U.S. patent application number 14/635233 was filed with the patent office on 2015-08-20 for direct printing to fabric.
The applicant listed for this patent is Nike, Inc.. Invention is credited to David P. Jones, Ryan R. Larson.
Application Number | 20150230562 14/635233 |
Document ID | / |
Family ID | 49151301 |
Filed Date | 2015-08-20 |
United States Patent
Application |
20150230562 |
Kind Code |
A1 |
Jones; David P. ; et
al. |
August 20, 2015 |
Direct Printing to Fabric
Abstract
Methods and systems are disclosed for three-dimensional printing
directly onto an article of apparel. Disclosed is a method and
system for direct three-dimensional printing onto an article of
apparel, including designing a three-dimensional pattern for
printing onto the article, positioning at least a portion of the
article on a tray in a three-dimensional printing system, the
portion being positioned substantially flat on the tray, printing a
three-dimensional material directly onto the article using the
designed pattern, curing the printed material, and removing the
article from the three-dimensional printing system.
Inventors: |
Jones; David P.; (Beaverton,
OR) ; Larson; Ryan R.; (Portland, OR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Nike, Inc. |
Beaverton |
OR |
US |
|
|
Family ID: |
49151301 |
Appl. No.: |
14/635233 |
Filed: |
March 2, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13553348 |
Jul 19, 2012 |
8993061 |
|
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14635233 |
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Current U.S.
Class: |
425/140 ;
425/166 |
Current CPC
Class: |
B33Y 80/00 20141201;
A43B 23/0235 20130101; B33Y 50/00 20141201; A43B 3/0084 20130101;
B33Y 10/00 20141201; A43D 8/00 20130101; A43B 1/04 20130101; A43D
2200/00 20130101; B29C 64/106 20170801; B29C 70/78 20130101; A43D
11/00 20130101; B33Y 30/00 20141201; B29L 2031/50 20130101; A43D
2200/60 20130101; B29K 2713/00 20130101; A43B 23/026 20130101 |
International
Class: |
A43D 8/00 20060101
A43D008/00 |
Claims
1. A system for three-dimensional printing directly onto a fabric
upper of an article of footwear, comprising: a first nontransitory
computer-readable medium encoded with a first computer program
product loadable into a first memory of a first computer and
including first software code portions for storing a
three-dimensional pattern for printing directly onto the fabric
upper; a print server; a switching device; a three-dimensional
printer device; wherein the print server is in direct communication
with the three-dimensional printer device and the switching device;
wherein the switching device is in direct communication with the
three-dimensional printer device and the print server; wherein the
first nontransitory computer readable medium is in direct
communication with the switching device; wherein the print server
comprises a second nontransitory computer-readable medium encoded
with a second computer program product loadable into a second
memory of a second computer and including second software code
portions configured, when executed on the second computer, for
instructing the three-dimensional printing device to print directly
onto the fabric upper through a sequence of printing steps; wherein
the three-dimensional printer device comprises a tray for receiving
the fabric upper, at least one printing head for printing
three-dimensional material onto the fabric upper in the sequence,
and at least one ultraviolet light for curing the three-dimensional
material printed onto the fabric upper; and wherein the
three-dimensional printer device is configured to print the
three-dimensional material onto at least a portion of the fabric
upper that has at least one irregular surface.
2. The system according to claim 1, wherein the three-dimensional
printer device is configured to compensate for irregularities in
the at least one irregular surface by at least one of adjusting a
distance between the at least one printing head and the at least
one irregular surface and adjusting at least one of size, rate, and
distribution of three-dimensional material ejected from the at
least one printing head.
3. The system according to claim 1, wherein the at least one
irregular surface comprises at least one of a knit and a weave of
the fabric upper.
4. The system according to claim 1, wherein the at least a portion
of the fabric upper comprises a side of the fabric upper; wherein
the three-dimensional printer device is configured to print a
plurality of loops onto the side of the fabric upper; and wherein
each loop of the plurality of loops extends upwardly from a lower
portion of the side of the fabric upper of the article of footwear
and around a lace aperture.
5. The system according to claim 1, wherein the second software
code portions are configured, when executed on the second computer,
to instruct the three-dimensional printing device to wait a
predetermined amount of time after printing of the
three-dimensional material prior to curing the three-dimensional
material with the at least one ultraviolet light, to allow the
three-dimensional material to at least partially absorb into the
fabric upper prior to curing the three-dimensional material.
6. The system according to claim 1, wherein the second software
code portions are configured, when executed on the second computer,
to instruct the three-dimensional printing device to: print a first
layer of three-dimensional material; wait a predetermined amount of
time after printing the first layer of three-dimensional material
prior to curing the first layer of three-dimensional material with
the at least one ultraviolet light, to allow the first layer of
three-dimensional material to at least partially absorb into fabric
of the at least a portion of the fabric upper; cure the first layer
of three-dimensional material with the at least one ultraviolet
light; print at least one additional layer of three-dimensional
material on the cured first layer; and cure the at least one
additional layer of three-dimensional material with the at least
one ultraviolet light.
