Foam Particle Additive Manufacturing for Custom Footwear
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Solution Overview
Problem
Existing manufacturing methods for athletic equipment and footwear struggle to combine performance, durability, and customization efficiently, particularly in achieving desired material properties and geometries.
Innovation Solution
The use of foam particles made from thermoplastic elastomers in additive manufacturing methods, such as selective laser sintering, allows for the creation of articles with varied material properties and complex geometries by fusing the foam particles together or to other materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manufacturing methods are used for athletic equipment and footwear, then production processes are well-established and reliable, but build time is long and customization is limited
Solution Approach 1:
The manufacturing process segments the article into multiple layers of foam particles that can be selectively fused. Each layer can be customized independently while maintaining overall structural integrity, enabling both rapid production and customization simultaneously
Solution Approach 2:
The patent changes the physical state of foam particles through controlled heating and fusing processes. By adjusting parameters such as temperature, fusion depth, and layer composition, the system achieves rapid manufacturing while accommodating diverse customization requirements
2Adaptability or versatility
If foam particles are used in additive manufacturing, then material properties and geometries can be varied, but manufacturing process complexity increases
Solution Approach 1:
The foam particle system serves multiple functions: it provides structural support, cushioning, and geometric complexity all through a single additive manufacturing process. The same foam particles can be fused to different extents to create varying material properties without requiring different manufacturing systems
Solution Approach 2:
The patent uses a binding agent as an intermediary to fuse foam particles together. This mediator simplifies the manufacturing process by enabling controlled fusion of particles through a single mechanism rather than requiring multiple complex bonding processes
3Manufacturing precision
If selective laser sintering is used to fuse foam particles, then manufacturing precision and material properties are improved, but energy consumption increases
Solution Approach 1:
The selective laser sintering process applies energy locally only to specific regions where foam particles need to be fused. This localized approach achieves high manufacturing precision while minimizing overall energy consumption by avoiding unnecessary heating of entire components
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the rapid production of customized footwear components with improved performance and material properties, reducing build time by at least one-third and allowing for the fabrication of components with multiple sub-regions of differentially fused foam particles.
Implementation Method 1
directing an energy beam at a target area of a layer of a plurality of foam particles for a period of time, wherein a selected portion of the layer of a plurality of foam particles is heated by the energy beam thereby melting a portion of one or more surfaces on the plurality of foam particles located therein
Implementation Method 2
a selected portion of the layer of a plurality of foam particles is heated by the energy beam thereby melting a portion of one or more surfaces on the plurality of foam particles located therein
Data Source
AI summary
Methods for manufacturing articles of footwear are provided. In various aspects, the methods comprise utilizing additive manufacturing methods with foam particles. In some aspects, the additive manufacturing methods comprise increasing the temperature of a plurality of foam particles with actinic radiation under conditions effective to fuse a portion of the plurality of foam particles comprising one or more thermoplastic elastomers. Increasing the temperature of the foam particles can be carried out for one or multiple iterations. The disclosed methods can be used to manufacturer articles with sub-regions that exhibit differing degrees of fusion between the foam particles, thereby resulting in sub-regions with different properties such as density, resilience, and/or flexural modulus. This abstract is intended as a scanning tool for purposes of searching in the particular art and is not intended to be limiting of the present disclosure.