, the main body 301 is made of a monofilament made of TPU. The adhesive is a polyurethane adhesive. The flock 303 is made of cotton fiber. This makes the main body 300 soft and the surface of the flock product 3 comfortable to the touch, making the flock product 3 a comfortable garment.

[0136] In a second example, the body 301 is manufactured using a core / sheath (e.g., a sheath containing fibers and / or particles). The adhesive is a polyurethane-based adhesive. In one example, the flock 303 can comprise the same type of material as the fibers and / or particles in the sheath (e.g., both are cotton). Alternatively, the flock 303 can comprise a different type of material than the fibers and / or particles in the sheath (e.g., one natural fiber and the other synthetic fiber (e.g., flock 303)). The combination of the sheath and flock makes the body 300 soft and also provides a multi-layered feel on the surface of the flock product 3, making the flock product 3 a comfortable garment.

[0137] As shown in FIGS. 20 and 21 , the flock product 3 includes a first linear body 331 and a second linear body 332. Therefore, in one or more embodiments, the description of FIG. 20 is similar to that of FIG. 5 . Therefore, in one or more embodiments, the description of FIG. 5 can also be applied to FIG. 20 . As an example, the description of the first linear body 201 and the second linear body can also be applied to the first linear body 331 and the second linear body 332, respectively. Each first linear body 331 extends in a meandering manner in the first direction D1. The first linear bodies 331 are arranged in the second direction D2. A gap 333 exists between adjacent first linear bodies 331. Each second linear body 332 extends in a meandering manner in the second direction D2. The second linear bodies 332 are arranged in the first direction D1. A gap 334 exists between adjacent second linear bodies 332. In one or some embodiments, the second direction D2 is perpendicular to the first direction D1. Alternatively, the second direction D2 is not perpendicular to the first direction D1. As a result, the first linear bodies 331 intersect with the second linear bodies 332 in a plan view. The flock product 3 also has a lattice-like planar shape.

[0138] In one or some embodiments, the second linear body 332 is disposed on top of the first linear body 331. More particularly, the second linear body 332 contacts the first linear body 331. As above, the joining of the first linear body 331 and the second linear body 332 is performed in one of a variety of ways, including using heat (e.g., placing a molten thermoplastic material on a previously deposited layer), building the object layer by layer, or 3D printing by interweaving the first linear body 331 and the second linear body 332 in a sequentially layered manner.

[0139] The flocked product 3 having the above-mentioned characteristics has any one, any combination, or all of the following characteristics: softness, comfort, breathability, wicking, controlled roughness and smoothness, or has a cloth-like feel and a comfortable feel. That is, flocking can transform 3D printed objects into truly wearable textiles or fabrics. The color of the flocked product 3 can also be changed.

[0140] 3. Manufacturing method of flock products FIG. 22 is a perspective view schematically illustrating a device for generating an applied force, such as an electrostatic deposition device used in the production of a flock product according to the third embodiment. The electrostatic deposition device 341 shown in FIG. 22 is an up-type electrostatic deposition device that causes flocks 303 to fly in a predetermined direction, such as vertically upward. Alternatively, the electrostatic deposition device may cause flocks 303 to fly in various other directions, such as downward or lateral. In this case, the electrostatic deposition device 341 may be an electrostatic deposition device other than an up-type electrostatic deposition device. For example, the electrostatic deposition device 341 may be a down-type electrostatic deposition device that causes flocks 303 to fly vertically downward.

[0141] 22, the electrostatic deposition apparatus 341 includes a first electrode 351, a second electrode 352, a chamber 353, and a power supply 354. In one or some embodiments, the first electrode 351 has a flat plate-like shape. Furthermore, in one or some embodiments, the first electrode 351 is installed horizontally.

[0142] In one or some embodiments, the second electrode 352 has a flat lattice shape. Furthermore, in one or some embodiments, the second electrode 352 is disposed vertically above the first electrode 351. In one or some embodiments, the second electrode 352 is installed horizontally. Therefore, the second electrode 352 is parallel to the first electrode 351. In one or some embodiments, the second electrode 352 is grounded. In one or some embodiments, the chamber 353 houses the first electrode 351 and the second electrode 352.

[0143] In one or some embodiments, the power supply 354 generates a high DC voltage. The positive terminal 361 of the power supply 354 is electrically connected to the first electrode 351. The negative terminal 362 of the power supply 354 is electrically connected to the second electrode 352 and is grounded. This allows the generated high DC voltage to be applied between the first electrode 351 and the second electrode 352. Other electrical connections between the first electrode 351 and the second electrode 352 are also possible.

[0144] When the flocks 303 are electrostatically deposited on the workpiece 371, the flocks 303 are placed on the upper surface 351S of the first electrode 351. Furthermore, the workpiece 371 is placed above the second electrode 352. Thereafter, the power supply 354 applies a high DC voltage between the first electrode 351 and the second electrode 352. As a result, the flocks 303 are charged by the applied voltage, and the charged flocks 303 fly from the upper surface 351S of the first electrode 351 to the second electrode 352 and then to the workpiece 371. At this time, the charged flocks 303 pass through a gap formed in the second electrode 352. The flocks 303 that have reached the workpiece 371 adhere to the workpiece 371. As a result, the flocks 303 are electrostatically deposited on the workpiece 371.

[0145] FIG. 23 is a flow diagram showing the manufacturing process of the flocked product of the third embodiment. When the flocked product 3 is manufactured, any one, any combination, or all of steps S101 to S106 shown in FIG. 23 are performed. Step S101 is a primary process of printing the main body 301 using a 3D printer. Steps S102 to S105 following step S101 are secondary processes performed on the surface of the printed main body 301 to modify the texture and / or appearance of the surface of the main body 301 by electrostatic deposition, i.e., electrostatic flocking. In this regard, in one or some embodiments, the manufacturing of the flocked product may be performed by a continuous process including the primary process of printing the main body 301 and the secondary process of modifying the texture and / or appearance of the surface of the main body 301 (e.g., by electrostatic deposition).

[0146] In step S101, a main body 301, which serves as a processing object, is manufactured. In one or some embodiments, the main body 301 is manufactured by a 3D printer and by the FFF method. Alternatively, the main body 301 may be manufactured by a modeling device other than a 3D printer, or by a modeling method other than the FFF method.

[0147] In the next step S102, the adhesive layer 302 is disposed on the surface 301S of the main body 301. This creates a workpiece 371 consisting of the main body 301 and the adhesive layer 302. In one or some embodiments, the liquid adhesive is applied to the surface 301S of the main body 301 by spraying, brushing, roller coating, doctor blade, or the like. The application of the liquid adhesive can be triggered in one of a variety of ways. In one method, the application of the liquid adhesive can be triggered in response to a determination that the adhesive layer 302 has been disposed on the surface 301S of the main body 301. This determination can be based on one or more sensors, such as a camera, analyzing one or more images of the adhesive layer 302 and / or the surface 301S of the main body 301 by the control electronics 285 to determine that the adhesive layer 302 has been disposed on the surface 301S of the main body 301. In this regard, the control electronics 285 is configured to perform image analysis (e.g., image segmentation and / or object recognition) of the one or more images to determine that the adhesive layer 302 has been disposed on the surface 301S of the body 301. Alternatively, or additionally, the control electronics 285 can command one or more motors 294 of the drive mechanism 283 to move the adhesive layer 302 and the surface 301S of the body 301 relative to one another (e.g., move the adhesive layer 302 so that it is disposed on the surface 301S of the body 301). The control electronics 285 can wait a predetermined period of time (without detecting that the adhesive layer 302 has actually been disposed on the surface 301S of the body 301) before applying the adhesive.

[0148] In one or some embodiments, a thin adhesive layer 302 can be applied over at least a portion of the surface 301S of the body 301, for example, the thin adhesive layer 302 can be applied to extend over the entire surface 301S of the body 301. In one or some embodiments, the applied adhesive is selected to be compatible with electrostatic deposition. The applied adhesive layer 302 promotes adhesion between the flock 303 and the body 301.

[0149] In the subsequent step S103, one or both of the flock 303 and the workpiece 371 are introduced into the chamber 353. At this time, the flock 303 is placed on the upper surface 351S of the first electrode 351. Furthermore, the workpiece 371 is placed vertically above the second electrode 352. Alternatively, the flock 303 and the workpiece 371 may be placed in different orientations relative to each other.

[0150] In the subsequent step S104, the flock 303 can penetrate the adhesive layer 302. This allows the flock 303 to penetrate the adhesive layer 302, thereby establishing a bond between the flock 303 and the adhesive layer 302. In one or some embodiments, the flock 303 penetrates the adhesive layer 302 by electrostatic deposition. In this process, the power supply 354 applies a high DC voltage between the first electrode 351 and the second electrode 352. This charges the flock 303, causing the charged flock 303 to fly or move from the upper surface 351S of the first electrode 351 to the second electrode 352 and onto the workpiece 371. The flock 303 that reaches the workpiece 371 adheres to the adhesive layer 302. As a result, the flock 303 is adhered to the surface 301S of the main body 301 via the adhesive layer 302 and covers the surface 301S of the main body 301. This provides a new tactile sensation. One end of the attached flock 303 is at least partially inserted into the adhesive layer 302, e.g., embedded in the adhesive layer 302 and fixed thereto. In one or some embodiments, the remainder of the attached flock 303 is disposed outside the adhesive layer 302. This allows the flock 303 to at least partially protrude from the adhesive layer 302 and be at least partially embedded in the adhesive layer 302. This allows the flock 303 to be stuck into the adhesive layer 302 while protruding from the adhesive layer 302. If the flock 303 is a fiber, the flock 303 can be stuck into the adhesive layer 302 while being approximately perpendicular to the surface 301S of the main body 301. This allows the electrostatic field to move the flock 303 upward, thereby allowing it to adhere perpendicularly to the surface. In particular, the vertical sticking of the flock 303 dramatically increases the surface area, thereby improving the density and final tactile feel of the product.

[0151] In a subsequent step S105, adhesive layer 302 is cured. While at least partially cured (e.g., during a general curing step), adhesive layer 302 is dried and baked, such as by heating.

[0152] In the next step S106, cleaning is performed, in which excess flock 303 that is not adhered to the main body 301 by the adhesive layer 302 is removed. In this way, the flock product 3 is completed.

[0153] In one or more embodiments, the flocking may be performed manually, such as with a handheld electrostatic applicator. Alternatively, the flocking may be performed at least partially automatically. For example, any one, any combination, or all of steps S101, S102, S103, S104, S105, and S106 may be performed automatically.