7. The system according to claim 6, wherein the first layer and the
at least one additional layer differ in at least one of modulus of
elasticity and color.
8. The system according to claim 1, wherein the fabric upper
comprises at least one of a textile, a natural fabric, a synthetic
fabric, a knit, a woven material, a nonwoven material, a mesh, a
leather, a synthetic leather, a polymer, a rubber, and a foam.
9. The system according to claim 1, wherein the fabric upper
prevents durable adhesion of the three-dimensional material to the
tray.
10. The system according to claim 1, wherein the three-dimensional
material comprises at least one of an ink, a resin, an acrylic, a
polymer, a thermoplastic material, a thermosetting material, and a
light-curable material.
11. The system according to claim 1, wherein the three-dimensional
material further comprises a filler material.
12. The system according to claim 1, wherein the three-dimensional
material is bonded to the fabric upper of the article of
footwear.
13. A system for printing three-dimensional material directly onto
a fabric portion of an upper of an article of footwear, comprising:
a three-dimensional printer device; a computer in communication
with the three-dimensional printer device, wherein the computer
includes: a first nontransitory computer-readable medium encoded
with a first computer program product loadable into memory of the
computer and including first software code portions for storing a
three-dimensional pattern for printing directly onto the fabric
portion; a second nontransitory computer-readable medium encoded
with a second computer program product loadable into memory of the
computer and including second software code portions for
instructing, when executed on the computer, the three-dimensional
printing device to print directly onto the fabric portion through a
sequence of printing steps corresponding to the three-dimensional
pattern; wherein the three-dimensional printer device comprises a
tray for receiving the upper, a printing head for printing
three-dimensional material onto the fabric portion in the sequence
of printing steps, and an ultraviolet light for curing the
three-dimensional material printed onto the fabric portion of the
upper; and wherein the second software code portions are
configured, when executed on the computer, to instruct the
three-dimensional printer device to print the three-dimensional
material onto an irregular surface of the fabric portion of the
upper.
14. The system according to claim 13, wherein the second software
code portions are configured, when executed, to instruct the
three-dimensional printer device to compensate for irregularities
in the irregular surface by at least one of adjusting a distance
between the printing head and the irregular surface and adjusting
at least one of size, rate, and distribution of three-dimensional
material ejected from the printing head.
15. The system according to claim 13, wherein the second software
code portions are configured, when executed, to instruct the
three-dimensional printer device to compensate for an uneven
surface of a knit or weave of the irregular surface of the fabric
portion of the upper.
16. The system according to claim 13, wherein the fabric portion of
the upper comprises a side of the upper; wherein the second
software code portions are configured, when executed, to instruct
the three-dimensional printer device to print a plurality of loops
onto the side of the upper; and wherein each loop of the plurality
of loops extends upwardly from a lower portion of the side of the
upper of the article of footwear and around a lace aperture.
17. The system according to claim 13, wherein the second software
code portions are configured, when executed, to instruct the
three-dimensional printing device to allow the three-dimensional
material to at least partially absorb into the fabric portion prior
to curing the three-dimensional material.
18. The system according to claim 13, wherein the computer
comprises a single computer, partial resources of a computer, or
two or more computers communicating with each other.
19. A system for printing three-dimensional material directly onto
a fabric portion of an upper of an article of footwear, comprising:
a three-dimensional printer device including a tray for receiving
the upper laid substantially flat on the tray with the fabric
portion presenting an irregular surface, a printing head for
printing three-dimensional material onto the fabric portion, and an
ultraviolet light for curing the three-dimensional material printed
onto the fabric portion; a computer in communication with the
three-dimensional printer device; wherein the computer provides the
three-dimensional printer device with instructions configured, when
executed on the three-dimensional printer device, to cause the
three-dimensional printer device to print directly onto the fabric
portion through a sequence of printing steps corresponding to a
three-dimensional pattern; and wherein, based on the instructions,
the three-dimensional printer device prints the three-dimensional
material onto the fabric portion while compensating for
irregularities in the irregular surface of the fabric portion.
20. The system according to claim 19, wherein, based on the
instructions, the three-dimensional printer device compensates for
irregularities in the irregular surface by at least one of
adjusting a distance between the printing head and the irregular
surface and adjusting at least one of size, rate, and distribution
of three-dimensional material ejected from the printing head.
Description
[0001] This application is a division of U.S. Patent Publication
Number US2014/0020191, published Jan. 23, 2014 (application Ser.
No. 13/553,348, filed Jul. 19, 2012), which is herein incorporated
by reference in its entirety.
