Contour-Adaptive 3D Printing Layers for Irregular Substrates

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Solution Overview

Problem

Existing three-dimensional printing technologies struggle to effectively print on substrates with irregular surfaces without the need for a perfectly flat surface or release layer, particularly in articles of footwear and apparel, as they often result in delamination and uneven layer deposition.

Innovation Solution

A three-dimensional printing system that utilizes a combination of optical sensing and computing systems to detect surface irregularities, adjust layer thickness dynamically, and apply print materials directly onto substrates with varying surface contours, ensuring smooth and planar deposition even on non-flat surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional three-dimensional printing is applied on substrates with irregular surfaces, then printing can be performed without surface preparation, but the printed layers become uneven and delamination occurs

Engineering Contradiction:

Improveprinting process simplicityVSAvoidlayer deposition uniformity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The system dynamically adjusts the deposition head's position and layer thickness in real-time based on feedback from optical sensors that scan the substrate surface. This dynamic adaptation allows the printing process to accommodate irregular surfaces without requiring surface preparation, while maintaining uniform layer deposition through continuous adjustment of printing parameters

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system incorporates optical sensing that detects surface irregularities and provides feedback to the control system. This feedback loop enables real-time modification of the printing path and layer parameters, allowing the system to compensate for surface variations and prevent delamination while maintaining printing simplicity

Inventive Principle:

Principle #23Feedback

2Reliability

If a release layer is applied to enable printing on irregular surfaces, then delamination is prevented, but the manufacturing process becomes more complex

Engineering Contradiction:

Improvelayer adhesionVSAvoidprinting process steps

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system uses the substrate's own surface characteristics as input for the printing process. Optical sensors scan the irregular surface and the control system automatically generates adjusted printing paths and layer parameters, eliminating the need for external release layers or surface preparation steps while ensuring proper layer adhesion

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system changes printing parameters such as layer thickness, deposition speed, and head position dynamically based on detected surface irregularities. This parameter adaptation allows direct printing on irregular surfaces without release layers, maintaining layer adhesion while simplifying the overall manufacturing process

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentEP4296042B1Printing layer in response to substrate contour

Publication Date: 2025.07.02 NIKE INNOVATE CV

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AI summary

A method of printing a three-dimensional structure onto a base having irregularities on the surface is disclosed. A sensing device determines the depth of the irregularity on the surface. A computing system receives an image file including a predetermined thickness of a layer to be printed onto the base. The predetermined thickness is adjusted based on the depth of the irregularity. A printing device prints a layer onto the base having the adjusted predetermined thickness print on the irregularity to make the surface substantially smooth.