Additive manufacturing

Abstract

A micro-factory additive manufacturing system and method of manufacturing a polymeric product using the system are provided. The system comprises a plurality of encapsulated manufacturing cells, each cell being closed and structurally configured to perform a respective manufacturing sub¬ process. The system comprises at least one polymeric material application cell, at least one drying and / or curing cell, at least one former configured to receive polymeric material thereon, at least one movable transfer mechanism structurally arranged to transfer the former between the encapsulated manufacturing cells, an automated door associated with each encapsulated manufacturing cell, and a control system operatively connected to the encapsulated manufacturing cells and the movable transfer mechanism, the control system configured to provide operational commands to at least the polymer application unit, the drying and / or curing unit, the automated doors, and the moveable transfer mechanism.

Description

[0001] ADDITIVE MANUFACTURING

[0002] TECHNICAL FIELD

[0003]

[0001] The present disclosure relates to additive manufacturing, and more specifically to additive manufacturing in a plurality of closed cells.

[0004] BACKGROUND

[0005]

[0002] Fabrics, textile, clothing, and synthetic leather products are on high demand in many global markets, for example, in fashion and footwear, medical, sportswear, cosmetic, domestic and transportation fields. However, manufacturing techniques haven't gone through substantial progress in decades. These are still labor based, and as such require large factories, to allow the accommodation of thousands of workers. These large factories are also involved in a long supply chain, about 15% waste due to the 'cut and sew' processes, international transportation which may take long, and many other disadvantages.

[0006]

[0003] Additive Manufacturing (AM) techniques are still far from being considered as mainstream, due to two main reasons:

[0007] (i) technological constraints - i.e., the inability of current 3D technologies to create fabrics that have a similar 'hand feel', draping, and other features and characteristics expected from the AM manufactured fabric;

[0008] (ii) inability to compete with current manufacturing advantages- currently there is no system that can 3D print acceptable products, (which are comparable to the state of the art products) in a commercially excepted volume, and comparable throughput, speed and price.

[0009]

[0004] Accordingly, there is a need for an Additive Manufacturing (AM) system and method to enable production of high quality products while overcoming the disadvantages of standard fabric manufacturing.SUMMARY

[0010]

[0005] The present disclosure relates to a unique and novel micro-factory additive manufacturing (AM) system and method for manufacturing a variety of products by the microfactory additive manufacturing system. The manufactured products may include, but are not limited to clothing, garments, fabrics and textile like sheets and related products, artificial leather sheets and related products, polymeric based sheet and related products, and so on.

[0011]

[0006] The micro-factory additive manufacturing system may be based on a modular, configurable closed cells system, comprising at least two capsulated manufacturing cells, and at least one mold, wherein each of the closed cells is dedicated to at least one manufactunng subprocess of the entire AM manufacturing process.

[0012]

[0007] The micro-factory system is a more compact system compared to standard manufacturing floors. The manufacturing system and method may comprise moving and transitioning the mold, between the closed cells and processes, by a movable device, in a controlled manner. The system and method may further comprise controlling the process in each closed cell, and controlling the manufactured products quality, while maximizing the microfactory throughput.

[0013]

[0008] In some embodiments, a micro-factory additive manufacturing system may comprise a plurality of encapsulated manufacturing cells, each cell being closed and structurally configured to perform a respective manufacturing sub-process; the plurality of encapsulated manufacturing cells comprise at least one polymeric material application cell comprising at least one polymer application unit; and at least one drying and / or curing cell comprising at least one drying and / or curing unit. The system may further comprise at least one former configured to receive polymeric material thereon; at least one movable transfer mechanism structurally arranged to transfer the former between the encapsulated manufacturing cells; an automated door associated with each encapsulated manufacturing cell; anda control system operatively connected to the encapsulated manufacturing cells and the movable transfer mechanism, the control system configured to provide operational commands to at least the polymer application unit, the drying and / or curing unit, the automated doors, and the moveable transfer mechanism, wherein the former is positionable within each encapsulated manufacturing cell by at least one holder to enable formation of a polymeric product on the former.

[0014]

[0009] Optionally, each encapsulated manufacturing cell may comprise structural walls and at least one automated door forming a sealed enclosure during operation.

[0015]

[0010] Optionally, at least one encapsulated manufacturing cell may comprise an air extraction unit configured to generate negative pressure within the cell.

[0016] [Oil] Optionally, the movable transfer mechanism may be configured to move the former through the automated door of each encapsulated manufacturing cell, and the automated door may be configured to close during at least a majority of the respective manufacturing sub-process.

[0017]

[0012] Optionally, at least one of the polymer application unit, or the drying or curing unit, may be mounted on a movable holder, configured to control trajectory, angle, distance, position or orientation relative to the former.

[0018]

[0013] In some embodiments, the polymeric material application cell may comprise at least one application unit selected from the group consisting of: a spray nozzle;

[0019] a needle or pointer nozzle configured to dispense polymeric material as strands;,

[0020] a precise liquid placement unit configured for localized deposition of polymeric material;

[0021] an air driven nozzle configured to dispense polymeric web-shaped material;

[0022] a bead nozzle configured to dispense polymeric material as a bead;a jetting nozzle; and

[0023] a foam nozzle configured to dispense polymeric foam material.

[0024]

[0014] In some embodiments, the system may further comprise an encapsulated dry-particles application cell comprising a dry-particles applicator unit and a former holder arranged within the cell.

[0025]

[0015] Optionally, the dry-particles application cell may be structurally integrated with the drying and / or curing cell to form a combined encapsulated manufacturing cell.

[0026]

[0016] In some embodiments, the dry-particles may comprise textile fibers, carbon particles, metallic powder or other mineral-based particles.