TECHNICAL FIELD
[0002] This disclosure relates generally to the field of
three-dimensional ("3D") printing onto an article of apparel,
footwear, or equipment, and more specifically to methods and
systems for 3D printing directly onto fabric apparel materials.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] The accompanying drawings, which are incorporated in and
constitute a part of this specification, illustrate embodiments
and, together with the description, serve to explain the features,
advantages, and principles of the embodiments disclosed throughout
this disclosure. For illustration purposes, the following drawings
may not be to scale. Moreover, like reference numerals designate
corresponding parts throughout the different views. In the
drawings:
[0004] FIG. 1 shows an elevated view of an article of footwear
consistent with an embodiment of the disclosure;
[0005] FIG. 2 shows an elevated view of a top portion of an article
of footwear consistent with an embodiment of the disclosure;
[0006] FIG. 3 shows an elevated view of a medial side of an article
of footwear consistent with an embodiment of the disclosure;
[0007] FIG. 4 shows a perspective cutaway view of an article of
footwear consistent with an embodiment of the disclosure;
[0008] FIG. 5 shows an exploded perspective cutaway view of an
article of footwear consistent with an embodiment of the
disclosure;
[0009] FIG. 6 shows a schematic view of a 3D printing system
consistent with an embodiment of the disclosure;
[0010] FIG. 7 shows a perspective view of a 3D printer with an
upper portion of an article of footwear inserted therein,
consistent with an embodiment of the disclosure;
[0011] FIG. 8 shows a cross sectional view of a conventional 3D
printed surface on a release layer over a substrate;
[0012] FIG. 9 shows a cross sectional view of a conventional 3D
printed surface being removed from a release layer and
substrate;
[0013] FIG. 10 shows a cross sectional view of a 3D printed
material on an upper portion of an article of footwear, consistent
with an embodiment of the disclosure;
[0014] FIG. 11 shows a cross sectional view of a 3D printed
material on an upper portion of an article of footwear being
removed from a tray, consistent with an embodiment of the
disclosure;
[0015] FIG. 12 shows a perspective view of a 3D printed material on
an upper portion of an article of footwear, consistent with an
embodiment of the disclosure;
[0016] FIG. 13 shows a perspective view of a 3D printed material on
an upper portion of an article of footwear being removed from a
tray, consistent with an embodiment of the disclosure;
[0017] FIG. 14 shows a cross sectional view of a first layer of 3D
printed material on an upper portion of an article of footwear and
a curing process, consistent with an embodiment of the
disclosure;
[0018] FIG. 15 shows a cross sectional view of a second layer of 3D
printed material on an upper portion of an article of footwear and
a curing process, consistent with an embodiment of the
disclosure;
[0019] FIG. 16 shows a cross sectional view of a third layer of 3D
printed material on an upper portion of an article of footwear and
a curing process, consistent with an embodiment of the
disclosure;
[0020] FIG. 17 shows a cross sectional view of a fourth layer of 3D
printed material on an upper portion of an article of footwear and
a curing process, consistent with an embodiment of the
disclosure;
[0021] FIG. 18 shows an overhead view of an upper portion of an
article of footwear placed on a tray and prior to 3D printing,
consistent with an embodiment of the disclosure;
[0022] FIG. 19 shows a cross sectional view of part of the upper
portion of an article of footwear shown in FIG. 18 placed on a tray
and prior to 3D printing, consistent with an embodiment of the
disclosure;
[0023] FIG. 20 shows an overhead view of an upper portion of an
article of footwear placed on a tray and post 3D printing,
consistent with an embodiment of the disclosure;
[0024] FIG. 21 shows a cross sectional view of part of the upper
portion of an article of footwear shown in FIG. 20 placed on a tray
and post 3D printing, consistent with an embodiment of the
disclosure;
[0025] FIG. 22 shows a schematic view of a 3D printing system and
method consistent with an embodiment of the disclosure;
[0026] FIG. 23 shows a process for manufacturing an article of
footwear, consistent with an embodiment of the disclosure;
[0027] FIG. 24 shows an overhead view of an upper portion of an
article of footwear after printing and prior to completion of
footwear assembly consistent with an embodiment of the
disclosure;
[0028] FIG. 25 shows a perspective view of an upper portion of an
article of footwear after printing and during placement in contact
with a sole portion during assembly consistent with an embodiment
of the disclosure;
[0029] FIG. 26 shows a perspective view of an upper portion of an
article of footwear after 3D printing and prior to completion of
footwear assembly consistent with an embodiment of the
disclosure;
[0030] FIG. 27 shows an elevated view of an article of footwear
assembled after printing of the 3D pattern shown in FIG. 26,
consistent with an embodiment of the disclosure;
[0031] FIG. 28 shows an elevated view of a top portion of the
article of footwear shown in FIG. 27, consistent with an embodiment
of the disclosure;
[0032] FIG. 29 shows an elevated view of a medial side of the
article of footwear shown in FIG. 27, consistent with an embodiment
of the disclosure; and
[0033] FIG. 30 shows an elevated view of a rear portion of the
article of footwear shown in FIG. 27, consistent with an embodiment
of the disclosure.
