Foam Particle Decoration via Additive Manufacturing
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Solution Overview
Problem
Traditional manufacturing methods for athletic equipment and footwear are limited in their ability to combine performance, material properties, and aesthetic appeal, particularly in terms of speed, customizability, and flexibility, especially when using foam particles.
Innovation Solution
The use of additive manufacturing methods to arrange and affix thermoplastic elastomer foam particles, allowing for the creation of components with varying bulk density and stiffness, and integrating decorating techniques such as coating, embossing, or debossing to enhance the appearance and functionality of the final product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional manufacturing methods are used for athletic equipment and footwear, then production processes are well-established and reliable, but the ability to combine performance, material properties, and aesthetic appeal is limited, and speed, customizability, and flexibility are reduced
Solution Approach 1:
The manufacturing process is segmented into distinct stages: arranging foam particles in desired patterns, affixing them to form components, and then decorating the assembled components. This segmentation allows each stage to be optimized independently, enabling high-speed additive manufacturing for structure creation while maintaining flexibility for customization and integration of decorating operations
Solution Approach 2:
The patent merges multiple manufacturing operations into an integrated additive manufacturing process. The arranging, affixing, and decorating operations are combined into a unified manufacturing flow, allowing simultaneous achievement of structural fabrication and aesthetic finishing without requiring separate production lines or post-processing steps
2Adaptability or versatility
If traditional manufacturing methods are used, then production speed is maintained, but the ability to create components with varying bulk density and stiffness is limited
Solution Approach 1:
The additive manufacturing process enables local quality variation by allowing different foam particle arrangements, densities, and affixing parameters in different regions of the component. This permits creation of zones with varying bulk density and stiffness tailored to specific performance requirements within the same component, while maintaining ease of manufacture through a single integrated process
3Productivity
If foam particles are used in traditional manufacturing, then material properties are achieved, but decoration and build time increase
Solution Approach 1:
The foam particles are arranged and affixed to form complete components in a single additive manufacturing process before decoration is applied. This preliminary formation of the structural component integrates what would traditionally be separate manufacturing and decoration operations, reducing total build time while maintaining manufacturing simplicity
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 reduces decoration and build time by up to one-third while enabling the fabrication of components with diverse sub-regions of affixed foam particles, offering improved performance and aesthetic appeal in athletic footwear components like midsoles, outsoles, and heel-cushioning pads.
Implementation Method 1
increasing a temperature of at least a portion of the plurality of foam particles with actinic radiation under conditions effective to melt or soften a portion of the first thermoplastic elastomer material at a first surface of at least one of the plurality of foam particles
Implementation Method 2
increasing a temperature of at least a portion of the plurality of foam particles with actinic radiation
Data Source
AI summary
Methods for manufacturing articles, including articles of footwear, apparel, and sporting equipment are provided. The methods comprise decorating a plurality of foam particles. The decorating can comprise applying a coating on the foam particles, or embossing or debossing the foam particles, or both. The decorating can comprise applying a coating on the foam particles by printing, painting, dyeing, applying a film, or any combination thereof. The plurality of foam particles are affixed utilizing aspects of additive manufacturing methods. 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.