[0154] Figure 24 is a photograph of a prototype of the main body provided in the flocked product of the third embodiment. Figure 25 is a photograph of a prototype of the flocked product of the third embodiment. Comparing the main body 301 before flocking shown in Figure 24 with the flocked product 3 after flocking shown in Figure 25, it can be seen that flocking allows complex irregularities to be formed on the surface of the flocked product 3.

[0155] Step S102 of placing adhesive layer 302 on surface 301S of body 301 and step S104 of piercing flock 303 into adhesive layer 302 require only a short time, e.g., 3-10 minutes. Further time reductions are possible if the process is automated. In one or some embodiments, step S105 of curing adhesive layer 302 requires a long time, e.g., several hours (e.g., at least 1 hour, at least 2 times, at least 3 times, at least 5 times, at least 10 times, or at least 20 times longer than one or both of steps S102 and S104). However, depending on the adhesive selected, it is possible to reduce the time required for step S105.

[0156] The coverage of the flocs 303 on the surface 301S of the main body 301 can be adjusted by adjusting one or more parameters of the electrostatic deposition in step S104. For example, by adjusting any one, any combination, or all of the voltage and / or current of the electrostatic unit, the height between the electrodes, the height of the substrate from the electrodes, and the flocking time (e.g., current application time), the entire surface 301S of the main body 301 can be uniformly covered with the flocs 303, or the surface 301S of the main body 301 can be covered with the flocs 303 so that the density of the flocs 303 has a gradient.

[0157] The feel of the flock product 3 can be adjusted by adjusting any one, any combination, or all of the flock 303 type, decitex (dTex), and length. Additionally, various types of fibers can be flocked, including natural or synthetic fibers, including cotton, wool, polyester, polyamide, or rayon. In one or more embodiments, decitex is the number of grams of thread per 10,000 meters of length. The density of the flock 303 can be adjusted by adjusting the body 301, adhesive properties, flock 303 properties, and process conditions.

[0158] In one or more embodiments, the flock 303 is insensitive to one, some, or all of the materials of the body 301, but can be adjusted by the choice of adhesive. This allows for the production of a flock product 3 suitable for a variety of applications. In this regard, the properties of the flock product 3 are insensitive to the properties of the body 301, but can be adjusted by the choice of adhesive, because the adhesive layer 302 acts as an intermediate layer connecting the flock 303 to the body 301. In one or more embodiments, the quality of the flocking is affected by any one, any combination, or all of the body, adhesive layer, type of flock, or parameters of the flocking process.

[0159] In one or more embodiments, two or more types of flock 303 may be combined to provide structure and properties in the flock product 3 that are not available with a single type of flock 303.

[0160] In one or more embodiments, a factory may be established to perform the above-described manufacturing method of flock products in response to customer requests or seasonal collections, performing the above-described primary and secondary processes. In particular, a factory may be established to perform only the above-described secondary process in response to customer requests, in which case the body 300 is provided by the customer.

[0161] A variety of fibers are contemplated, particularly current implementations of fibers available on the market today, including the following fibers:

[0162] (i) Monofilament: These fibers are relatively stiff, making them unsuitable for clothing. These fibers are generally non-breathable or have limited breathability. These fibers do not have moisture-wicking properties, so moisture (e.g., sweat) remains on the surface of garments woven with monofilament fibers. These properties of monofilament fibers, when woven into clothing, make the garment uncomfortable.

[0163] (ii) Multifilament: Multifilament fibers have properties that provide a soft feel to garments woven from such fibers. Multifilament fibers are considered more breathable than monofilament fibers, allowing more moisture to pass through materials woven using these fibers (compared to materials woven using monofilament fibers). Such materials also have better moisture-wicking properties (compared to materials woven using monofilament fibers), meaning that moisture (e.g., sweat) is not retained on the surface but is wicked away by the material.

[0164] Current TPU filaments on the market are monofilament structures, which are stiff and uncomfortable, making them not suitable fiber candidates for producing wearable fabrics.

[0165] A feature of the present invention relates to the design and manufacture of filament structures referred to herein as "comfort fibers" (also referred to as "fibers"). These filament structures are also referred to as "comfort filaments." Comfort fibers inherently include properties like moisture wicking, providing softness and comfort to the wearer of a garment constructed from these filaments. In one aspect, comfort fibers can include any one, any combination, or all of the desired characteristics of multifilament fibers. An example of a comfort fiber is shaped material 1. In one aspect, comfort fibers can include one or both of the following:

[0166] (i) Outer Layer (also known as the “sheath”). This layer can be similar to sheath 112. In one aspect, the sheath can include one or more types of natural powders and fibers (e.g., ramie, cotton, wool, silk, chitosan) to add texture to the outer surface of the sheath. In another aspect, the sheath can include one or more types of natural powders mixed with the fibers (e.g., when producing a sheath with a higher aspect ratio). Generally, the sheath can include any one, any combination, or all of powders, natural fibers, and additives combined in suitable proportions to produce a comfort fiber with one or more desired properties (e.g., moisture wicking properties and similar). These materials can be dispersed within the sheath as a plurality of particles. When water droplets or other moisture accumulate on a first surface of the fabric (e.g., the inner surface that contacts the skin of an individual wearing the fabric), in a fabric formed from one or more comfort fibers, these particles can wick water vapor from the surface. As part of this moisture wicking process, water vapor can pass through the powder and be transported to a second surface (e.g., the outer surface) of the fabric. This transport can occur via the capillary effect. Such structures are also softer and less artificial than current materials such as polyolefin-based fibers (PP and PE fibers) and polyurethane fibers.

[0167] (ii) an inner core similar in structure and properties to core 111;

[0168] FIG. 26 shows comparative cross-sectional views of a comfort fiber and a current filament. A conventional multifilament is illustrated in FIG. 26A, and a comfort fiber is illustrated in FIG. 26B. The comfort fiber is shown to consist of a foam core axially encased within a sheath. In another aspect, the core is not foamed. The comfort fiber can be designed to incorporate desired qualities of the multifilament (e.g., flexibility, breathability, moisture wicking, etc.). A foam core can provide multifilament properties such as flexibility and / or breathability to the comfort fiber. FIG. 26 illustrates how a conventional multifilament fiber performs moisture wicking. FIG. 26 also illustrates that the comfort fiber provides similar moisture wicking properties described herein.

[0169] Generally, multifilaments are strong, stiff structures with limited deformability and shape control during the weaving / braiding process (or lower deformability and higher shape control than monofilaments during the weaving / braiding process). In the final state (e.g., as a fabric), the multifilaments are held in position only by frictional forces formed between adjacent multifilaments. During the weaving / braiding process, the multifilaments can be constrained in a crisscross (e.g., weft and warp) pattern or a unidirectional (e.g., braid) pattern.

[0170] In contrast to multifilaments, comfort fibers can be shaped during production into different geometric shapes and are not constrained to a crisscross or unidirectional pattern. In the final state (e.g., as a fabric), comfort fibers can be held together by heat welding.

[0171] The moisture-wicking effect of multifilament fibers is based on several strategies, including any one, any combination, or all of the following: multilayer structure, chemical modification, and surface modification (e.g., plasma treatment). The mechanism for reducing or removing moisture / water molecules from the skin within multifilament fibers, especially in fast-wicking / drying fabrics, is based on the hydrophobic and capillary effect of the inner (skin-contacting) layer and the hydrophilicity of the outer layer, allowing for excellent moisture diffusion and evaporation. The differential capillary effect and water affinity between the different layers are key to wicking and fast-drying properties. If a fabric is designed not to support fast-drying using the above strategies, the drying process will be slower due to the large surface area and capillary effect, which limit the diffusion and removal / desorption of moisture and water molecules. In contrast, the moisture-wicking effect of comfort fibers may be based on a different mechanism. Moisture and water molecules are adsorbed and then absorbed within the comfort fibers due to the porous structure with surface protrusions that increase the surface area and the presence of highly hydrophilic particles (e.g., cotton, wool, ramie, etc.) on the surface. The combination of hydrophilic particles and large surface area can increase the absorption of moisture and water molecules from the skin into the comfort fabric.

[0172] In one or some embodiments, quick drying is also made possible by the comfort fiber structure through any one, any combination, or all of three mechanisms: (i) localizing hydrophilic materials only on the surface, thereby reducing the effective paths for diffusion, (ii) reducing or minimizing the capillary effect that slows the drying process, and (iii) the porous open structure of the printed fabric allows moisture transport and evaporation. Thus, comfort fibers can have desirable properties comparable to, and in some cases superior to, multifilament fibers.

[0173] SEM micrographs demonstrating this concept are described below.

[0174] The design features of comfort fibers allow them to be processed (e.g., used to design and build) into final products (e.g., garments or apparel) using techniques such as 3D printing, bonding, heat pressing, weaving, knitting, crocheting, braiding, non-woven processes, and other textile applications, in any one, any combination, or all of these. 3D printing can offer the advantage that the production of final products using comfort fibers is not limited to large-scale textile facilities; individuals with a 3D printer and related experience can manufacture articles using comfort fibers at home or in relatively small facilities. Using comfort fibers with similar properties to multifilament is advantageous in this regard, because multifilament cannot be used to manufacture final products using techniques such as 3D printing. In this regard, comfort fiber technology can democratize the production of comfort textiles, providing small-scale clothing designers with more options for designing comfort garments and more localized manufacturing options, thereby reducing impact on the supply chain. Designers have access to customizable design choices (e.g., any one, any combination, or all of color, mechanical properties, chemical properties, tactile feel, flexibility, moisture wicking and similar properties, breathability, etc.) The use of 3D printing and the small scale manufacturing afforded by this process allows for product customization and other benefits, such as a more tailored fit, customized designs and design details, branding, fabric patterns, etc.

[0175] Another advantage of comfort fibers is that they are manufactured to be recyclable, thereby providing environmentally friendly properties, which is very important considering the amount of non-biodegradable clothing that ends up in landfills.

[0176] In one aspect, the steps involved in producing the comfort fiber can include one or both of filament production or 3D printing.