DETAILED DESCRIPTION
[0034] The following discussion and accompanying figures disclose
methods and systems for 3D printing and assembly of an article of
footwear having an upper that includes 3D printing directly onto
the upper material. In particular, an exemplary method is disclosed
for 3D printing directly onto a fabric material, which allows
building of a structure on the fabric for use in apparel
applications. The disclosed methods and systems may use any
suitable 3D printing system.
[0035] As used throughout this disclosure, the terms
"three-dimensional printing system," "three-dimensional printer,"
"3D printing system," and "3D printer" refer to any known 3D
printing system or printer. Contrary to known 3D printing methods,
however, the disclosed methods and systems accomplish 3D printing
directly onto any surface of a textile, a natural fabric, a
synthetic fabric, a knit, a woven material, a nonwoven material, a
mesh, a leather, a synthetic leather, a polymer, a rubber, and a
foam, or any combination of them, without the need for a release
layer interposed between a substrate and the bottom of the printed
material, and without the need for a perfectly or near-perfectly
flat substrate surface on which to print. For example, the
disclosed methods may include printing a resin, acrylic, or ink
material onto a fabric, for example a knit material, where the
material is adhered/bonded to the fabric and where the material
does not generally delaminate when flexed, rolled, worked, or
subject to additional assembly processes/steps. As used throughout
this disclosure, the term "fabric" may be used to refer generally
to materials chosen from any textile, natural fabric, synthetic
fabric, knit, woven material, nonwoven material, mesh, leather,
synthetic leather, polymers, rubbers, and foam. Also as used
throughout this disclosure, the terms "printing" or "printed," and
"depositing" or "deposited," are each used synonymously, and are
intended to refer to the association of a material from a source of
the material to a receiving surface or object.
[0036] Consistent with an embodiment, an exemplary article of
footwear is disclosed as having a general configuration suitable
for walking or running. As used throughout this disclosure, the
terms "article of footwear" and "footwear" include any footwear and
any materials associated with footwear, including an upper, and may
also be applied to a variety of athletic footwear types, including
baseball shoes, basketball shoes, cross-training shoes, cycling
shoes, football shoes, tennis shoes, soccer shoes, and hiking
boots, for example. As used throughout this disclosure, the terms
"article of footwear" and "footwear" also include footwear types
that are generally considered to be nonathletic, formal, or
decorative, including dress shoes, loafers, sandals, slippers, boat
shoes, and work boots. Disclosed embodiments apply, therefore, to
any footwear type.
[0037] While the disclosed embodiments are described in the context
of footwear, the disclosed embodiments may further be equally
applied to any article of clothing, apparel, or equipment that
includes 3D printing. For example, the disclosed embodiments may be
applied hats, caps, shirts, jerseys, jackets, socks, shorts, pants,
undergarments, athletic support garments, gloves, wrist/arm bands,
sleeves, headbands, any knit material, any woven material, any
nonwoven material, sports equipment, etc. Thus, as used throughout
this disclosure, the term "article of apparel" may refer to any
apparel or clothing, including any article of footwear, as well as
hats, caps, shirts, jerseys, jackets, socks, shorts, pants,
undergarments, athletic support garments, gloves, wrist/arm bands,
sleeves, headbands, any knit material, any woven material, any
nonwoven material, etc. As used throughout this disclosure, the
terms "article of apparel," "apparel," "article of footwear," and
"footwear" may also refer to a textile, a natural fabric, a
synthetic fabric, a knit, a woven material, a nonwoven material, a
mesh, a leather, a synthetic leather, a polymer, a rubber, and a
foam. For example, materials used in footwear formation are
disclosed in U.S. Pat. No. 5,709,954, which is incorporated by
reference.
[0038] In accordance with the systems and methods described
throughout this disclosure, there is provided a method of direct
three-dimensional printing onto an article of apparel, comprising:
designing a three-dimensional pattern for printing onto the
article; positioning at least a portion of the article on a tray in
a three dimensional printing system, the portion being positioned
substantially flat on the tray; printing a three-dimensional
material directly onto the article using the designed pattern;
curing the printed material; and removing the article from the
three-dimensional printing system.
[0039] In accordance with the systems and methods described
throughout this disclosure, there is also provided a method of
fabricating an article of footwear, comprising: designing a
three-dimensional pattern for printing onto an upper; providing the
pattern to a print server; positioning at least a portion of the
upper on a tray in a three dimensional printing system, the portion
being positioned substantially flat on the tray; aligning the
portion of the upper on the tray with the pattern; printing a
three-dimensional material directly onto the upper using the
designed pattern on the print server and the three-dimensional
printing system; curing the printed material; removing the upper
from the three-dimensional printing system; and assembling the
article of footwear using the printed upper and at least one
footwear component chosen from a sock liner, a midsole, and an
outsole.