[0027]

[0017] Optionally, the former may provide a shape of a finished or a semi-finished product and is plain, curved, concave, or fully three-dimensional, and optionally comprises holes, embossing, logos, textures, or any combinations thereof.

[0028]

[0018] Optionally, the former may be configured for repeated reuse after removal of a polymeric product, or the former may be configured to remain incorporated as a structural layer of the finished or semi-finished polymeric product.

[0029]

[0019] Optionally the system may further comprise a product removal device comprising at least one of a gripper or a vacuum element configured to remove the polymeric product from the former.

[0030]

[0020] Optionally, the former may be a shape-changing printing bed subsystem configured to change a size and / or shape of a printing surface onto which a polymeric material is applied.

[0031]

[0021] Optionally, the control system may be configured to control and coordinate operation of the automated doors, the holder, the material application units, and the drying and / or curing units, whereby the control system may be configured to schedule transfer of the former between encapsulated manufacturing cells based on manufacturing parameters to increase throughput.

[0022] Optionally, the control system may be connected to an external data source, wherein the external data source dictates the production operations, including selection of formers, polymeric materials, dry particles, and manufacturing parameters.

[0032]

[0023] Optionally, the control system may be configured to control and coordinate operation of the automated doors, the holder, the material application units, the drying and / or curing units, an air extractor, an air filter, the adjustable shape mold, a former reconditioning system, and a postprocess cell.

[0033]

[0024] In some embodiments, the control system may be configured to schedule transfer of the former between encapsulated manufacturing cells based on manufacturing parameters to increase throughput.

[0034]

[0025] In some embodiments, a method of manufacturing a polymeric product using a micro-factory additive manufacturing system may comprise: positioning a former within an encapsulated polymeric material application cell; applying at least one polymeric material onto at least a portion of the former using a polymer application unit while the polymeric material application cell is sealed; transferring the former to at least one additional encapsulated manufacturing cell using a movable transfer mechanism; curing and / or drying the polymeric material in an encapsulated curing and / or drying cell; and forming a polymeric product on the former.

[0035]

[0026] Optionally, the method may further comprise repeating the steps of applying polymeric material and curing and / or drying to form a multilayer polymeric product within the encapsulated cells.

[0036]

[0027] Optionally, the method may further comprise applying dry particles onto the polymeric material in an encapsulated dry-particles application cell.

[0037]

[0028] Optionally, the method may further comprise adjusting a shape of the former prior to or duringapplication of the polymeric material.

[0038]

[0029] Optionally, the method may further comprise removing the polymeric product from the former and reusing the former for manufacture of an additional product.

[0039]

[0030] Optionally, transferring the former and performing the applying and curing steps are coordinated by a control system to enable simultaneous manufacture of multiple polymeric products.

[0040]

[0031] Optionally, the polymeric material is applied by spraying within the encapsulated polymer application cell while the automated door of the polymer application cell remains closed; an air extraction unit generates negative pressure within the polymer application cell during spraying;

[0041] the former is transferred by a robotic arm through the automated door into an encapsulated curing cell;

[0042] curing is performed by at least one of hot air curing or ultraviolet curing while the automated door of the curing cell remains closed; and the former is positioned relative to the polymer application unit and the curing unit by at least one movable holder controlled by the control system.

[0043] BRIEF DESCRIPTION OF THE DRAWINGS

[0044]

[0032] Some non-limiting exemplary embodiments or features of the disclosed subject matter are illustrated in the following drawings.

[0045]

[0033] In the drawings:

[0046]

[0034] FIG. 1A is a schematic illustration of a micro-factory system including several closed cells, according to embodiments of the present disclosure;

[0047]

[0035] FIG. 1 is a schematic illustration of a micro-factory system including two closed cells, according to some embodiments of the present disclosure; and

[0048]

[0036] FIG. 2 is a schematic flow chart illustrating a method of additive manufacturing using amicro-factory, according to some embodiments of the present disclosure.

[0049]

[0037] With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of embodiments of the disclosure. In this regard, the description taken with the drawings makes apparent to those skilled in the art how embodiments of the disclosure may be practiced.

[0050]

[0038] Identical or duplicate or equivalent or similar structures, elements, or parts that appear in one or more drawings are generally labeled with the same reference numeral, optionally with an additional letter or letters to distinguish between similar entities or variants of entities and may not be repeatedly labeled and / or described. References to previously presented elements are implied without necessarily further citing the drawing or description in which they appear.

[0051]

[0039] Dimensions of components and features shown in the figures are chosen for convenience or clarity of presentation and are not necessarily shown to scale or true perspective. For convenience or clarity, some elements or structures are not shown or shown only partially and / or with different perspectives or from different point of views.

[0052] DETAILED DESCRIPTION

[0053]

[0040] Throughout this disclosure, the terms '3D printing', 'Additive Manufacturing', and 'AM' are interchangeable, and all refer to manufacture of textile-related products that have a flat or 3D form.

[0054]

[0041] Throughout this disclosure, the terms 'mold', 'former' and ‘surface’ are interchangeable, and all refer to a base of a specific shape onto which the polymers are applied.

[0055]

[0042] Throughout this disclosure, theterms 'encapsulated' and'closed' are interchangeable, and all refer to cells of the micro-factory system, such that the manufacturing process is confined and contained within each of the manufacturing cells. The cells may comprise structured walls andan automated door forming a sealed enclosure during operation.

[0056]

[0043] Throughout this disclosure, the terms ‘application’ and ‘deposition’ are interchangeable, and all refer to layering materials over a surface.