[0177] Filament Manufacturing As described above, filaments can be used for 3D printing. Filaments can be produced by one of a variety of methods. See FIGS. 28 and 43. For example, in one or some embodiments, as a first step, an elastomer, such as a thermoplastic elastomer (TPU or equivalent) or other thermoplastic polymer, is mixed with natural powder via a process (such as twin-screw extrusion). This is shown, for example, in step S201 of FIG. 28. The amount of fiber mixed with the polymer can range between 5 and 40% by weight, although lesser or greater amounts can be used. Any one, any combination, or all of the powder content, powder / fiber type, and associated aspect ratio can be relevant factors in controlling the morphology of the final printed product (e.g., comfort fiber). In one or some embodiments, natural powder can be used for this purpose. Additionally, in one or more embodiments, the orientation of the fibers and / or particles is controlled via one or more processing techniques, such as any one, any combination, or all of the following: print angle, print speed, particle length, relative thickness of the sheath layer (e.g., relative to particle length), or viscosity of the polymer in which the fibers and / or particles are contained within the sheath layer. Control of the orientation of the fibers can thereby be used, for example, to control the effect of the fibers on the skin of a user of the built article.

[0178] In one aspect, a twin-screw extruder (described further below) can be used for the melting / mixing step, and its mixing capabilities can result in a homogeneous mixture. This, in turn, can result in better dispersion and distribution of particles within the polymer matrix, reducing or minimizing agglomeration that can adversely affect the properties of the filament as well as the printed article. The compound resulting from the twin-screw extrusion process can be one of the raw materials used in the next step of filament production.

[0179] As a second step, converting the feedstock into a filament (e.g., for 3D printing applications) is performed, for example, via a co-extrusion process. See step S202 of FIG. 28. In such a process, two different extruders convey melt streams to a die head. The melt streams are formed into a coaxial structure having a core and a sheath layer. In one aspect, the filament diameter is approximately 1.75 mm. While 1.75 mm is more common among users, the process is not limited to that particular diameter, and other diameters (e.g., 2.8 mm, etc.) may be produced. Generally, filament diameters greater or smaller than 1.75 mm may be used. The two most common filament diameters in FDM / FFF processes are 1.75 mm and 2.85 mm, although other diameters are contemplated.

[0180] As discussed above, various hardware for producing the filament is contemplated. One exemplary block diagram 4200 of hardware is illustrated in FIG. 42, in which multiple extruders are used, such as a core extruder 4210 and a sheath extruder 4220. As discussed above, the core is comprised of a single material. Alternatively, the core may include multiple materials. In examples where the core is comprised of a single material, a single extruder can be used. In examples where the core includes multiple materials (e.g., TPU and fibers / particles), a twin-screw extruder can be used.

[0181] Thus, in one or some embodiments, the raw materials can be used as is (e.g., in their natural form, such as intact plastic pellets). Alternatively, the raw materials may be used as compounds containing different additives and / or polymers. A combination of the two is also contemplated. Furthermore, in one or some embodiments, the core layer is mostly based on a thermoplastic elastomer, but other additives may be added during extrusion to impart different properties to the final filament / printed article.

[0182] Similarly, in instances where the sheath contains multiple materials, a twin-screw extruder can be used. Furthermore, while the raw materials for the sheath layer are based on the compounds described herein, other additives and / or polymers may be introduced during the extrusion of the filaments. These additives and / or polymers are added to achieve desired properties. The sheath layer is responsible for the roughness formed on the surface of the filaments, and this feature, along with the material properties following the printing process, determines the textile properties of the printed fabric.

[0183] In one or some embodiments, the extruder can perform one or more functions, such as inserting material into a vat, container, etc., melting material, mixing the molten material, and / or squeezing / extruding the mixed / molten material from the extruder to a die head. In this regard, the extruder can generally include a gearbox / motor 4214, 4224 (e.g., working in conjunction with a gearbox to generate motion and translate the motion to rotate one or more screws), a feeder 4212, 4222 (e.g., feeding material to a predetermined desired portion of the vat or container), one or more screws 4216, 4226 (e.g., a single screw in a single-screw extruder, two screws in a twin-screw extruder, for rotating the material in the vat), and a heater 4218, 4228 (e.g., for heating the material in the vat). Thus, in one embodiment, the core extruder 4210 can include a single-screw extruder (having a single screw) for mixing a single material. Alternatively, the core extruder 4210 can include a twin-screw extruder (having at least two screws) for mixing multiple materials. Additionally, the sheath extruder 4220 for mixing multiple materials for the sheath can include a twin-screw extruder having at least two screws. In one or some embodiments, one or more sensors can be positioned in or on the vat or vessel to provide feedback to one or both of the heaters 4218, 4228 and the controller 4270 to regulate the amount of heat generated by the heaters 4218, 4228 to heat one or more pumps used to extrude the molten / mixed materials (not shown in FIG. 42 ).

[0184] Thus, the molten / mixed material from each of the core extruder 4210 and the sheath extruder 4220 is routed to different portions of the die head 4230, i.e., the output from the core extruder 4210 is routed to the core portion 4232, and the output from the sheath extruder 4220 is routed to the sheath portion 4234. In one or some embodiments, the length of the die head 4230 can be at least 100 mm or at least 200 mm. In practice, the material extruded into the die head is cooled, resulting in a filament. Various methods for cooling the material are possible, such as using a drawing device 4240 to draw the material from a cooling device 4250 (e.g., a cooling bath). A winding / collection device 4260 (e.g., a motor and / or a spool) is then configured to collect the cooled filament.

[0185] 42 also illustrates a controller 4270, which may include one or more controllers. As shown, the controller 4270 is external to any one, any combination, or all of the core extruder 4210, sheath extruder 4220, drawing device 4240, cooling device 4250, and winding / recovery device 4260. Alternatively, or additionally, the controller 4270 may be internal to any one, any combination, or all of the core extruder 4210, sheath extruder 4220, drawing device 4240, cooling device 4250, and winding / recovery device 4260. Furthermore, a central controller may control any one, any combination, or all of the core extruder 4210, sheath extruder 4220, drawing device 4240, cooling device 4250, and winding / recovery device 4260. Alternatively, or in addition, a local controller (resident or associated) may be used to control any one, any combination, or all of the core extruder 4210, sheath extruder 4220, drawing device 4240, cooling device 4250, and winding / recovery device 4260 (in response to commands sent from the central controller and / or based on its own analysis).

[0186] In practice, the controller 4270 may communicate via wired and / or wireless communication (as shown at 4280). Furthermore, in practice, any one, any combination, or all of the functions of the core extruder 4210, the sheath extruder 4220, the drawing device 4240, the cooling device 4250, and the winding / recovery device 4260 may be automatically controlled by the controller 4270. By way of example, any one, any combination, or all of the feeders 4212, 4222, the gearbox / motors 4214, 4224, the one or more screws 4216, the at least two screws 4226, and the heaters 4218, 4228 may be automatically controlled by the controller 4270.

[0187] FIG. 43 illustrates an example flow diagram 4300 for manufacturing a filament. In step 4310, materials are fed into one or more machines, with a first set of materials for the core (which may consist of a single material or include multiple materials) being fed into a first machine and a second set of materials for the sheath being fed into a second machine. In step 4320, the materials are heated in each machine (e.g., the first set of materials is heated in the first machine and the second set of materials is heated in the second machine). After melting the materials, in step 4330, the materials are mixed in each machine. In step 4340, the mixed / molten materials are extruded from each machine into different portions of a die head (e.g., the first set of materials for the core is extruded into the core portion of the die head and the second set of materials for the sheath is extruded into the sheath portion of the die head). In step 4350, the materials are cooled to form a filament.

[0188] In one or more embodiments, the core / sheath area / diameter ratio (eg, cross-section / area ratio) becomes an important factor and can be adjusted / balanced to achieve desired properties.

[0189] With regard to the material selection for the sheath layer, the final roughness is adjusted by the amount of particles and / or fibers introduced into the compound in the manner described above. A greater amount of particles and / or fibers is used to densify (e.g., increase) the roughness, while a smaller amount of particles and / or fibers is used to minimize the roughness. In another aspect, control of the surface roughness can also be achieved by varying the aspect ratio of the particles.

[0190] Figures 27A and B illustrate two different embodiments of comfort fibers. Figure 27A is a cross-sectional view of a comfort fiber with a medium particle loading within the associated sheath layer. Figure 27B is a cross-sectional view of a comfort fiber with a high particle loading within the associated sheath layer. This sheath layer is characterized by a relatively high content (higher density) of natural fibers. Varying the density of particles within the sheath layer can be used to change the properties of the printed article / fabric.

[0191] Because the sheath layer is kept relatively thin in most cases, friction between the die wall and the particles and / or fibers during extrusion pushes the particles toward the surface of the filament. This, in turn, creates roughness that masks the "plastic-like feel" of the filament or printed article. The resulting filament emerging from the die lip is introduced into a cooling bath for cooling, and then dried and collected. The end product of this process is a comfort fiber. At this point, Figures 27A and B illustrate at least three things: (1) Objects 3D printed from filaments with a core / sheath structure generally maintain the core / sheath structure within the printed layers, (2) the shape can change (e.g., the diameter of the 3D printed layers within the object can become smaller, by at least a factor of two or even a factor of four, see a reduction from 1.75 mm to 0.4 mm), and (3) one or more materials within the sheath of the filament can protrude from the 3D printed layers of the object (e.g., fibers and / or particles within the filament, such as the natural fibers illustrated in Figures 27A and B, can be pushed outward from the sheath of the 3D printed layers, thereby potentially accentuating the effect of the fibers and / or particles on the user's skin).

[0192] Different filaments with a range of properties can be produced by varying any one, any combination, or all of the following: material composition, core / sheath ratio, extrusion process parameters, extruder and die head configuration, etc.

[0193] 3D printing (e.g., for manufacturing objects) In one aspect, the comfort fiber can be used to manufacture a final product (e.g., an article of clothing) by 3D printing. See step S203 of FIG. 28, where 3D printing is performed on the comfort fiber to form the comfort fiber into a desired final shape. The comfort fiber is introduced into a 3D printer, which forms the comfort fiber into the desired final shape. Because the flow generated within the print head is laminar, the coaxial structure of the comfort fiber is maintained during the printing process, and the particles and / or fibers are pushed toward the outer surface of the printed layer. As the filament shrinks during printing, the overall diameter as well as the relative diameter of the core / sheath layer is reduced (depending on the die head). This, in turn, can push the particles and / or fibers to protrude from the surface of the printed layer, creating the desired roughness. Another parameter that controls the level of protrusion (i.e., roughness) is the ratio between the length of the particle / fiber and the thickness of the sheath layer. Longer fibers cause significant protrusion from the surface, thus increasing the number and roughness of the fibers on the surface. The aspect ratio of the particle / fiber also affects its stiffness. This can alter the softness and feel of the printed article / fabric. The resulting combination of roughness and material properties can impart a soft feel to the final product (e.g., the final printed article / textile). In this regard, various characteristics of the comfort fiber, including one or both of roughness and stiffness, can be controlled based on the selection of particles / fibers, based on at least one characteristic of the sheath (e.g., the polymer thickness of the sheath layer), or based on one or both of the particles / fibers and the sheath (e.g., the ratio between the length of the particles / fibers and the thickness of the sheath layer).