[0040] In accordance with the systems and methods described
throughout this disclosure, there is provided a method of
fabricating an article of footwear, comprising: designing a
three-dimensional pattern for printing onto an upper; providing the
pattern to a print server; positioning at least a portion of the
upper on a tray in a three dimensional printing system, the portion
being positioned substantially flat on the tray; aligning the
portion of the upper on the tray with the pattern; printing a first
layer of three-dimensional material directly onto the upper using
the designed pattern on the print server and the three-dimensional
printing system; allowing the first layer of printed material to at
least partially absorb into a surface of the upper; curing the
first layer, wherein the cured first layer has a first modulus of
elasticity; printing at least one additional layer of the material
on the cured first layer; curing the at least one additional layer,
wherein the cured at least one additional layer has a different
modulus of elasticity than the first modulus; removing the upper
from the three-dimensional printing system; and assembling the
article of footwear using the printed upper and at least one
footwear component chosen from a sock liner, a midsole, and an
outsole.
[0041] In accordance with the systems and methods described
throughout this disclosure, there is provided a method of
fabricating an article of footwear, comprising: designing at least
a first three-dimensional pattern and a second three dimensional
pattern for printing onto an upper; providing the at least first
and second three-dimensional patterns to a print server;
positioning at least a first portion of the upper on a tray in a
three dimensional printing system, the first portion being
positioned substantially flat on the tray; aligning the first
portion of the upper with the first pattern; printing at least one
layer of a first three-dimensional material having a first material
property directly onto the first portion of the upper using the
designed first pattern; allowing the at least one layer of printed
first three-dimensional material to at least partially absorb into
a first portion of a surface of the upper; curing the at least one
layer of printed first three-dimensional material; positioning at
least a second portion of the upper on the tray, the second portion
being positioned substantially flat on the tray; aligning the
second portion of the upper with the second pattern; printing at
least one layer of a second three-dimensional material having a
second material property directly onto the second portion of the
upper using the designed second pattern; allowing the at least one
layer of printed second three-dimensional material to at least
partially absorb into a second portion of the surface of the upper;
curing the at least one layer of printed second three-dimensional
material; removing the upper from the three-dimensional printing
system; and assembling the article of footwear using the printed
upper and at least one footwear component chosen from a sock liner,
a midsole, and an outsole.
[0042] In accordance with the systems and methods described
throughout this disclosure, there is provided a system for
three-dimensional printing directly onto a fabric upper,
comprising: a first nontransitory computer-readable medium encoded
with a first computer program product loadable into a first memory
of a first computer and including first software code portions for
storing a three-dimensional pattern for printing directly onto the
upper; a print server; a switching device; and a three-dimensional
printer device, wherein the print server is in direct communication
with the three dimensional printer device and the switching device,
wherein the switching device is in direct communication with the
three dimensional printer device and the print server, wherein the
first nontransitory computer readable medium is in direct
communication with the switch, wherein the print server comprises a
second nontransitory computer-readable medium encoded with a second
computer program product loadable into a second memory of a second
computer and including second software code portions for
instructing the three-dimensional printing device to print directly
onto the upper through a sequence of printing steps; wherein the
three dimensional printer device comprises a tray receiving the
fabric upper, at least one printing head for printing onto the
upper in the sequence, and at least one ultraviolet light for
curing material printed onto the upper, and wherein the three
dimensional printing system does not require a substantially flat
surface for printing.
[0043] Additional features and advantages will be set forth in part
in the description that follows, being apparent from the
description or learned by practice of embodiments. Both the
foregoing description and the following description are exemplary
and explanatory, and are intended to provide further explanation of
the embodiments as claimed.
[0044] An article of footwear generally includes two primary
elements: an upper and a sole structure. The upper may be formed
from a plurality of material elements (e.g., one or more layers of
a textile, a natural fabric, a synthetic fabric, a knit, a woven
material, a nonwoven material, a mesh, a leather, a synthetic
leather, a polymer, a rubber, and a foam, etc.) stitched or
adhesively bonded together to form a void on the interior of the
footwear for comfortably and securely receiving a foot. More
particularly, the upper forms a structure that extends over instep
and toe areas of the foot, along medial and lateral sides of the
foot, and around a heel area of the foot. The upper may also
incorporate a lacing system to adjust fit of the footwear, as well
as permitting entry and removal of the foot from the void within
the upper. In addition, the upper may include a tongue that extends
under the lacing system to enhance adjustability and comfort of the
footwear, and the upper may incorporate a heel counter. For
example, the upper may be a high tensile strength knit or mesh
sockfit upper.