[0057]

[0044] The micro-factory 3D Printing throughput for a typical clothing item, such as a T-shirt, may vary in the range of manufacturing a product every 30 minutes, to manufacturing a product every 5 seconds, depending on the number of molds, and on the micro-factory number of cells and / or cells arrangement and layout. For example, if a product requires 4 sessions of polymeric deposition it can be performed in one polymer deposition cell, such that the former that is configured to receive polymeric material thereon, is positioned in this cell four times along the process, or it may be part of an arrangement of four polymer deposition cells located along the process, while other formers make their way within the micro-factory system and its different cells.

[0058]

[0045] The micro-factory footprint may be in the range of circa 4 Sqm for the smallest microfactory model, to circa 100 Sqm for the largest micro factory model or configuration.

[0059]

[0046] The micro-factory system and method may be based on a configurable array of closed cells, wherein each cell is dedicated to a specific manufacturing semi-process (i.e., partial process) of the entire AM process. Using closed cells as part of the micro-factory is important to prevent pollution of sprayed materials, e.g., liquids, fibers, gas and other polluting materials outside of the cells, to the open air, thereby avoiding contamination of the surroundings of the micro-factory.

[0060]

[0047] The micro-factory is designed to create polymeric based products, by fast application or deposition and then curing of waterborne or any other form of polymers, on a flat or 3D surface.

[0061]

[0048] The micro-factory allows On-Demand creation of products, in either mass production, or mass customization, or personalized, for example - changing the product's color according to customers' orders, even in small batches or one of a kind unit production.

[0062]

[0049] Production versatility together with throughput maximization are software driven, and arephysically performed by movable manipulators, such as robotic arms. These moveable manipulators may move the molds between the different closed cells, through a cell opening, which closes after the mold is being transferred into or out of a cell. Molds are moved from one closed cell to another to create polymeric based products over said molds. The molds' position in each cell may also be manipulated in a controlled manner, by a moving device, e.g., within the cell.

[0063]

[0050] Controlling the relative position, in the 3D space, between the mold and the polymer application device inside a closed polymer application cell, as well as in the other cells, allows liquid polymers to be applied and deposited at any desired zone / area of the mold, dry particles to be applied at any desired zone / area of the mold, and drying and / or curing to be performed at any desired zone / area of the mold. Therefore, a variety of products can be created according to the desired product characteristics, e.g., shape and design. Accordingly, the micro-factory of the present disclosure provides a very versatile and flexible, high throughput AM printer system, which may provide a variety of textile-related products that may be custom made.

[0064]

[0051] One of the present system's advantages is the possibility to apply different polymeric and / or dry particles compositions at different zones of any complex, e.g., 3D shaped molds, thus creating hybrid polymeric structures, for example, for certain high-performance shoes.

[0065]

[0052] The micro-factory of the present disclosure may optionally comprise, one or more of the following elements:

[0066] a. One encapsulated polymer application cell;

[0067] b. One encapsulated drying and / or curing cell;

[0068] c. One former / mold;

[0069] d. One moving system, the moving system transfers the former between at least two closed cells;

[0070] e. Product removal device (removal from the micro factory);

[0071] f. Control system; and

[0072] g. Materials deposition dozing systems.

[0053] The micro-factory of the present disclosure may optionally comprise one or more of the following optional cells:

[0073] (1) Encapsulated dry particles application cell;

[0074] (2) Encapsulated mold's reconditioning cell; and

[0075] (3) Additional finishing operations cell.

[0076]

[0054] Dry particles, may consist of, for example, short fibers, such as flocked textile fibers, carbon particles, metallic powder or other mineral-based particles. Dry particles cell, which may also be encapsulated, may comprise a flocking unit, of any kind, for example, brush driven, pneumatic and electrostatic, or any combination thereof.

[0077]

[0055] Each one of the encapsulated / closed cells may further comprise at least one automated door to provide an opening through which the former / mold may be inserted or removed.

[0078]

[0056] Doors’ opening and closing may be controlled by the micro-factory control system according to the different process durations, as calculated by the control system algorithms.

[0079]

[0057] Each one of the encapsulated cells may further comprise an air extractor equipped with an air filter. The air extractor may be individually associated with each closed cell, or may be shared by at least two encapsulated / closed cells.

[0080]

[0058] Each one of the encapsulated / closed cells, may further comprise either a static former holder or a movable former holder, for example, a conveyor belt, a piston or a robotic arm.

[0081]

[0059] Reference is made to FIG. 1A, which is a schematic illustration of a micro-factory system including several closed cells, according to embodiments of the present disclosure. According to some embodiments, a micro-factory additive manufacturing system (1010) is illustrated. Micro-factory additive manufacturing system (1010) may comprise a plurality of encapsulated manufacturing cells, each cell being closed and structurally configured to perform a respective manufacturing sub-process. According to some embodiments, a former (500) may be configured to receive polymeric material thereon by being transferred between oneencapsulated manufacturing cell to another.

[0082]

[0060] In some embodiments, micro-factory additive manufacturing system (1010) may comprise at least one polymeric material application closed cell (200) comprising at least one polymer application unit, at least one drying and / or curing closed cell (100) comprising at least one drying and / or curing unit, at least one moveable transfer mechanism (1400) structurally arranged to transfer the former between the encapsulated manufacturing cells, and control system (600) operatively connected to the encapsulated manufacturing cells and the movable transfer mechanism. The control system (600) may be configured to provide operational commands to the polymer application unit, the drying and / or curing unit, automated doors of each of the encapsulated manufacturing cells, and the moveable transfer mechanism. In some embodiments, micro-factory additive manufacturing system (1010) may further comprise additional encapsulated manufacturing cells, for example, one or more of: at least one dry particles application closed cell (1500), at least one former reconditioning cell (1600), and at least one post process closed cell (1700). The different encapsulated manufacturing cells will be described in detail hereinbelow. It should be noted that micro-factory additive manufacturing system (1010) may comprise additional similar or different encapsulated manufacturing cells from those disclosed in the present disclosure. The number of each encapsulated manufacturing cells may also differ to thereby create a different micro-factory additive manufacturing system.

