3D Printed Shoe Surface Zoning With Adaptive Infill Transitions
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Solution Overview
Problem
Conventional 3D printing methods for shoes struggle to efficiently apply multiple textures and achieve different material properties without extensive manual adjustments, leading to longer production times and compromised structural integrity and comfort.
Innovation Solution
A method and system for 3D printing footwear that automates the application of textures based on predefined surface properties in a digital model, ensuring seamless transitions between textures and maintaining structural integrity and comfort by controlling material properties during the printing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple closed outer sections are added to create different appearances, then design versatility is improved, but the shoe upper becomes stiffer and less comfortable
Solution Approach 1:
The patent applies different infill densities to different sections of the shoe upper. Closed outer sections have higher infill density for structural support, while mesh sections have lower infill density for flexibility and comfort. This local differentiation allows the shoe to have diverse appearances with closed sections while maintaining overall softness through strategically placed mesh areas with reduced material density.
2Device complexity
If closed outer sections are connected to mesh sections, then design complexity is improved, but the connection becomes stiff and unstable
Solution Approach 1:
The transition zones between closed and mesh sections use gradient infill density changes rather than abrupt transitions. The infill density gradually decreases from the closed section toward the mesh section, creating a smooth mechanical transition that maintains structural integrity while allowing flexibility. This gradual change prevents stress concentration at sharp boundaries.
Solution Approach 2:
The patent employs adaptive infill patterns that adjust density based on local structural requirements. In connection areas, the infill pattern dynamically transitions between different configurations (e.g., from rectangular to triangular patterns) to optimize both strength and flexibility at the interface between closed and mesh sections.
3Manufacturing precision
If manual adjustments are made for each texture variation, then manufacturing precision is improved, but production time increases
Solution Approach 1:
The patent pre-defines multiple infill patterns and density configurations in the digital model before printing. These pre-configured patterns can be automatically selected and applied to different sections based on the desired appearance, eliminating the need for manual adjustments during production. The slicing software automatically assigns appropriate infill parameters to each section based on the model's geometric features.
Solution Approach 2:
The system automatically varies infill parameters (density, pattern type, orientation) across different sections of the shoe based on the digital model's specifications. This parametric control allows precise texture and structural variations to be achieved through software parameters rather than manual physical adjustments, significantly reducing production time while maintaining high precision.
Data Source
AI summary
The invention relates to a method for designing and 3D printing a shoe (100), wherein said shoe (100) comprises a plurality of outer surface areas (101, 102, 103) with different outer surface properties. The method comprises the steps of capturing design input data for a 3D shoe model defining the plurality of different surface areas (101, 102, 103); slicing the 3D shoe model based on the design input data with infill structures (131) at the different surface areas and based on a shoe size with an individual slicing model for said shoe size; and printing the shoe in a print cycle based on the individual slicing model and the respective shoe size.