[0194] Any one, any combination, or all of the filament structure, material composition, printing process parameters, printer configuration, and print geometry can determine the final properties of the fabric or textile produced using the comfort fibers. Properties including any one, any combination, or all of breathability, wicking and similar properties, moisture control, quick-drying, hand, drape, and soft feel can be adjusted during each of the manufacturing processes to modify the final properties. The comfort fibers may also be processed using the flocking process described herein. As discussed above, a flow diagram of the comfort fibers and a method for producing articles of clothing from the comfort fibers is illustrated in FIG. 28.

[0195] In one embodiment, fabrics / textiles printed using comfort fibers are not limited to the crisscross weave and / or knit directions prevalent in the textile industry, and therefore multi-directional patterns can be achieved by properly processing the comfort fibers.

[0196] Various characteristics of the comfort fabric can include any one, any combination, or all of the following:

[0197] (i) Avoiding the "plastic-like" or "artificial" feel of other consumable filaments available on the market by adding a functional sheath layer.

[0198] (ii) The surface roughness created by the sheath layer after the printing process and / or the material composition of this layer can impart any one, any combination, or all of the following properties to printed articles produced using the comfort fibers: soft feel, air tunnels (e.g., when in contact with the skin), wicking-like effects, quick drying, or reduced coefficient of friction.

[0199] (iii) The combination of materials within the sheath layer can be used to "tune" or "alter" the resulting properties and roughness described in (ii).

[0200] (iv) The resulting core / sheath structure can impart any one, any combination, or all of the following properties to the printed article: comfortable feel, flexibility, resilience, breathability, air permeability, antibacterial properties, high strength, moisture permeability, lightweight (e.g., due to foaming), or design flexibility (e.g., custom / made to order).

[0201] (v) The combination of materials in the core / sheath layers and / or the ratio between the core and sheath can be used to adjust the properties described in (iv). The printing process itself can provide additional design dimensions that can be used to modify the properties described in (iv).

[0202] (vi) Final products printed from the above structures (unflocked) can be recycled.

[0203] (vii) The printed filaments can be printed directly onto different types of substrates, including any one, any combination, or all of the following: surfaces, textile fabrics, apparel, plastics and polymers, metals, and ceramics.

[0204] Post-processing of 3D printed fabric Various post-treatments of 3D printed fabrics are contemplated. For example, in one or more embodiments, fabrics produced using non-flocked comfort fibers generally do not have the feel of flocked fibers, regardless of the filament used to produce the fabric. In addition to flocking, a combination of one or more other treatments can be applied to the printed article after 3D printing for additional benefits, such as softness. Such treatments can include any one, any combination, or all of laser ablation, plasma treatment, surface texturing / roughening, and cleaning techniques.

[0205] For example, in one or some embodiments, laser ablation can include controlling at least one laser to direct laser energy (laser radiation) at the surface of the object. Indeed, the laser energy can alter at least a portion of the object, such as one or both of (i) the surface and (ii) the interior of the object, via heat generated in or on the object. As one example, laser ablation can affect the surface of the object (e.g., the texture or roughness of the surface, fibers and / or particles on the surface) via heat. Alternatively, or additionally, laser ablation can affect the interior of the object (additives in an inner layer of the object can be affected or activated by the laser energy).

[0206] As one example, laser ablation can be used on a structure, such as a structure formed from the above-described build material 1 having at least one sheath 112. In particular, the structure can include one or more layers, with at least one, at least some, or all layers having a core / sheath structure. Alternatively, or additionally, the structure can be partially (or entirely) composed of a layer having a core structure, with laser ablation affecting one, some, or all layers of the structure, including the interior of the layer and / or one or both of the surfaces of the layer having the core structure.

[0207] In particular, laser ablation can affect a build in one of a variety of ways, such as one or both of: (i) affecting the surface of the build (e.g., the surface of a layer of the build) and (ii) affecting the interior of the build (e.g., the interior of a layer). For example, laser ablation can generate heat within a sheath layer to affect one or more materials within the sheath layer (e.g., laser energy affecting one or more materials within the sheath, such as affecting the TPU of the sheath, thereby highlighting fibers and / or particles within the sheath of the build, and / or directly affecting fibers and / or particles within the sheath, as described below). As one example, laser ablation can form uniform and / or non-uniform patterns, such as micropatterns (textures) on the surface of a build (e.g., the top layer of a printed fabric or other type of feature), to achieve different surface properties, such as a soft feel, a cloth-like feel, moisture management (e.g., wicking), and surface energy tuning (e.g., hydrophobicity / hydrophilicity of the surface), any combination thereof, or all of these. In one or more embodiments, the ablated pattern can be unidirectional or multidirectional and need not be limited to a specific shape. By way of example only, laser ablation can add texture to the surface of a shaped object to achieve a predetermined shape, such as a "hair-like" structure that can easily conform to the applied force. Typical apparel, upon closer inspection, has tiny or loose fibers on its surface. These loose fibers can escape the grasp of the main textile, creating a pleasing tactile experience. These tiny particles contribute to a softer feel and promote a more skin-responsive fabric. With this in mind, one goal of using laser treatment is to alter surfaces to mimic these tiny "hair-like" patterns, which can make the user feel more comfortable and softer. Ultimately, when such tiny elements touch the skin, the user can easily bend them, thereby exerting less pressure on the skin. Additionally, the gaps formed between the fibers and the skin improve breathability.While theoretically desirable, such a shape is very difficult to achieve through the printing process. Therefore, a second process, laser irradiation, is used to achieve such an effect. In response to the use of a laser with micron-scale resolution (e.g., less than 1 mm), the surface of the object can be altered to mimic a "hair-like" shape, or at least form tiny elements on the surface of the object that improve interaction with the skin.

[0208] Thus, in one or some embodiments, the high resolution (e.g., micron-scale or sub-1 mm) of a laser is used to geometrically alter a surface to meet predetermined requirements and characteristics. Thus, in one or some embodiments, laser ablation can affect the surface of a built object (e.g., the surface of the sheath 112 of the built object).

[0209] Alternatively, or in addition, laser ablation can create effects within the build, such as (i) within the sheath of a layer of the build, and / or (ii) within the core of a layer of the build (e.g., by affecting fibers and / or particles (fibers / particles 123) within the sheath to provide a more pronounced or noticeable effect (after 3D printing) to the end user of the build). As one example, laser ablation can expose protruding fibers by removing a thin polymer film covering the surface of the fibers and / or particles. Exposing fibers / particles within the sheath of each layer (e.g., the top layer exposed to the skin) can improve skin interaction through intimate contact, thus improving or maximizing the potential of the fibers / particles embedded in the sheath layer. Exposing fibers and / or particles can also adjust the “surface chemistry” to control / adjust the hydrophobicity / hydrophilicity of the surface. This allows laser heat to expose fibers and / or particles up to or near the surface of the build, thereby affecting the tactile feel of the product. Alternatively, or in addition, various additives, such as fibers / particles 123 within the sheath, can be affected by the laser heat (e.g., the fibers / particles 123 are activated by the laser heat). Thus, in one or some embodiments, the hydrophobicity / hydrophilicity of a surface can be determined by any one, any combination, or all of: (i) forming a pattern on the surface of one or more layers of the build; (ii) exposing fibers / particles within the sheath; and (iii) activating or altering the chemistry of the material within the sheath.

[0210] As another example, laser ablation can be used on a built object that includes a core (e.g., core 111) composed of a single material and / or with additives (e.g., fibers and / or particles) but no sheath. In such an example, laser ablation can affect the surface of the built object (e.g., the surface of core 111), and the fibers and / or particles within the core can have a noticeable effect on the user after laser ablation. This allows laser ablation to affect one or more surfaces of the built object, potentially exposing the fibers and / or particles for easier contact with the end user's skin. Alternatively, or additionally, additives within core 111 can be similarly activated by laser heat. Still alternatively, a built object that includes a layer that includes (or consists of) a core of a single material can be altered by potentially removing a portion of the core material through laser ablation, thereby mechanically affecting a layer (e.g., outer and / or inner layer) of the built object.

[0211] As described above, laser ablation can affect one or more layers of the object. As one example, laser ablation can affect the surface of a printed fabric that directly contacts the user's skin. Alternatively, or in addition, laser ablation can affect an inner layer of the object (e.g., a layer that is effectively hidden from the user). In particular, laser ablation can be performed from different directions on "hidden" layers of the object that do not directly contact the skin or are off-center from the main linear body (e.g., by removing one or more printed layers from the direction of the linear body that contacts the skin). Thus, by selectively ablating hidden surfaces, properties such as moisture management (e.g., wicking and moisture absorption) and drape can be tailored.

[0212] As described in more detail below, the laser radiation generated by the laser can be controlled to be directed in a controlled manner to any portion of the object, such that the laser radiation can affect the surface of one or more layers of the object and / or can affect the interior of one or more layers of the object (e.g., within the sheath and / or within the core).

[0213] Laser ablation can thereby alter a build in one of a variety of ways, including altering the surface (e.g., creating a different roughness, texture, or pattern) and / or the interior (e.g., altering mechanical properties and / or increasing remaining material by activating interior additives and / or removing material). In one particular example, the roughness / texture of a build's layers can be determined by any one, any combination, or all of the ablation regime, process parameters, and material response to the laser. Generally, the finer the detail (e.g., the desired texture), the less roughness there will be. In this regard, strategic, controlled application of laser ablation can provide post-processing of a build after 3D printing. Thus, in one or some embodiments, laser ablation applied after 3D printing can effectively modify or enhance the 3D printing process. Indeed, a filament, such as a monofilament or multifilament, can have predetermined properties (e.g., roughness) before 3D printing. 3D printing can alter these properties, for example, altering the filament's roughness during the production of the build. This allows laser ablation to control surface properties such as roughness due to 3D printing or the desired predetermined texture of the surface after the 3D printing process.

[0214] Figure 44 is a block diagram 4400 of an exemplary laser projection system for use in conjunction with 3D printer 271. In particular, Figure 44 illustrates a part printed by 3D printer 271. In one or some embodiments, the part is automatically delivered (such as by a conveyor) to the laser projection system, which may include any one, any combination, or all of laser 4410, lens 4420, mount 4450, motor / robot 4440, and controller 4270. Alternatively, the part is manually delivered to the laser projection system.