[0083]

[0061] As illustrated in FIG. 1. the micro-factory system (1000) of the present disclosure, may comprise a plurality of encapsulated manufacturing cells, each cell being closed and structurally configured to perform a respective manufacturing sub-process. In some embodiments, system (1000) may comprise at least one encapsulated cell for polymeric material application (200), which may comprise at least one polymer application unit (300). The polymer application unit (300) may comprise a fast-acting application spray gun for applying plain polymeric layers, typically used to create the base layer or the foundation of the manufactured product.

[0084]

[0062] In some embodiments, the polymeric material applied within the polymeric material application cell (200) may comprise waterborne polymers, including but not limited to polyurethane,acrylic, latex, silicone-based polymers, or combinations thereof.

[0085]

[0063] The polymeric materials may have viscosities suitable for spray jetting, bead, foam, or needlebased deposition, and may further comprise functional additives such as pigments, softeners, conductive particles, fire retardants, impact-resistant fillers, fragrances, or optical effect materials.

[0086]

[0064] Drying and / or curing of the polymeric material may be performed using thermal curing, hot air drying, ultraviolet (UV) curing, or combinations thereof. In some embodiments, curing temperatures, radiation intensity, or curing duration may be selected according to polymer composition and desired material properties of the finished product. Drying and / or curing may be performed in an encapsulated cell separate from polymeric material application cell (200).

[0087]

[0065] The polymer's application unit (300) may further comprise one or more alternative or additional material application systems such as:

[0088]

[0066] (1) Needle or pointer nozzles or any kind of dedicated nozzles, such as bead, jetting nozzle, or air driven nozzle (for example, Nordson CF nozzle) for controllable creation of strings or threadlike polymeric patterns, the strings may be embedded between at least two plain polymeric layers or added on at least one plain polymeric layer, which may be created by a spray gun. The strings may work as a built-in mesh and / or web for strength, decoration, or any other functional purpose.

[0089]

[0067] Precise liquid placement system, such as inkjet system, for any digitally derived graphical pattern, for functional or decoration purposes. The patterns may be retrieved from external data sources, for example, via internet communication, by the control system (600).

[0090]

[0068] Dedicated foam nozzle, (for example, in the shape of a rectangular orifice, for application of a foam layer, typically as an integral component of certain products, for example, bras and upholstery.

[0091]

[0069] In some embodiments, the polymeric material application cell (200) may comprise one or more of the abovementioned types of polymer application units (300). In some embodiments, in case multiple polymer application units (300) are implemented as part of micro-factory system (1000), each of the multiple polymer application units (300) may be encapsulated in a separate closed cell.

[0070] The polymer application cell(s) (200) may apply the same or different compounds of polymers, in one deposition session.

[0092]

[0071] As illustrated in FIG. 1, the micro-factory system (1000) may further comprise a polymer application unit holder (400), for holding the polymer application unit (300) in a either a standstill position when holder (400) is static or may move the polymer application unit (300) when the holder (400) is a movable device.

[0093]

[0072] When holder (400) is movable, it may position and or move the polymer application unit / s (300) inside the polymer application cell (200), in the desired trajectory, speed, distance, and angle, relatively to the former / mold (500) that is also within the closed polymer application cell (200), to achieve a controllable and desired polymeric layer deposition, uniform or otherwise, to prevent polymer leakage, create a specific polymeric pattern as desired and chosen, over any desired zone of the mold, according to the finished product’s nature and pre-defined design.

[0094]

[0073] The movable polymer application unit holder (400) may be controlled by the micro-factory control system (600) and a dedicated computer program.

[0095]

[0074] The movable polymer application unit holder (400) may be any suitable moveable device, for example, a piston, or a robotic arm.

[0096]

[0075] According to some embodiments, the polymer application unit (300) may be moveable while a former holder (800) may be stationary, whereas in other embodiments, polymer application unit (300) may be immobile, while former holder (800) may be moveable. In yet other embodiments, the former holder (800) may be immobile, while polymer application cell (200) may comprise more than one moveable polymer application unit (300), positioned within polymer application cell (200), e.g., at the top end of polymer application cell (200) and at the bottom end of polymer application cell (200). Another embodiment may comprise a moveable polymer application unit (300) and a moveable former holder (800). All of these options are to ensure a consistent and controlled manner of polymer application onto the former, e.g., former (500).

[0076] An automated door (700) of polymer application cell (200) is to be kept closed during the polymer application session, and preferably for an additional predefined time period following the end of that application session, for example, for a period of 1 to 5 seconds after the polymer deposition session is accomplished, such that the polymer application cell (200) is sealed during the polymer application session. This is to prevent environmental contamination by polymeric droplets, related fumes, pollution and odor.

[0097]

[0077] The movable former holder (800) may position the former (500) that is configured to receive polymeric material thereon in the desired position, distance, and angle relative to any of the polymer application units (300), according to the desired, chosen manufacturing process, and may also be controlled by the micro-factory control system (600) and its dedicated computer program.

[0098]

[0078] The movable former holder (800) may be any suitable device, for example, a piston, a conveyor belt, a step or servo motor (e.g., to spin the former inside the cell) or a robotic arm. In some embodiments, micro-factory system (1000) may comprise an optional air exhauster or extractor unit (900) that is configured to suck the air from a closed cell and move it out of the room in which the micro-factory is placed. The air extractor (900) creates a negative air pressure level within the closed cell, further enhancing prevention of environmental contamination by the different materials deposited within the encapsulated / closed cell, e.g., polymer application cell (200). The air extractor unit (900) may comprise or be associated with a filtering system (910) so that air that may be recycled into the room, or outside the room, is filtered and clean.