[0045] Various material elements forming the upper may impart
different properties to different areas of the upper. For example,
textile elements may provide breathability and may absorb moisture
from the foot, foam layers may compress to impart comfort, and
leather may impart durability and wear-resistance. Consistent with
an embodiment, therefore, 3D printed materials disposed on the
upper during assembly of an article of footwear may thus be used to
customize the properties of the upper and hence article of
footwear. As disclosed throughout this disclosure, for example, 3D
printed materials may be disposed on the upper to impart customized
material properties such as increased strength, rigidity, support,
flexibility, abrasion resistance, or variations thereof, based on
desired material properties for specific portions of the upper and
the article of footwear as a whole.
[0046] A sole structure is secured to a lower portion of the upper
so as to be positioned between the foot and the ground. In athletic
footwear, for example, the sole structure includes a midsole and an
outsole. The midsole may be formed from a polymer foam material
that attenuates ground reaction forces (i.e., provides cushioning)
during walking, running, and other ambulatory activities. The
midsole may also include cushions, such as fluid-filled chambers,
plates, moderators, or other elements that further attenuate
forces, enhance stability, or influence the motions of the foot,
for example. The outsole forms a ground-contacting element of the
footwear and is usually fashioned from a durable and wear-resistant
rubber material that includes texturing to impart traction. The
sole structure may also include a sockliner positioned within the
upper and proximal to a lower surface of the foot to enhance
footwear comfort.
[0047] Consistent with an embodiment, an article of footwear 10,
throughout this disclosure referred to simply as footwear 10, is
depicted in FIGS. 1-3 as including an upper 20 and a sole structure
30. For reference purposes, footwear 10 may be divided into three
general regions: a forefoot region 11, a midfoot region 12, and a
heel region 13. Footwear 10 also includes a lateral side 14 and a
medial side 15. Forefoot region 11 generally includes portions of
footwear 10 corresponding with the toes and the joints connecting
the metatarsals with the phalanges. Midfoot region 12 generally
includes portions of footwear 10 corresponding with the arch area
of the foot, and heel region 13 corresponds with rear portions of
the foot, including the calcaneus bone. Lateral side 14 and medial
side 15 extend through each of forefoot region 11, midfoot region
12, and heel region 13 (as seen in FIG. 3) and correspond with
opposite sides of footwear 10 that are separated by a lace region
16, which extends along a length of footwear 10. Forefoot region
11, midfoot region 12, heel region 13, lateral side 14, and medial
side 15 are not intended to demarcate precise areas of footwear 10.
Rather, they are intended to represent general areas of footwear 10
to aid in this description. In addition to footwear 10, forefoot
region 11, midfoot region 12, heel region 13, lateral side 14, and
medial side 15 may also be applied to upper 20, sole structure 30,
and individual elements thereof.
[0048] Upper 20 is secured to sole structure 30 and extends between
the foot and the ground when footwear 10 is worn. The primary
elements of sole structure 30 are a midsole 31, an outsole 32, and
a sockliner 33. A lower surface of upper 20 is secured to midsole
31, and midsole 31 may be formed from a compressible polymer foam
element (e.g., a polyurethane or ethylvinylacetate foam) that
attenuates ground reaction forces (i.e., provides cushioning) when
compressed between the foot and the ground during walking, running,
or other ambulatory activities. In further configurations, midsole
31 may incorporate fluid-filled chambers, plates, moderators, or
other elements that further attenuate forces, enhance stability, or
influence the motions of the foot, or midsole 31 may be primarily
formed from a fluid-filled chamber. Outsole 32 is secured to a
lower surface of midsole 31 and may be formed from a wear-resistant
material (e.g., a polymer or a rubber) that is textured to impart
traction and provide durability. Sockliner 33 is located within
upper 20 and is positioned to extend under a lower surface of the
foot. Although this configuration for sole structure 30 provides an
example of a sole structure that may be used in connection with
upper 20, a variety of other conventional or nonconventional
configurations for sole structure 30 may also be utilized.
Accordingly, the structure and features of sole structure 30 or any
sole structure utilized with upper 20 may vary considerably.
[0049] Upper 20 may be stitched or bonded together to form a void
within footwear 10 for receiving and securing a foot relative to
sole structure 30. The void is shaped to accommodate the foot and
extends along the lateral side of the foot, along the medial side
of the foot, over the foot, around the heel, and under the foot.
Access to the void is provided by an ankle opening 50 located in at
least heel region 13.
[0050] Lace 40 may extend through various lace apertures 41 and
permits the wearer to modify dimensions of upper 20 to accommodate
the proportions of the foot. More particularly, lace 40 may permit
the wearer to tighten upper 20 around the foot, and lace 40 may
permit the wearer to loosen upper 20 to facilitate entry and
removal of the foot from the void (i.e., through ankle opening 50).