[0215] Additionally, the use of more than one laser is contemplated, such as a single laser / lens combination or multiple individual laser / lens combinations. In one or some embodiments, laser 4410 can include a UV laser. Alternatively, other wavelength lasers are contemplated. Additionally, laser 4410 can include one or more laser processing parameters that can be controlled by controller 4270, as described below. Additionally, lens characteristics can be selected for a given application of laser irradiation. In particular, any one, any combination, or all of the following laser processing or lens parameters can be selected and / or controlled by controller 4270: Laser power and / or intensity, laser resolution (e.g., higher resolution results in more accurate pattern representation and finer detail in the ablated surface), laser wavelength, lens dimensions (e.g., diameter), lens-to-substrate distance and / or focal position (e.g., affected by movement of one or both of lens 4420 and mount 4450 by motor / robot 4440, as described below), irradiation field, scan speed (e.g., faster speed results in faster processing, and scan speed also affects potential heat accumulation in or on layers of the build), pulse energy (e.g., higher energy, deeper and wider features), pulse frequency (e.g., higher frequency results in faster processing, and pulse frequency also affects potential heat accumulation in or on layers of the build), shape of the ablated pattern, distance between lines, line depth, etc. (e.g., the shape pattern can only be the desired shape / texture, but the final texture is determined by a combination of the processing parameters and the desired shape), shape pattern of the surface being processed (e.g., the shape of a printed fabric).

[0216] Other process parameters that affect the application of laser radiation can include the material composition of the sheath layer and / or the core / sheath ratio. For example, with regard to the material composition of the sheath layer, the laser response to the substrate is largely influenced by the chemistry of the material. Different additives (added to one or both of the core and sheath) can be used to tune the laser response to some extent. Additives may be introduced into the sheath if deeper laser penetration into each layer is desired to achieve specific properties. Furthermore, the core / sheath ratio can affect the laser response, such as when specific additives are introduced into the sheath to enhance the response. Various materials or additives that react or change in response to laser radiation are contemplated. As one example, carbon-based materials such as carbon black can enhance the laser response. Alternatively, or in addition, different dyes can improve the laser response of polymers (e.g., using one or both of tin and antimony to increase the laser response of polymers). As another example, shelf-like additives can be used to increase the polymer's response to laser ablation.

[0217] Additionally, the object 4430 can be held in or on a mount 4450. In one or more embodiments, one, some, or each of the layers of the object 4430 can have a core / sheath structure. Alternatively, or additionally, one, some, or each of the layers of the object 4430 can be configured in a core structure (without a sheath). In either case, the laser radiation generated by the laser 4410 can affect one or more layers (e.g., the surface of each layer and / or the interior of each layer).

[0218] 44 also illustrates a motor / robot 4440 and a controller 4270. As described above, the controller 4270 can be configured to control one or more devices, such as any one, any combination, or all of the laser 4410, the mount 4450, and the motor / robot 4440. Indeed, the controller 4270 can be configured to control one or more parameters associated with the laser 4410 (e.g., any one, any combination, or all of the laser power / intensity, laser resolution, laser wavelength, scan speed, pulse energy, pulse frequency, etc.). Alternatively, or additionally, the controller 4270 can be configured to control the motor / robot 4440 to mechanically manipulate and / or move various objects. As one example, the controller 4270 can be configured to control the motor / robot 4440 to move the build 4430 to the mount 4450.

[0219] As another example, the controller 4270 can be configured to control the motor / robot 4440 to move the lens 4420 and the laser 4410 relative to one another (e.g., hold the laser 4410 stationary and move the lens 4420, hold the lens 4420 stationary and move the laser 4410, or move both the laser 4410 and the lens 4420), thereby achieving relative movement of the laser 4410 and the lens 4420 in one of various axes (e.g., defining movement in any direction), for example, along any one, any combination, or all of the x-axis, y-axis, and z-axis.

[0220] As yet another example, the controller 4270 can be configured to control the motors / robots 4440 to move the lens 4420 / laser 4410 and the mount 4450 (or mount 4450 / build 4430) relative to one another by moving one or both of the lens 4420 / laser 4410 and the mount 4450 (or mount 4450 / build 4430) (e.g., by holding the lens 4420 / laser 4410 stationary and moving the mount 4450, by holding the mount 4450 stationary and moving the lens 4420 / laser 4410, or by moving both the lens 4420 / laser 4410 and the mount 4450), thereby achieving relative movement of the lens 4420 / laser 4410 and the mount 4450 in one of various axes (e.g., defining movement in any direction), e.g., along any one, any combination, or all of the x-axis, y-axis, and z-axis.

[0221] In one or more embodiments, the controller 4270 can be configured to control the focus of the laser radiation generated by the laser 4410 relative to the object 4430 to apply the laser radiation in a predetermined manner within or on various portions of the object 4430. As described above, the laser radiation can be applied to alter one or more layers of the object 4430. As one example, the outer layer of the object (which contacts the user's skin) can be altered by the laser radiation. In such cases, the laser radiation alters the surface of the outer layer (e.g., the surface that directly contacts the user's skin), resulting in a pattern, etching, or the like. Alternatively, or additionally, the laser radiation can alter the interior of the outer layer (e.g., the interior of the core and / or sheath layer of a sheath / core structure of the outer layer, the interior of the core of a core structure of the outer layer). As one example, the laser radiation can include laser ablation, which effectively removes material or portions of the outer layer. As one particular example, the laser irradiation can ablate the TPU (or other material) within the sheath of each outer layer, thereby potentially increasing the amount of other material within each outer layer (e.g., fibers and / or particles within the sheath of the outer layer) and / or potentially changing the mechanical properties of the sheath of each outer layer. This is similar to adding PVA (or other water-soluble material) to the outer layer, and after washing, the PVA can be removed from the outer layer (e.g., from the sheath of the outer layer). In contrast, because the laser irradiation is controlled or directed, the ablated portion can be more tightly controlled to more selectively remove material from the outer layer. Alternatively, or additionally, in another particular example, the laser irradiation can ablate the TPU (or other material) within the core of each outer layer, thereby potentially increasing the amount of other material within the core of each outer layer or potentially changing the mechanical properties of the core of each outer layer. In yet other particular instances, laser irradiation can alter certain additives within the respective outer layers (e.g., within the sheath and / or core), effectively enhancing the response of the particular additive.

[0222] In another example, inner layers (not in contact with the user's skin) of the object 4430 can be altered by laser irradiation. As described above, inner layers (or hidden layers) of the object 4430 can be altered by selectively applying laser irradiation to hidden surfaces, or by selectively ablating portions of the interior or surface of each inner layer, thereby changing properties of the object 4430, such as moisture management and / or drapeability. In one particular example, the laser irradiation can effectively remove material or portions of the inner layer (e.g., remove a portion of the TPU in each inner layer), thereby affecting the mechanical properties of the inner layer and / or increasing other material in the inner layer (e.g., within the sheath and / or core of each inner layer). In this case, the laser irradiation can be controlled or directed so that the ablated portions are more tightly controlled to more selectively remove material from the hidden layers. In yet another particular example, the laser irradiation can alter certain additives within each inner layer (e.g., within the sheath and / or core), effectively enhancing the response of the particular additive.

[0223] As described above, controller 4270 can be configured to direct the laser radiation generated by laser 4410 to a predetermined portion within or on the build 4430. For example, the focal point of the laser radiation generated by laser 4410 can be varied by controller 4270, as described above. In this regard, the focal point of the laser radiation can be positioned in a predetermined manner relative to each layer (e.g., outer and / or inner layers) of build 4430 to affect each layer of build 4430. Thus, the focal point of the laser radiation can be positioned in one of a variety of ways relative to each layer, including any one, any combination, or all of "above" (e.g., closer to laser 4410), within each layer, or "below" (farther from laser 4410) each layer. This allows controller 4270 to direct the laser radiation in a highly directed, pinpointed manner to achieve the results described above.

[0224] To that end, Figure 45 illustrates an exemplary flow diagram 4500 for performing laser ablation. In step 4510, a build is placed in or on a mount. In step 4520, one or both of the laser / lens and mount are moved in preparation for laser processing. In step 4530, the laser is manipulated (e.g., while one or both of the laser / lens and mount are moving and / or while the laser / lens and mount are stationary) to direct laser radiation to a predetermined layer in or on the build.

[0225] Another example of post-processing of a built object is plasma treatment. In one or more embodiments, plasma surface treatment can be used to modify the surface properties of a built object, such as surface energy, surface functionalization, and cleaning (e.g., cleaning of contaminants). In this regard, plasma treatment can be used to modify the composition of the sheath layer (e.g., adjusting the chemistry within the sheath layer to increase / decrease its reaction and reactivity to the plasma) and / or to generate a geometric pattern on the treated surface. Various parameters of plasma treatment can be considered, such as adjusting the plasma power (e.g., higher power results in more extensive modification and / or potential degradation), plasma exposure time, plasma pressure (e.g., lower pressure, more energetic particles, deeper modification), and gas composition (e.g., determining the reactive species and resulting in specific surface changes).

[0226] Various hardware for performing plasma processing is contemplated, an example of which is illustrated in block diagram 4600 of FIG. 46. In particular, FIG. 46 shows that a model can be printed by a 3D printer 271. In one or some embodiments, the model can be automatically transported (such as by a conveyor) to the plasma processing device, which can include any one, any combination, or all of the following: a vacuum plasma chamber device 4610, a gas injector 4620, a gas pump 4640, a motor / robot 4440, and a controller 4270. Alternatively, the product can be manually transported to the plasma processing device.

[0227] In particular, FIG. 46 illustrates a vacuum plasma chamber apparatus 4610 (also referred to as a plasma chamber or plasma enclosure) including a plasma generator 4630 and an electrode 4632, within which a build 4430 is placed. In one or more embodiments, plasma processing is performed in the vacuum plasma chamber apparatus 4610 under vacuum (e.g., vacuum plasma). Air within the chamber or enclosure is pumped out using gas pump 4640 and gas line 4642 prior to gas introduction. Gas is then introduced into the vacuum plasma chamber apparatus 4610 at low pressure using gas injector 4620 and gas line 4622. This occurs before any energy (e.g., power) is applied. Thus, plasma processing performed at low temperatures treats heat-sensitive materials, such as one or more layers of the build 4430.