[0099]

[0079] It should be noted that the air extractor unit (900), with or without an air filter or filtering system (910), may be implemented in any of the encapsulated manufacturing cells.

[0100]

[0080] In some embodiments, micro-factory system (1000) may comprise an optional reclaiming unit (920), to collect and reuse over-deposited or over-sprayed polymers, and / or dry particles, such as flock fibers. The reclaiming unit (920) may comprise reclaiming pump(s), valves, hoses, etc., as known in the art.

[0101]

[0081] According to some embodiments, the micro-factory system (1000) may comprise at leastone drying and / or curing capsulated cell (100). The drying / curing cell (100) may comprise at least a drying and / or curing unit (110). The drying and / or curing unit (110) may comprise a drying mechanism, for example, a hot air blower, wherein the polymeric layer deposited in polymer application cell (200) is dried and / or heated to a temperature at which crosslinking occurs.

[0102]

[0082] The drying and / or curing unit (110) may comprise any other curing system, for example, UV curing, to create the necessary level of crosslinking of the deposited polymeric layers.

[0103]

[0083] Curing may be performed by more than one of the above mechanisms or methods and drying and / or curing cell (100) may be built to comply with the requirements of any kind of polymer and its corresponding crosslinking method.

[0104]

[0084] According to some embodiments, drying and / or curing cell (100) may comprise a drying and / or curing unit holder (120). Drying and / or curing unit holder (120) may be static, i.e., holding the drying and / or curing unit (110) in a standstill position, or it may be a movable device, i.e., enabling movement of the drying and / or curing unit (110) along different positions and angles within the drying and / or curing cell (100).

[0105]

[0085] A movable curing unit holder (120) may position and or move the drying and / or curing unit(s) (110) inside the drying and / or curing cell (100), in a desired trajectory, speed, distance, and angle, relative to the former / mold, to achieve a controllable and desired curing level, uniform or otherwise, as desired and chosen, at any desired zone of the product, according to the product’s nature and preselected design.

[0106]

[0086] A movable drying and / or curing unit holder (120) may be any suitable device, for example, a piston, or a robotic arm.

[0107]

[0087] The movable drying and / or curing unit holder (120) may be controlled by the micro-factory control system (600) and its dedicated computer program.

[0108]

[0088] A cell door (700) may be part of drying and / or curing cell (100), and may be kept closedduring most (typically at least 90%) of the curing application session, and may preferably be open merely for insertion and removal of the former / mold, in and out of the drying and / or curing cell (100). This is to keep the drying and / or curing cell (100) sealed during the curing session, such to prevent loss of heat to the room in which the micro-factory system (1000) is located at, and maintain controlled temperature throughout the drying and or curing session, or to prevent any contamination which might be caused by chemical reaction generated by the curing process.

[0109]

[0089] A movable former holder (130) may position the former in a desired position, distance, and angle relative to any of the drying and / or curing unit(s) (110), according to the desired, chosen manufacturing process, and may be controlled by the micro-factory control system (600) and its dedicated computer program.

[0110]

[0090] In one embodiment, drying and / or curing cell (100) may be integrated with an optional dry particles application cell (1500, FIG. 1A), as will be described hereinafter. This combined operation in one cell, allows a more compact overall micro-factory size and better space utilization.

[0111]

[0091] The combination of versatile polymers application unit(s) and curing units as described above, all in one micro-factory system, enables fast creation, yet cost and time effective production, of fabrics, garments and clothing items of any kind, including undergarments and outwear items, footwear items, upholstery items, inflatable items of any kind, automotive and aviation interior items, bandages and medical products, variety of polymeric sheets and any item made from a sheet, either flat, curved, or full 3D shaped, including sheet based products, having complex 3D shapes, such as shoes, balls, bags, and the like.

[0112]

[0092] In some embodiments, amoveable manipulator (1400) may be located between or in close proximity to at least two cells. The moveable manipulator (1400) may be movable transfer mechanism structurally arranged to transfer the former (500) between the encapsulated manufacturing cells. The moveable manipulator (1400) may be located such to reach each of the closed cells adjacent to it, and to move the former (500) from one closed cell to another, via theirrespective doors (700). In some embodiments, a micro-factory system (1000) may comprise more than one moveable manipulator (1400) per each micro-factory system (1000), e.g., between two-adjacent cells.

[0113]

[0093] In some embodiments, moveable manipulator (1400) may be used for transferring a former from one encapsulated cell to another, while also serving as a moveable former holder within at least one encapsulated cell. In such cases, the automated door (700) may comprise an opening for the moveable manipulator (1400) to pass therethrough. The automated door (700) may be further configured to close over the moveable manipulator (1400) to ensure minimum exit of polymer particles or contaminates outside the encapsulated cell.

[0114]

[0094] According to some embodiments, the micro-factory system (1000) may comprise at least one product removal device (not shown). The product removal device may be located within a designated cell, and may be equipped with automated grippers for removing the finished product from the former, e.g., by peeling the finished product from the former by using any suitable gripping mechanism, for example, mechanical gripping and / or vacuum.

[0115]

[0095] The product removal device may be located in a separate, dedicated cell, for high throughput micro-factories or it may be embedded as part of another cell designated for a different session, for saving space in micro-factory arrays such as micro-factory system (1000).

[0116]

[0096] Optionally, the micro-factory system (1000) may further comprise a capsulated cell for applying dry particles (1500), comprising: at least one dry particles application unit; and a dry particles applicator unit holder, which may be static, or may be a movable device moving inside the dry particles application closed cell (1500).

