3D Printed Shoe Part Infill Orientation for Flexibility and Breathability
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Solution Overview
Problem
Existing 3D printing methods for shoe components fail to achieve a balance between breathability, aesthetics, and flexibility, often compromising on one or more of these aspects, and do not effectively utilize the outer and inner contours of the shoe to control infill patterns for optimal mechanical properties and appearance.
Innovation Solution
A method for 3D printing shoe parts that involves constructing infill patterns based on the outer and inner contours of the shoe, with orientations of infill connecting lines determined by these contours, allowing for variable flexibility and appearance through angles and layer-by-layer adjustments using flexible filaments like TPU, TPE, PP, and bio-based polymers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If regular infill patterns (honeycomb, grid, triangles) are used throughout the entire printing layer, then manufacturing simplicity is maintained, but the outer appearance and softness of the printed article are compromised
Solution Approach 1:
The patent applies different infill patterns to different regions of the shoe upper. Specifically, a first infill pattern is used in a first region and a second infill pattern is used in a second region, allowing each region to have optimized properties for its specific function (e.g., breathability in some areas, structural support in others).
Solution Approach 2:
The shoe upper is divided into multiple printing layers, with at least one open printing layer that contains infill patterns. This segmentation allows the infill to be strategically placed only where needed for structural support, while other areas remain open for breathability and aesthetic purposes.
2Strength
If closed shell structures are used, then structural integrity and representation of the model are improved, but breathability is reduced
Solution Approach 1:
The shell is segmented into open printing layers and closed printing layers. Open layers provide breathability by allowing air flow through the structure, while closed layers provide structural integrity where needed. This segmentation resolves the contradiction by distributing the functions spatially.
Solution Approach 2:
The open printing layers create a porous structure that allows air permeability while maintaining structural coherence. The infill patterns within these open layers provide internal support without completely closing the structure, thus maintaining breathability.
3Productivity
If infill patterns are oriented independently of the outer contour, then printing speed is maximized, but flexibility and strength in specific directions are compromised
Solution Approach 1:
The infill pattern orientation is adapted to match the local geometry of the shoe upper. Connection lines are oriented to follow the contours and curvature of each specific region, providing optimal strength and flexibility in the directions required by the local structure rather than using a uniform orientation throughout.
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
The method enhances the flexibility and appearance of 3D printed shoe parts by creating a mesh-like structure that adapts to the shoe's shape, providing improved mechanical properties and design consistency across varying thicknesses, while maintaining breathability and aesthetic appeal.
Implementation Method 1
a 3D printing head with a nozzle and an extruder for extruding thermoplastic material
Implementation Method 2
said infill structure comprising infill connecting lines (31) and/or infill connecting structures (32), wherein the orientations of the infill connecting lines (31) and/or the infill connecting structures (32) are determined based on the outer section (11) of the part of the shoe
Data Source
AI summary
The invention relates to 3D printing of a shoe part (100) with a plurality of different printing layers (10), wherein said shoe part is made by additive layer-by-layer printing. Each printing layer (10) defines an outer section (11) of the shoe part, an inner section (12) of the shoe part and an intermediate section (13) which connects the outer section (11) and the inner section (12) by an infill structure (30), wherein and said infill structure (30) comprising infill connecting lines (31) and/or infill connecting structures (32). According to the novel approach of the present invention, no predetermined standard infill structures are used but rather the orientations of the infill connecting lines (31) and/or the infill connecting structures (32) are determined based on the outer section (11) of the part of the individual shoe.