[0228] In one or some embodiments, the plasma generator 4630 can generate the radio frequency (RF) power necessary to generate and sustain a plasma within the plasma chamber of the vacuum plasma chamber apparatus 4610. Plasma generation is achieved by applying sufficient energy to the gas within the vacuum plasma chamber apparatus 4610 using a gas injector 4620 to liberate electrons from atoms or molecules and expel the resulting ions and electrons together. As mentioned above, in one or some embodiments, one method of generating an ionized gas or plasma is to introduce the gas using the gas injector 4620 into the space between two parallel electrodes 4632. One electrode is grounded, and the other electrode is energized with power from a radio frequency generator. Capacitive or high frequency inductive coupling between the electrodes excites the gas and generates the plasma. In one or some embodiments, the radio frequency power frequency used for plasma generation is 13.56 MHz. Other frequencies, such as 40 kHz and 2.45 GHz, are also contemplated.

[0229] FIG. 46 also illustrates a controller 4270 configured to control any one, any combination, or all of the vacuum plasma chamber apparatus 4610, the motor / robot 4440, the gas injector 4620, and the gas pump 4640. For example, the controller 4270 can control the motor / robot to move the model 4430 into and / or out of the vacuum plasma chamber apparatus 4610. As another example, the controller 4270 can control the gas pump 4640 to pump gas out of the vacuum plasma chamber apparatus 4610 (e.g., before and / or after plasma processing). As yet another example, the controller 4270 can control the gas injector 4620 to inject gas into the vacuum plasma chamber apparatus 4610. As yet another example, the controller 4270 can control the vacuum plasma chamber apparatus 4610 to generate plasma.

[0230] An exemplary flow diagram 4700 for performing plasma processing is shown in Figure 47. In step 4710, the object to be processed is introduced into a plasma chamber, which is typically a vacuum chamber. The chamber is then evacuated to create a low-pressure environment.

[0231] In step 4720, a gas is introduced into the vacuum plasma chamber. In one or some embodiments, the gas may include argon, oxygen, or nitrogen. Further, in one or some embodiments, the gas is introduced into the vacuum plasma chamber at a flow rate that ensures an adequate process pressure to produce a stable plasma.

[0232] In step 4730, a plasma is generated by ionizing the gas. In particular, an electrical signal, which may be DC (direct current), RF (radio frequency), or microwave, is used to ionize the gas, thereby generating the plasma. The plasma may comprise (or consist of) a cloud of ionized gas, including ions, electrons, neutral atoms, or molecules.

[0233] In step 4740, surface modification is performed using plasma. Specifically, as the plasma contacts the material, the plasma can chemically alter the surface of the outer layer of the object. Additionally, plasma can be used to, among other things, add or remove functional groups from the outer layer of the object, increase wettability, or improve adhesion.

[0234] In step 4750, the vacuum plasma chamber is vented to atmospheric pressure and the object is removed from the vacuum plasma chamber. In particular, once the desired surface modification is achieved, the vacuum plasma chamber is vented to atmospheric pressure using air or nitrogen gas, and the object is then removed from the vacuum plasma chamber.

[0235] Other treatments may be performed separately or in addition to the laser ablation and / or plasma treatment. As an example, in one or some embodiments, the flocking process is a relatively fast process that can quickly change the properties of a printed object / surface, imparting any one, any combination, or all of the following properties (due to the flocked fibers): cloth-like feel, soft and comfortable feel, wicking effect, tailored / altered surface polarity (e.g., hydrophilic / hydrophobic), more natural feel, breathability, moisture permeability, quick drying, warmth, antibacterial properties, gradient / graded changes in properties in the same product (e.g., by selective flocking), controlled density to tailor surface properties, and design flexibility (custom / made to order).

[0236] Additionally, in one or some embodiments, flocking the printed article potentially improves properties including any one, any combination, or all of thermal insulation, electrical conductivity, antistatic properties, and sound absorption, although other properties may not be discernible in textile applications.

[0237] Garments made using comfort fibers can include one or more of the desired qualities of comfort fibers described herein. With the development / advancement of new technologies for 3D printing based on melt processes, robotic arm-based direct extrusion and co-extrusion can be utilized as part of the comfort fiber and textile manufacturing process. One aspect involves the use of one or more robotic arms for direct extrusion and co-extrusion. In addition to producing the final material by 3D printing, the filament (comfort fiber) can be used to form comfort fiber materials for other textile applications, such as any one, any combination, or all of bonding, heat pressing, weaving, knitting, crocheting, braiding, non-woven, and other textile techniques. These techniques can be made from the filament in its original form (e.g., unprinted), or by printing the filament into a yarn or other geometric pattern, a printed yarn / pattern formation can be used in textile techniques. Additional heating and / or welding and / or bonding techniques (e.g., heat pressing, hot air, high frequency welding, adhesives, etc.) can be applied to aid in curing or bonding / sealing the material and adding additional properties.

[0238] In one aspect, moisture regain can measure the tactile comfort of a material. Moisture regain for different materials is as follows: wool: 15%, cotton: 8.5%, ramie: 12%, polyester: 0.4%, nylon: 4.5%, polypropylene: 0%, and TPU: 0.4-0.8%. Generally, a higher moisture regain provides a better hand feel.

[0239] Scanning electron microscope (SEM) images of different fiber types are shown in Figures 29A-38B. Figures 29A-B depict TPU-based monofilaments. Cross-sectional views (as shown in Figure 29A) and external views (as shown in Figure 29B) are shown. The cross-sectional view in Figure 29A shows a clear, homogeneous cross-section, while the magnified view of the external surface in Figure 29B shows a smooth morphology with only slight roughness.

[0240] Figures 30A and 30B depict a core / sheath filament with cotton powder within the sheath layer. A cross-sectional view (shown in Figure 30A) and an enlarged external view of the sheath layer (shown in Figure 30B) are shown. The filament shown in Figures 30A and 30B is a 1.75 mm filament. The cross-sectional view (shown in Figure 30A) illustrates the concept of a core coaxially wrapped within the sheath. Particles are visible only within the sheath layer. In the enlarged external view (shown in Figure 30B), cotton particles are visible within the sheath layer. Such filaments can be used to construct comfort fibers.

[0241] Figures 31A and 31B show magnified views of different dimensions of the outer surface of a core / sheath filament with cotton particles in the sheath layer. Figure 31A shows the outer surface of the filament, demonstrating the roughness created around the sheath layer due to the presence of the particles. Figure 31B shows a further magnified view of the outer layer, demonstrating the micron-scale roughness morphology of the outer layer. Such filaments can be used to construct comfort fibers.

[0242] Figures 32A and 32B depict a core / sheath filament with wool particles within the sheath layer. A cross-sectional view (shown in Figure 32A) and an exterior view (shown in Figure 32B) are shown. The filament shown in Figures 32A and 32B is a 1.75 mm filament. The cross-sectional view (shown in Figure 32A) illustrates the concept of a core coaxially enclosed within a sheath. Particles are visible only within the sheath layer. In the enlarged exterior view (shown in Figure 32B), wool particles are visible within the sheath layer. Such filaments can be used to construct comfort fibers.

[0243] Figures 33A and 33B show close-ups of the outer surface of a core / sheath filament with wool particles in the sheath layer. Figure 33A shows the outer surface of the filament, illustrating the roughness created around the sheath layer due to the presence of the particles. Figure 33B shows a further close-up of the outer layer, illustrating the micron-scale roughness morphology of the outer layer. Such filaments can be used to construct comfort fibers.

[0244] Figures 34A and 34B show cross-sections of 3D printed fabrics based on core / sheath filaments (e.g., comfort fibers) with cotton particles in the sheath layer. Figure 34A shows a cross-section of a printed article based on core / sheath filaments with cotton particles in the sheath layer. The roughness created by the particles is visible on the outer surface of the printed layer. Figure 34B shows a similar view of another section of the fabric.

[0245] Figures 35A and 35B show cross-sections of 3D printed fabrics based on core / sheath filaments (e.g., comfort fibers) with cotton particles in the sheath layer. Figure 35A shows a cross-section of an article printed based on core / sheath filaments with cotton particles in the sheath layer. Particles are visible around the sheath layer. Figure 35B shows an enlarged cross-section of the printed article. Cotton particles (arrows 370 in Figure 35B) are visible in and around the outer surface.

[0246] Figures 36A and 36B show a printed fabric based on a TPU monofilament (e.g., a current filament). Figure 36A shows a top view of an article printed based on a TPU monofilament. The smooth surface of the printed layer is visible in the photograph. Figure 36B shows an enlarged top view, showing the smooth surface of the printed layer.

[0247] Figures 37A and 37B show cross-sections of a fabric printed based on the TPU monofilament shown in Figures 36A and 36B. Figure 37A shows a cross-section of an article printed based on the TPU monofilament. The outer surface of the filament is smooth, except for shear bands that appear on the cross-section due to cutting the sample during the preparation process. Figure 37B shows a close-up of the cross-section of the printed article, demonstrating that the outer surface of the printed article is smooth with minimal roughness.

[0248] Figures 38A and 38B show a final product (e.g., printed fabric) based on core / sheath filaments (e.g., comfort fibers) with cotton particles in the sheath layer. Figure 38A shows a top view of the print bed side with multiple layers. Figure 38B shows a top view of a printed article based on comfort fibers with cotton particles in the sheath layer. The porosity (holes) and protruding cotton particles formed on the surface can promote the absorption of moisture and water molecules from the skin (e.g., moisture wicking-like effect). Figure 38B shows an enlarged cross-sectional view showing how the particles protrude from the surface and how these particles, along with the porosity (holes) formed on the surface, promote the absorption of moisture and water molecules from the skin (e.g., moisture wicking-like effect).

[0249] Chemical resistance to seawater (salt water) and chlorine water Different clinical tests were carried out to analyze the effect of different water / aqueous media on the chemical resistance of different comfort fabrics. The two media tested in this aspect were:

[0250] (1) Seawater (e.g., saltwater): Chemical resistance is determined using tensile tests before and after exposure to measure stress (e.g., modulus) at the following elongations: 100%, 200%, and 300%.

[0251] (2) Chlorine water (test conducted according to ISO17608:2015): Chemical resistance is determined using tensile tests before and after exposure to measure stress (e.g., modulus) at the following elongations: 100%, 200%, and 300%.

[0252] The filaments / comfort fibers tested were (i) TPU monofilament (1.75 mm diameter), (ii) TPU-based core / sheath filament with wool powder in the sheath layer (1.75 mm diameter), and (iii) TPU-based core / sheath filament with cotton powder in the sheath layer (1.75 mm diameter). Test results show that under natural / room conditions (23°C, 50% relative humidity), the core / sheath filament outperforms the TPU monofilament, exhibiting higher moduli at 100%, 200%, and 300% elongation.