[0117]

[0097] The dry particles application closed cell (1500) may comprise a movable former holder, similar to former holder (800), which may position the former at a preferred position, distance, and angle relative to any of the dry particles' application unit, to achieve the best product quality, according to the desired and chosen manufacturing process. The dry particles application closed cell (1500) may be controlled by the micro-factory control system (600) and its dedicatedcomputer program.

[0118]

[0098] The movable former holder may be any suitable device, for example, a piston, a conveyor belt contained in the closed cell, a step or servo motor to spin the former inside the cell, or a robotic arm.

[0119]

[0099] It should be noted that any moveable former holder in any of the closed cells of the present disclosure, whether in any of the following cells: polymer application cell, drying cell, curing cell, dry particles application cell (1500), any former reconditioning cell (1600, FIG. 1A), or any other closed cell, may be configured to position the former at a preferred position, distance, and angle relative to any of the dry particles' application unit, to achieve the best product quality, according to the desired and chosen manufacturing process. Any of these moveable former / mold holders may be any suitable device, for example, a piston, a conveyor belt contained in the closed cell, a step or servo motor to spin the former inside the cell, or a robotic arm.

[0120]

[0100] In some embodiments, the dry particles application closed cell (1500) may comprise at least one automated door, such as door (700). The door is to be kept closed during the dry particles’ application session and for an additional period following end of the session. Preferably, a period of 1 to 5 seconds after the dry particles’ application session is accomplished. This may ensure that the cell is sealed during the dry particles’ application session, to prevent environmental contamination by dry particles or any related pollution.

[0121]

[0101] According to some embodiments, the micro-factory system (1000) may comprise at least one former / mold (500), which provides the shape of the finished product. The former

[0122]

[0102] (500) may be movable between the above-mentioned cells or any other cell types during the manufacturing process. The former (500) may be of a shape that is plain, curved, concave or any combination thereof. In some embodiments, former (500) may have a full 3D complex shape, such as of a sports clothing, a bra, a shoe, and items of the sort. Former (500) may comprise holes, embossing, for example, of a logo, textures and any combinations thereof, which will be reflected and shown in the finished product.

[0103] In some embodiments, the former (500) may be a shape-changing printing bed subsystem as disclosed in US Patent Application Publication No. US20250058517A1, filed December 21, 2022, and entitled “An Adjustable Shape Changing Printing Bed For Additive Manufacturing” hereby incorporated by reference in its entirety. The shape-changing printing bed subsystem may comprise an elastic sheet having an inner side and an external side, the external side defining a printing surface. A manipulator unit may be positioned adjacent to the inner side of the elastic sheet and may be configured to apply force against the elastic sheet so as to change a size and / or shape of the printing surface.

[0123]

[0104] The manipulator unit may comprise at least one inflatable or partly inflatable article having a back surface and a front surface, wherein the front surface faces the inner side of the elastic sheet. Inflation and deflation of the inflatable or partly inflatable article may cause the front surface to move relative to the elastic sheet in one or more of X, Y, and Z axes, thereby applying force to the elastic sheet in one or more coordinates.

[0124]

[0105] In certain embodiments, the inflatable or partly inflatable article may comprise a plurality of independently inflatable zones, enabling localized and differential deformation of the elastic sheet. The subsystem is configured to dynamically alter the geometry of the printing surface during at least a portion of an additive manufacturing process and may be integrated as a component within a larger manufacturing system.

[0125]

[0106] In some embodiments, the manufactured product may be peeled and removed from the former (500), to be used at a standalone finished or partially finished product, in such case the same former (500) is repeatedly used for the creation of more similar products.

[0126]

[0107] In other embodiments, the former (500) is used as one layer of the finished product. In such case the product incorporates the former (500) and the cured polymeric material, which is applied during the water-borne polymer application session. That is, the former (500) is incorporated into each finished product, therefore a new former is used for each new product.

[0127]

[0108] According to some embodiments, the micro-factory system (1000) may further comprisea computerized control system (600). The control system (600) may control the entire operation of the micro-factory system (1000) and each of its closed cells (e.g., cells 200, 100 and others). Control system (600) may control operation of the various units within the closed cells, such as the polymers application unit(s) (300), the dry particles application unit, the drying and / or curing unit (110), as well as the cells' automated doors (700), the air extraction and filtration units (900, 910), the reclaiming units (920), the robotic arm(s) (400, 120, 1400) and every other relevant component of the micro-factory system (1000).

[0128]

[0109] In some embodiments, control system (600) may control operation of the micro-factory system ( 1000) such that there is maximum output, for example, by transferring the mold from one capsulated cell to another within minimum time, and / or by inserting a new mold to an encapsulated cell once that cell has been vacated from a previous mold, such that a few series of product may be manufactured substantially simultaneously, without interfering the process of manufacture using each mold on its own. In some embodiments the control system (600) is connected to an external data source, wherein the external data source demands, and dictates the production operations, including choosing the right production parameters, such as the former(s) type and shape, the polymers’ type, the dry particles characteristics, and any other parameter, relevant for the production.

[0129]

[0110] In some embodiments, the control system (600) may be configured to coordinate operation of the encapsulated manufacturing cells and the movable transfer mechanisms to enable parallel processing of multiple formers within the micro-factory system (1000).

[0130]

[0111] The control system (600) may determine manufacturing sequences based on parameters including, but not limited to, polymer type, drying and / or curing duration, cell availability, former geometry, and desired product characteristics.

[0131]

[0112] In some embodiments, while a first former undergoes drying and / or curing in a drying and / or curing cell, a second former may undergo polymer application in a polymer application cell, thereby increasing overall throughput.

[0113] The control system (600) may further be configured to receive production instructions from an external data source, and dynamically adjust manufacturing parameters and scheduling in response thereto.

[0132]

[0114] In one embodiment, the micro-factory system (1000) may comprise one polymer application cell (200) and one drying and / or curing cell (100).