As an alternative to lace apertures 41, upper 20 may include other
lace-receiving elements, such as loops, eyelets, and D-rings. In
addition, upper 20 may include a tongue 60 that extends between
ankle opening 50 and lace 40 to enhance the comfort and performance
of footwear 10. In some configurations, upper 20 may incorporate a
heel counter that limits heel movement in heel region 13 or a
wear-resistant toe guard located in forefoot region 11. In some
cases, upper 20 may include a plurality of lace apertures 41,
including evenly spaced apertures on lateral side 14 of lace region
16 extending from ankle opening 50 to forefoot region 11.
Similarly, upper 20 may include a symmetrical, evenly spaced group
of lace apertures 41 on medial side 14 of lace region 16. Lace 40
may be interwoven though apertures 41 in any suitable
configuration.
[0051] Still referring to FIGS. 1-3, upper 20 includes regions or
patterns of printed material 70. Consistent with an embodiment,
printed material 70 may be formed by direct 3D printing and curing
of material onto upper 20 in any desired pattern, shape, thickness,
or coverage. Printing and curing of printed material 70 will be
described in greater detail hereinbelow. As shown in FIGS. 1-3,
printed material 70 is depicted in an exemplary manner as a pattern
of interconnected strips and loops of predetermined thickness
attached to various portions of upper 20 to provide structural
support and/or aesthetic improvements to footwear 10. Various
portions of printed material 70 may be interconnected, but may also
not be interconnected. Consistent with an embodiment, printed
material 70 is adhered or otherwise bonded to upper 20, may be at
least partially absorbed into a surface of upper 20, and may be
formed in one or more contiguous or disjointed layers on upper 20.
Each of these features will be described in greater detail
below.
[0052] Consistent with an embodiment, printed material 70, also
referred to herein as "three-dimensional material," may be made of
a material that includes an ink, a resin, an acrylic, a polymer, a
thermoplastic material, a thermosetting material, a light-curable
material, or combinations thereof. Also consistent with an
embodiment, printed material 70 may be formed from printing of one
or more layers in a sequence of depositions of material to any
desired thickness, and may also include a filler material to impart
a strengthening or aesthetic aspect to printed material 70. For
example, the filler material may be a powdered material or dye
designed to impart desired color or color patterns or transitions,
metallic or plastic particles or shavings, or any other powdered
mineral, metal, or plastic, and may customize the hardness,
strength, or elasticity of printed material 70 depending on desired
properties. Filler material may be premixed with printed material
70 prior to printing, or may be mixed with printed material 70
during printing onto upper 20. Consistent with an embodiment,
printed material 70 may thus be a composite material.
[0053] FIGS. 4 and 5 show a perspective cutaway view and exploded
perspective cutaway view, respectfully, of section 4 of footwear 10
shown in FIG. 3, including sole structure 30 comprising outsole 32,
midsole 31, and sockliner 33. It will be appreciated that some
illustrated portions of sole structure 30 may be optional, and
certain portions may be omitted in some embodiments. Alternatively,
sole structure 30 may optionally comprise additional layers. For
example, sole structure 30 may additionally comprise one or more
layers of material (not shown) printed in accordance with disclosed
embodiments. Such materials may comprise, for example, one or more
printed polyurethane layers to form an enclosed region of air or
other gas or fluid in one or more regions of sole structure 30,
thus providing an enclosed cushioning region (not shown) in
footwear 10.
[0054] As shown in FIGS. 4 and 5, footwear 10 also includes upper
20 and tongue 60, upper 20 being attached to sole structure 30 as
previously described. Consistent with an embodiment, printed
material 70 may be adhered or bonded on or in an exterior surface
of upper 20. It will be appreciated that some illustrated elements
of printed material 70 may vary in appearance. Alternatively, other
additional elements may be included. For example, printed material
70 may comprise one or more additional layers to constitute
material of any desired thickness, which will be described in
greater detail below.
[0055] A method for making an article of apparel or footwear may
include provisions for direct 3D printing onto the article.
Consistent with an embodiment, FIG. 6 shows an exemplary system 80
for 3D printing directly onto a fabric upper, such as, for example,
upper 20 shown in any of FIGS. 1-5. System 80 may include 3D
printer device 81, computer/workstation 82, print server 83, and
optional switching device 84. 3D printer device 81, computer 82,
print server 83, and switching device 84 may be in communication
and/or networked as shown in FIG. 6. One of ordinary skill in the
art will recognize that portions of system 80 may be omitted in
some embodiments.
[0056] Still referring to FIG. 6, computer 82 may be in direct
communication with 3D printer device 81 and print server 83 via
switching device 84. For example, print server 83 may be in direct
communication with 3D printer device 81 and switching device 84,
and switching device 84 may likewise be in direct communication
with 3D printer device 81 and print server 83. Print server 83 may
include a second nontransitory computer-readable medium encoded
with a second computer program product loadable into a memory of
print server 83 and include second software code portions for
instructing 3D printer device 81 to print directly onto upper 20
through a sequence of printing steps to produce a 3D result of
printed material 70 from CAD representation 89 on computer 82.