[0253] A similar trend was observed when the filaments were exposed to a seawater medium, with both wool and cotton core / sheath filaments exhibiting higher modulus at 100%, 200%, and 300% elongation. Test results confirm that core / sheath filaments have better chemical resistance to seawater compared to TPU monofilaments, as reflected by their higher modulus and dimensional stability.

[0254] The core / sheath comfort fiber showed similar trends in chlorinated water, confirming that the addition of a wool-based sheath layer provided better chemical resistance than TPU monofilament. In all tested chlorinated media (per ISO 17608:2015 standard), the wool-based sheath layer had higher moduli at 100%, 200%, and 300% elongation, indicating that the material was less sensitive to chlorinated environments. This also confirmed that wool-based sheath filaments had better chemical resistance than TPU monofilament. This feature may provide the advantage that fabrics constructed using comfort fiber technology last longer than fabrics made with conventional TPU fibers. However, environmental conditions such as seawater exposure during washing (e.g., laundry) can wear out garments constructed from TPU fibers more quickly than garments constructed from comfort fibers.

[0255] As concluded above, the core / sheath structure has been confirmed to have not only a higher modulus and dimensional stability, but also improved chemical resistance that is less susceptible to the media tested.

[0256] Table 1, shown in Figure 39, summarizes the tensile test results at standard conditions (23°C, 50% relative humidity) at 100%, 200%, and 300% elongation. Data are presented as absolute modulus (in MPa).

[0257] Table 2, shown in Figure 40, summarizes the results of tensile tests for chemical resistance to seawater and chlorine water, taking into account the modulus (recorded stress) at 100%, 200%, and 300% elongation as the evaluation criterion for chemical resistance. The data are presented as the reduction in modulus (%) compared to a reference sample under the same conditions (23°C, 50% relative humidity).

[0258] Moisture absorption of comfortable fabric The wicking properties of different comfort fibers were studied to investigate the benefits of core / sheath construction with respect to wicking properties, which in turn correlate with the comfort feel of fibers and fabrics.

[0259] The tests were carried out for 2 and 6 hours in a humidity chamber at 40°C and 95% relative humidity. The samples were first dried and weighed before being introduced into the humidity chamber.

[0260] Three different types of filaments / comfort fibers were tested: (i) TPU monofilament (1.75 mm diameter), (ii) core / sheath filament based on TPU with wool powder in the sheath (1.75 mm diameter), and (iii) core / sheath filament based on TPU with cotton powder in the sheath layer (1.75 mm diameter).

[0261] The test results, summarized in Table 3 of Figure 41, show that the core / sheath structure absorbed higher levels of moisture, especially the wool-based sheath layer, which had almost double the moisture content (above 90%) compared to the TPU monofilament. The cotton-based sheath layer also showed higher moisture levels compared to the TPU monofilament, but at a slower absorption rate compared to the wool-based layer. This evidence supports the notion that core / sheath filaments in the form of comfort fibers / filaments are suitable candidates for textile applications such as skin-contacting fabrics / fibers and apparel due to their high moisture absorption.

[0262] Considering the maximum moisture absorption rate of 0.8% for PET (polyethylene terephthalate), the test results confirm that Comfort Fiber outperforms other multifilaments, highlighting the advantages of Comfort Fiber for textile applications.

[0263] The present disclosure is not limited to the above-described embodiments, and may be substantially replaced with a configuration that is substantially identical to the configuration shown in the above-described embodiments, a configuration that has the same effect, or a configuration that can achieve the same purpose.

[0264] As described above, various aspects of the process can be controlled by a computer. In this regard, the present technological advances, programmed according to this disclosure, should be used in conjunction with a computer in such computer-controlled applications. By way of example only, various devices described herein can include a computer or can interface with (e.g., be executed by) a computer, as illustrated, for example, in Figures 19, 22, 42, 44, and 46. For example, computer functionality is designated as control electronics 285 or controller 4270. As such, computer functionality can be incorporated into any of the electronic devices described herein. By way of example only, Figure 48 illustrates an exemplary computer system that can be utilized to implement methods, including flow diagrams, described herein. A central processing unit (CPU) 4802 is connected to a system bus 4804. The CPU 4802 can be any general-purpose CPU; however, other types of architectures for the CPU 4802 (or other elements of the exemplary computer system 4800) can be used as long as the CPU 4802 (and other elements of the computer system 4800) support the operations described herein. While only a single CPU 4802 is shown in FIG. 48, those skilled in the art will appreciate that additional computers may be present. Furthermore, computer system 4800 may include a networked multiprocessor computer system, including a hybrid parallel CPU / GPU system. CPU 4802 may execute various logical instructions according to the various teachings disclosed herein. For example, CPU 4802 may execute machine-level instructions to implement processing according to the operational flows described herein.

[0265] The computer system 4800 may also include computer components such as non-transitory computer-readable media. Examples of computer-readable media include computer-readable non-transitory storage media such as random access memory (RAM) 4806, which may be SRAM, DRAM, SDRAM, etc. The computer system 4800 also includes additional non-transitory computer-readable storage media such as read-only memory (ROM) 4808, which may be PROM, EPROM, EEROM, etc. The RAM 4806 and ROM 4808 store user and system data and programs known to those skilled in the art. In this regard, the computer-readable media may include executable instructions to implement any one, any combination, or all of the blocks in the flow diagrams of Figures 23, 28, 43, 45, and 47. The computer system 4800 may also include an input / output (I / O) adapter 4810, a graphics processing unit (GPU) 4814, a communications adapter 4822, a user interface adapter 4824, a display driver 4816, and a display adapter 4818.

[0266] The I / O adapter 4810 can connect additional non-transitory computer-readable media to the computer system 4800, such as storage devices 4812, including, for example, hard drives, compact disc (CD) drives, floppy disk drives, tape drives, etc. Storage devices are used when the RAM 4806 is insufficient to store the data required for the operation of the present technology. The data storage of the computer system 4800 is used to store information and / or other data generated or used as described herein. For example, the storage device 4812 may be used to store configuration information or additional plug-ins used by the present technology. Additionally, the user interface adapter 4824 connects user input devices, such as a keyboard 4828, a pointing device 4826, and / or output devices, to the computer system 4800. The display adapter 4818, driven by the CPU 4802, controls the display on the display device 4820 to present information to a user, such as images generated by the methods described herein.

[0267] The architecture of the computer system 4800 can be varied as desired. For example, any suitable processor-based device can be used, including, without limitation, a personal computer, a laptop computer, a computer workstation, and a multiprocessor server. Furthermore, the present technological advances can be implemented on application-specific integrated circuits (ASICs) or very large-scale integrated (VLSI) circuits. Indeed, one skilled in the art can use any number of suitable hardware structures capable of performing the logical operations of the present technological advances. The term "processing circuitry" includes hardware processors (as found in the hardware devices described above), ASICs, and VLSI circuits. Input data to the computer system 4800 can include various plug-ins and library files. The input data can additionally include configuration information.

[0268] The above detailed description of the invention is intended to be understood as illustrating selected forms the invention can take, not as a definition of the invention. The invention is defined solely by the following claims, including all equivalents intended to define the scope of the claimed invention. Furthermore, any feature of any preferred embodiment described herein can be used alone or in combination with other features. Finally, the methods are computer-implemented, as one skilled in the art will readily appreciate that in the preferred embodiments, some or all of the steps described herein are implemented using a computer. In such cases, the resulting models described herein can be downloaded or saved to computer storage.

[0269] Exemplary embodiments of the present invention are also disclosed below. Embodiment 1 1. A method of manufacturing a filament (at least partially or wholly computer-implemented), the method comprising: extruding, using one or more extruders, a first set of materials for the cores of the filaments and a second set of materials for the sheaths of the filaments, the second set of materials including one or both of fibers and particles; using a core portion and a sheath portion of at least one die head to route the first set of materials and the second set of materials extruded from the one or more extruders, respectively; and cooling the first set of materials and the second set of materials to form filaments during or after use of the core portion and the sheath portion of the at least one die head. A method comprising:

[0270] Embodiment 2 the one or more extruders include at least a first extruder that melts, mixes, and extrudes the first set of materials, and at least a second extruder that melts, mixes, and extrudes the second set of materials; The at least second extruder comprises a twin-screw extruder. 2. The method of embodiment 1.

[0271] Embodiment 3 3. The method of claim 1 or 2, wherein the second set of materials comprises at least one thermoplastic polymer and one or both of fibers and particles.

[0272] Embodiment 4 4. The method of any one of claims 1 to 3, wherein the second set of materials further comprises a water-soluble polymer.

[0273] Embodiment 5 5. The method according to any one of claims 1 to 4, wherein the diameter of the core portion of the at least one die head is at least 5 times greater than the thickness of the sheath portion of the at least one die head.

[0274] Embodiment 6 1. A method (at least partially or wholly computer-implemented) for processing a 3D printed object, the method comprising: receiving the 3D printed object; and After receiving the object, the object is subjected to at least one of a laser irradiation treatment and a plasma treatment. A method comprising:

[0275] Embodiment 7 the shaped object has one or more layers; and After 3D printing the object, applying laser radiation to a surface or interior of at least one of the one or more layers. 7. The method of embodiment 6.

[0276] Embodiment 8 the one or more layers include an outer layer having a surface configured to contact the skin of a user of the shaped article; applying the laser radiation includes laser ablation to form a pattern on the surface of the outer layer to change the tactile feel of the outer layer when in contact with the user's skin. 8. The method of embodiment 6 or 7,

[0277] Embodiment 9 the one or more layers include an outer layer having a surface configured to contact the skin of a user of the shaped article; and applying the laser radiation changes the interior of the outer layer; 9. The method according to any one of embodiments 6 to 8, wherein

[0278] Embodiment 10 10. The method of any one of embodiments 6-9, wherein the applying laser radiation comprises laser ablation of at least a portion of the interior of the outer layer.

[0279] Embodiment 11 the inner portion of the outer layer comprises at least one thermoplastic polymer and one or both of fibers and particles; and the laser ablation includes removing at least a portion of the at least one thermoplastic polymer to enhance the effect of the object on the user's skin. 11. The method according to any one of embodiments 6 to 10.

[0280] Embodiment 12 the one or more layers include an inner layer having a surface configured not to contact the skin of a user of the shaped article; and The laser radiation is applied to the inner layer of the object. 12. The method according to any one of embodiments 6 to 11,

[0281] Embodiment 13 13. The method according to any one of embodiments 6 to 12, wherein the laser radiation is applied to the inner layer of the object to ablate at least a portion of the inner layer.

[0282] Embodiment 14 14. The method according to any one of claims 6 to 13, wherein removing at least a portion of the inner layer changes at least one of moisture management and drape of the shaped object.