[0133]

[0115] In another embodiment, at least one encapsulated manufacturing cell may integrate multiple sub-processes, including, for example, polymer application and drying and / or curing within the same cell.

[0134]

[0116] In yet another embodiment, the micro-factory system (1000) may comprise multiple polymer application cells and multiple drying and / or curing cells arranged in a modular array, enabling simultaneous manufacture of multiple products.

[0135]

[0117] According to some embodiments, the micro-factory system (1000) may further comprise an additional closed cell, which may have similar construction and features as those of the cells detailed hereinabove. This additional closed cell may be an at least one capsulated cell for former reconditioning (1600). A former reconditioning cell (1600) may be used to reutilize a former after a product has been removed off it, and prior to reusing the former for manufacture of a new product. A former reconditioning cell (1600) may comprise a washing unit which may implement, for example, water jets and brushes, and / or may comprise a drying system, for example, a hot air blower.

[0136]

[0118] In some embodiments, the former reconditioning cell (1600) may comprise a static or moveable former holder, which may be any suitable device, for example, a piston, a conveyor belt contained in the cell, a step or servo motor to spin the former inside the cell, or a robotic arm.

[0137]

[0119] The movable former holder may position the former in the best position, distance, and angle relative to the former reconditioning device located within former reconditioning cell (1600), to achieve the best product quality, according to the desired and chosen manufacturing process. Themoveable former holder may be controlled by the micro-factory control system (600) and its dedicated computer program.

[0138]

[0120] In other embodiments, the former holder may be static, holding the former in a standstill position, while the systems inside the closed cell may be moveable in a controlled manner to a desired position, distance and angle, controlled by control system (600), to ensure the former is properly cleaned, i.e., reconditioned for full reutilization of the former.

[0139]

[0121] According to some embodiments, the micro-factory system (1000) may further comprise at least one post-process cell (1700, FIG. 1A). The at least one post-process cell (1700) may be equipped with a variety of systems, for operations such as gluing, folding, stitching, fastening, and the like. This may be used to add or combine any additional parts of the product that are manufactured separately and should be applied to the finished product at the post-process cell (1700).

[0140]

[0122] The at least one post- process cell (1700) may comprise a former holder, which may be static or moveable as mentioned hereinabove with respect to previously disclosed cells.

[0141]

[0123] According to some embodiments, the micro-factory system (1000) may be modular and may comprise more than one of any of the disclosed cells or others, and one or more moving mechanism in any desired order, array or layout, such that the micro-factory footprint and throughput may be adjusted per need.

[0142]

[0124] The micro-factory system (1000)may further comprise a variety of auxiliary systems, as common in the art, for example, vision (e.g., via imaging devices such as cameras), internet communication, for receiving data from external sources, over the air (OTA) updates, barcode readers, RFID systems and the like.

[0143]

[0125] In some embodiments, the present disclosure further provides a method (2000) for manufacturing a polymeric product using a micro-factory additive manufacturing system comprising a plurality of encapsulated manufacturing cells.

[0144]

[0126] The method (2000) may comprise operation (2010) which may comprise positioning a formerwithin a first encapsulated polymer application cell, e.g., polymeric material application cell (200). Method (2000) may further comprise operation (2020) comprising applying at least one polymeric material onto at least a portion of the former using at least one polymer application unit, e.g., polymer application unit (300), while the polymeric material application cell is sealed by an automated door, e.g., automated door (700).

[0145]

[0127] Following application of the polymeric material, the method (2000) may comprise operation (2030), which may comprise transferring the former from the polymeric material application cell to at least one additional encapsulated manufacturing cell using a movable transfer mechanism, e.g., moving mechanism (1400). In some embodiments, the automated door of each encapsulated manufacturing cell is configured to remain closed during at least a majority of a respective manufacturing sub-process, and possibly for an additional time period following the completion of that sub-process.

[0146]

[0128] The method (2000) may further comprise an operation (2040), which may comprise drying and / or curing the applied polymeric material in a dedicated encapsulated drying and / or curing or cell, e.g., drying and / or curing cell (100), using at least one curing or drying unit, such that the polymeric material undergoes crosslinking and forms at least one polymeric layer on the former. Method (2000) may comprise operation (2050) comprising forming a polymeric product on the former.

[0147]

[0129] In some embodiments, the method (2000) further comprises an additional operation, which may comprise applying dry particles onto the polymeric material in an encapsulated dry-particles application cell, wherein the dry particles may comprise textile fibers, flocked fibers, or other particulate materials, thereby forming a composite polymeric structure.

[0148]

[0130] In some embodiments, the method (2000) may comprise comprising repeating one or more cycles of polymeric material application and drying and / or curing , optionally with different polymer compositions or additives, to form a multilayer polymeric product having spatially varying properties.

[0149]

[0131] The method (2000) may further comprise removing the finished or semi-finished polymericproduct from the former using a product removal device. In some embodiments, the former is subsequently transferred to a former reconditioning cell, e.g., former reconditioning cell (1600) prior to reuse.

[0150]

[0132] In other embodiments, the former remains incorporated as a structural layer of the finished product.

[0151]

[0133] Conjugated terms such as, by way of example, 'a thing property' implies a property of the thing, unless otherwise clearly evident from the context thereof.

[0152]

[0134] The flowchart and block diagrams illustrate, functionality or an operation of possible implementations of systems, and methods according to various embodiments of the present disclosed subject matter. It should also be noted that, in some alternative implementations, illustrated or described operations may occur in a different order or in combination or as concurrent operations instead of sequential operations to achieve the same or equivalent effect.