[0283] Embodiment 15 The shaped object comprises one or more layers; and After 3D printing the object, the plasma treatment is applied to at least one surface of the one or more layers. 15. The method according to any one of embodiments 6 to 14,

[0284] Embodiment 16 16. The method according to any one of embodiments 6 to 15, wherein the plasma treatment cleans the surface of at least one of the one or more layers.

[0285] Embodiment 17 1. An apparatus configured to process a 3D printed object, the apparatus comprising: At least one of a laser irradiation device and a plasma processing device configured to receive a 3D printed object from at least one 3D printer; at least one control device configured to control at least one of the laser irradiation device and the plasma treatment device in order to apply laser irradiation or plasma treatment to the object; 10. An apparatus comprising:

[0286] Embodiment 18 The shaped article includes at least one layer; and the at least one control device is configured to control the laser irradiation device to apply laser irradiation to at least one surface or within the one or more layers. 18. The device of embodiment 17.

[0287] Embodiment 19 the one or more layers include an outer layer having a surface configured to contact the skin of a user of the shaped article; and the at least one control device is configured to control the laser irradiation device to apply laser irradiation by laser ablation to form a pattern on the surface of the outer layer to change the tactile feel of the outer layer when in contact with the user's skin. 19. The device of embodiment 17 or 18.

[0288] Embodiment 20 the one or more layers include an outer layer having a surface configured to contact the skin of a user of the shaped article; and the at least one control device is configured to control the laser irradiation device to apply laser irradiation to alter the interior of the outer layer. 20. The device according to any one of embodiments 17 to 19.

[0289] Embodiment 21 21. The device of any one of embodiments 17 to 20, wherein the at least one control device is configured to control the laser irradiation device to apply laser irradiation by laser ablation to remove at least a portion of the interior of the outer layer.

[0290] Embodiment 22 the inner portion of the outer layer comprises at least one thermoplastic polymer and one or both of fibers and particles; and the at least one control device is configured to control the laser irradiation device to remove at least a portion of the at least one thermoplastic polymer to promote an effect of the model on the skin of a user of the model. 22. The device according to any one of embodiments 17 to 21.

[0291] Embodiment 23 the one or more layers include an inner layer having a surface configured not to contact the skin of a user of the shaped article; and the at least one control device is configured to control the laser irradiation device to apply laser irradiation to the inner layer of the object; 23. The device according to any one of embodiments 17 to 22.

[0292] Embodiment 24 The apparatus described in any one of embodiments 17 to 23, characterized in that the at least one control device is configured to control the laser irradiation device and apply laser irradiation to the inner layer of the object to remove at least a portion of the inner layer.

[0293] Embodiment 25 25. The apparatus according to any one of embodiments 17 to 24, wherein the at least one control device is configured to control the laser irradiation device and apply laser irradiation to change at least one of moisture management and drapeability of the object.

[0294] Embodiment 26 The shaped object comprises one or more layers; and the at least one controller is configured to control the plasma treatment device to apply a plasma treatment on at least one surface of the one or more layers. 26. The device according to any one of embodiments 17 to 25.

[0295] Embodiment 27 A core / sheath structure constituting a modeling material or a modeled object produced from the modeling material, the core / sheath structure comprising: a core comprising at least one thermoplastic polymer and having a linear shape and an outer circumferential surface; a sheath at least partially covering the outer peripheral surface, the sheath including (i) one or both of fibers and particles, and (ii) at least one of a soluble material, an antimicrobial material, a UV protection material, an odor management material, and a moisture management material; A core / sheath structure comprising:

[0296] Embodiment 28 the core / sheath structure is configured for 3D printing; and the sheath comprises a water-soluble material; 28. The core / sheath structure of embodiment 27.

[0297] Embodiment 29 29. The core / sheath structure of claim 27 or 28, wherein the water-soluble material comprises polyvinyl alcohol. [Explanation of symbols]

[0298] 1 Build material (filament), 101 core / sheath structure, 111 core, 112 sheath, 121 first thermoplastic polymer, 122 second thermoplastic polymer, 123 fiber / particle, 1M build material, 2 build object, 201 first filament, 202 second filament, 210 filament, 221 core / sheath structure, 231 core, 232 sheath, 241 filament body, 242 protrusion, 251 cross fiber / cross particle, 261 human skin, 271 3D printer, 281 filament spool, 282 print head, 283 drive mechanism, 284 plate, 288 melt, 3 flock product, 301 body, 302 adhesive layer, 303 flock, 311 human skin, 331 first filament, 332 Second linear body, 341 electrostatic deposition device, 351 first electrode, 352 second electrode, 353 chamber, 354 power supply, 361 positive electrode, 362 negative electrode, 4800 computer system, 4812 storage device, 4820 display device, 4826 pointing device, 4828 keyboard

Claims

1. 1. A method of producing a filament, the method comprising: extruding a first set of materials for the cores of the filaments and a second set of materials for the sheaths of the filaments using one or more extruders, the second set of materials including one or both of fibers and particles; using a core portion and a sheath portion of at least one die head to route the first set of materials and the second set of materials extruded from the one or more extruders, respectively; and cooling the first set of materials and the second set of materials to form filaments during or after use of the core portion and the sheath portion of the at least one die head. A method comprising:

2. the one or more extruders include at least a first extruder that melts, mixes, and extrudes the first set of materials, and at least a second extruder that melts, mixes, and extrudes the second set of materials; the at least second extruder comprises a twin-screw extruder; 2. The method of claim 1 .

3. 3. The method of claim 2, wherein the second set of materials includes at least one thermoplastic polymer and one or both of fibers and particles.

4. The method of claim 3 , wherein the second set of materials further comprises a water-soluble polymer.

5. 4. The method of claim 3, wherein the diameter of the core portion of the at least one die head is at least five times greater than the thickness of the sheath portion of the at least one die head.

6. 1. A method for processing a 3D printed object, the method comprising: receiving the 3D printed object; and After receiving the shaped object, at least one of a laser irradiation treatment and a plasma treatment is performed on the shaped object. A method comprising:

7. the shaped object has one or more layers; and After 3D printing the object, applying laser radiation to a surface or interior of at least one of the one or more layers.

7. The method of claim 6.

8. the one or more layers include an outer layer having a surface configured to contact the skin of a user of the shaped article; applying the laser radiation includes laser ablation to form a pattern on the surface of the outer layer to change the tactile feel of the outer layer when in contact with the user's skin.

8. The method of claim 7.

9. the one or more layers include an outer layer having a surface configured to contact the skin of a user of the shaped article; and applying the laser radiation changes the interior of the outer layer; 8. The method of claim 7.

10. 10. The method of claim 9, wherein applying the laser radiation comprises laser ablation of at least a portion of the interior of the outer layer.

11. the inner portion of the outer layer comprises at least one thermoplastic polymer and one or both of fibers and particles; and the laser ablation includes removing at least a portion of the at least one thermoplastic polymer to enhance the effect of the object on the user's skin.

11. The method of claim 10.

12. the one or more layers include an inner layer having a surface configured not to contact the skin of a user of the shaped article; and The laser radiation is applied to the inner layer of the object.

8. The method of claim 7.

13. 13. The method of claim 12, wherein the laser radiation is applied to the inner layer of the structure to ablate at least a portion of the inner layer.

14. 14. The method of claim 13, wherein removing at least a portion of the inner layer alters at least one of moisture management and drape properties of the object.

15. The shaped article comprises one or more layers; and After 3D printing the object, the plasma treatment is applied to at least one surface of the one or more layers.

15. The method of claim 14.

16. 16. The method of claim 15, wherein the plasma treatment cleans the surface of at least one of the one or more layers.

17. 1. An apparatus configured to process a 3D printed object, the apparatus comprising: At least one of a laser irradiation device and a plasma processing device configured to receive the 3D printed object from at least one 3D printer; at least one control device configured to control at least one of the laser irradiation device and the plasma treatment device in order to apply laser irradiation or plasma treatment to the object; 10. An apparatus comprising:

18. The shaped article includes at least one layer; and the at least one control device is configured to control the laser irradiation device to apply laser irradiation to at least one surface or within the one or more layers.

18. The device of claim 17.

19. the one or more layers include an outer layer having a surface configured to contact the skin of a user of the shaped article; and the at least one control device is configured to control the laser irradiation device to apply laser irradiation by laser ablation to form a pattern on the surface of the outer layer to change the tactile feel of the outer layer when in contact with the user's skin.

20. The device of claim 18.

20. the one or more layers include an outer layer having a surface configured to contact the skin of a user of the shaped article; and the at least one control device is configured to control the laser irradiation device to apply laser radiation to alter the interior of the outer layer.

20. The device of claim 18.

21. 21. The apparatus of claim 20, wherein the at least one control device is configured to control the laser irradiation device to apply laser irradiation by laser ablation to remove at least a portion of the interior of the outer layer.

22. the inner portion of the outer layer comprises at least one thermoplastic polymer and one or both of fibers and particles; and the at least one control device is configured to control the laser irradiation device to remove at least a portion of the at least one thermoplastic polymer to promote an effect of the model on the skin of a user of the model.

22. The apparatus of claim 21 .

23. the one or more layers include an inner layer having a surface configured not to contact the skin of a user of the shaped article; and the at least one control device is configured to control the laser irradiation device to apply laser irradiation to the inner layer of the object; 20. The device of claim 18.

24. 24. The apparatus of claim 23, wherein the at least one control device is configured to control the laser irradiation device to apply laser radiation to the inner layer of the object to ablate at least a portion of the inner layer.

25. 25. The apparatus of claim 24, wherein the at least one control device is configured to control the laser irradiation device to apply laser irradiation to change at least one of moisture management and drapeability of the build.

26. The shaped article comprises one or more layers; and the at least one controller is configured to control the plasma treatment device to apply a plasma treatment on at least one surface of the one or more layers.

18. The device of claim 17.

27. A core / sheath structure constituting a modeling material or a modeled object produced from the modeling material, the core / sheath structure comprising: a core comprising at least one thermoplastic polymer and having a linear shape and an outer circumferential surface; a sheath at least partially covering the outer peripheral surface, the sheath including (i) one or both of fibers and particles, and (ii) at least one of a soluble material, an antimicrobial material, a UV protection material, an odor management material, and a moisture management material; A core / sheath structure comprising:

28. the core / sheath structure is configured for 3D printing; and the sheath comprises a water-soluble material; 28. The core / sheath structure of claim 27.

29. 30. The core / sheath structure of claim 28, wherein the water-soluble material comprises polyvinyl alcohol.

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