[0153]

[0135] The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprising", “including” and / or "having" and other conjugations of these terms, when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0154]

[0136] The terminology used herein should not be understood as limiting, unless otherwise specified, and is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosed subject matter. While certain embodiments of the disclosed subject matter have been illustrated and described, it will be clear that the disclosure is not limited to the embodiments described herein. Numerous modifications, changes, variations, substitutions and equivalents are not precluded.

Claims

CLAIMSWhat is claimed is:

1. A micro-factory additive manufacturing system, comprising:a plurality of encapsulated manufacturing cells, each cell being closed and structurally configured to perform a respective manufacturing sub-process;said plurality of encapsulated manufacturing cells comprise at least one polymeric material application cell comprising at least one polymer application unit; andat least one drying and / or curing cell comprising at least one drying and / or curing unit;at least one former configured to receive polymeric material thereon;at least one movable transfer mechanism structurally arranged to transfer the former between the encapsulated manufacturing cells;an automated door associated with each encapsulated manufacturing cell; anda control system operatively connected to the encapsulated manufacturing cells and the movable transfer mechanism, the control system configured to provide operational commands to at least the polymer application unit, the drying and / or curing unit, the automated doors, and the moveable transfer mechanism,wherein the former is positionable within each encapsulated manufacturing cell by at least one holder to enable formation of a polymeric product on the former.

2. The system of claim 1, wherein each encapsulated manufacturing cell comprises structural walls and at least one automated door forming a sealed enclosure during operation.

3. The system of claim 2, wherein at least one encapsulated manufacturing cell comprises an air extraction unit configured to generate negative pressure within the cell.

4. The system of claim 1, wherein the movable transfer mechanism is configured to move the former through the automated door of each encapsulated manufacturing cell, and wherein the automated door is configured to close during at least a majority of the respective manufacturing sub-process.

5. The system of claim 1, wherein at least one of the polymer application unit, or the drying or curing unit, is mounted on a movable holder, configured to control trajectory, angle, distance, position or orientation relative to the former.

6. The system of claim 1, wherein the polymeric material application cell comprises at least one application unit selected from the group consisting of:a spray nozzle;a needle or pointer nozzle configured to dispense polymeric material as strands;.a precise liquid placement unit configured for localized deposition of polymeric material;an air driven nozzle configured to dispense polymeric web-shaped material;a bead nozzle configured to dispense polymeric material as a bead;a jetting nozzle; anda foam nozzle configured to dispense polymeric foam material.

7. The system of claim 1, further comprising an encapsulated dry-particles application cell comprising a dry-particles applicator unit and a former holder arranged within the cell.

8. The system of claim 7, wherein the dry-particles application cell is structurally integrated with the drying and / or curing cell to form a combined encapsulated manufacturing cell.

9. The system of claim 7, wherein said dry-particles comprise textile fibers, carbon particles, metallic powder or other mineral-based particles.

10. The system of claim 1, wherein the former provides a shape of a finished or a semi-finished product and is plain, curved, concave, or fully three-dimensional, and optionally comprises holes, embossing, logos, textures, or any combinations thereof.

11. The system of claim 1, wherein the former is configured for repeated reuse after removal of a polymeric product, or wherein the former is configured to remain incorporated as a structural layer of the finished or semi-finished polymeric product.

12. The system of claim 1, further comprising a product removal device comprising at least one of a gripper or a vacuum element configured to remove the polymeric product from the former.

13. The system of claim 1, wherein the former is a shape-changing printing bed subsystem configured to change a size and / or shape of a printing surface onto which a polymeric material is applied .

14. The system of claim 1, wherein the control system is configured to control and coordinate operation of the automated doors, the holder, the material application units, and the drying and / or curing units,wherein the control system is configured to schedule transfer of the former between encapsulated manufacturing cells based on manufacturing parameters to increase throughput.

15. The system of claim 14 wherein the control system is connected to an external data source, wherein the external data source dictates the production operations, including selection of formers, polymeric materials, dry particles, and manufacturing parameters.

16. The system of claim 1, wherein the control system is configured to control and coordinate operation of the automated doors, the holder, the material application units, the drying and / or curing units, an air extractor, an air filter, the adjustable shape mold, a former reconditioning system, and a post-process cell;wherein the control system is configured to schedule transfer of the former between encapsulated manufacturing cells based on manufacturing parameters to increase throughput.

17. A method of manufacturing a polymeric product using a micro-factory additive manufacturing system, the method comprising:positioning a former within an encapsulated polymeric material application cell;applying at least one polymeric material onto at least a portion of the former using a polymer application unit while the polymeric material application cell is sealed;transferring the former to at least one additional encapsulated manufacturing cell using a movable transfer mechanism;curing and / or drying the polymeric material in an encapsulated curing and / or drying cell; and forming a polymeric product on the former.

18. The method of claim 17, further comprising repeating the steps of applying polymeric material and curing and / or drying to form a multilayer polymeric product within the encapsulated cells.

19. The method of claim 17, further comprising applying dry particles onto the polymeric material in an encapsulated dry-particles application cell.

20. The method of claim 17, further comprising adjusting a shape of the former prior to or during application of the polymeric material.

21. The method of claim 17, further comprising removing the polymeric product from the former and reusing the former for manufacture of an additional product.

22. The method of claim 17, wherein transferring the former and performing the applying and curing steps are coordinated by a control system to enable simultaneous manufacture of multiple polymeric products.

23. The method of claim 17, wherein the polymeric material is applied by spraying within the encapsulated polymer application cell while the automated door of the polymer application cell remains closed;an air extraction unit generates negative pressure within the polymer application cell during spraying;the former is transferred by a robotic arm through the automated door into an encapsulated curing cell;curing is performed by at least one of hot air curing or ultraviolet curing while the automated door of the curing cell remains closed; andthe former is positioned relative to the polymer application unit and the curing unit by at least one movable holder controlled by the control system.

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