Consistent with an embodiment, one of ordinary skill will
understand that system 80 may require both computer 82 and print
server 83, or may require just one of computer 82 and print server
83.
[0057] Consistent with an embodiment, computer 82 may comprise a
central processing device 85, viewing interface 86 (e.g., a monitor
or screen), input devices 87 and 88 (e.g., keyboard and mouse), and
software for designing a computer-aided design ("CAD")
representation 89 of a printing output designed for upper 20. The
term "computer," as used throughout the disclosure, means a single
computer, the partial computing resources of a computer, or two or
more computers communicating with each other. Computer 82 may thus
include a first nontransitory computer-readable medium in central
processing device 85 encoded with a first computer program product
loadable into a memory of computer 82 and include first software
code portions for storing a 3D pattern for printing directly onto
upper 20. Consistent with an embodiment, computer 82 may be used to
prepare a CAD representation 89 for any desired printed pattern or
chemistry for printed material 70 on upper 20.
[0058] As shown in FIG. 7, 3D printer device 81 comprises a tray 90
for receiving upper 20 for printing. 3D printer device 81 also may
comprise at least one printhead 92, printhead maneuverability
assembly 94, and lid 96. Printing material to be ejected from at
least one printhead 92 may be stored or supplied in compartment 98.
Consistent with an embodiment, FIG. 7 illustrates a completed
pattern of printed material 70 printed on upper 20, in accordance
with exemplary CAD representation 89 shown in FIG. 6, and
implemented by print server 83 and/or computer 82. Printhead 92 may
also include, for example, a UV light producing mechanism for
curing printed material 70 upon printing by printhead 92 as
printhead 92 is moved over upper 20 via printhead maneuverability
assembly 94. Upon completion of printing onto upper 20, lid 96 may
be opened and upper 20 may be removed from 3D printer device
81.
[0059] Contrary to what is known in the art, embodiments of the
disclosed methods do not require a hydrophobic or otherwise
non-wetting surface on which to print. One of ordinary skill in the
art will understand that known 3D printing systems require a
hydrophobic sheet or release layer on a tray or substrate prior to
printing/building of a 3D object. Such a hydrophobic sheet or
release layer may be preexisting on the tray or substrate, or may
be a printed hydrophobic material provided by the 3D printing
system itself. In known 3D printing systems, the required
hydrophobic sheet or release layer prevents wetting of printed
material onto the tray or substrate during printing/building of the
3D object and thus permits removal of the 3D object from the tray
or substrate upon completion of printing. Consistent with an
embodiment, however, 3D printer device 81 does not require a
hydrophobic or otherwise non-wetting surface on which to print,
because 3D printing is accomplished directly onto a material (e.g.,
upper 20) placed on tray 90. Upper 20, if an exemplary fabric
material, may also be hydrophilic. That is, wetting and
adhering/bonding/curing of printed material 70 to upper 20 is
desirable. After printing, upper 20 may be removed from tray 90
with printed material 70 adhered/bonded/cured to upper 20, and
without concern for adhesion of upper 20 or printed material 70 to
tray 90.
[0060] Contrary to what is known in the art, embodiments of the
disclosed methods also do not require a perfectly or near-perfectly
flat substrate surface on which to print. One of ordinary skill in
the art will understand that known 3D printing systems require a
perfectly or near-perfectly flat substrate surface on which to
print in order to allow the systems to print/build 3D objects on a
planar surface. Consistent with an embodiment, however, upper
20--even if laid substantially flat inside 3D printer device 81 on
tray 90--may still have an uneven surface due to either the knit or
weave of its fabric, or irregular surface topology in general due
to the need for subsequent working and assembly steps. Consistent
with an embodiment, 3D printer device 81 may account for surface
irregularities of upper 20, and compensate for any such
irregularities by adjusting one or more of the distance between
printhead 92 and upper 20, and the size/rate/distribution of
material ejected from printhead 92 during printing onto upper 20.
That is, printing may occur directly onto a surface of upper 20,
such that upper 20 may be subsequently removed from 3D printer
device 81 without any concern for surface irregularities in upper
20.
[0061] For example, with reference to FIGS. 8 and 9, known 3D
printing techniques require printing on flat substrate 100 having a
release layer 102 placed/formed/printed thereon. To prevent printed
object 104 from adhering to substrate 100, release layer 102 is
interspersed therebetween. Release layer 102 could be a wax paper,
for example, or a layer of hydrophobic printed material to
facilitate removal of printed object 104 from substrate 100. As
shown in FIG. 9, removal of printed material 104 may thus be
accomplished by removing release layer 102 from substrate 100 as
shown by motion 106, followed by removal of printed material 104
from release layer 102 as shown by motion 108. Thus, known 3D
printing techniques require both a flat surface on which to print,
and a release layer to prevent adhesion of the printed material to
the substrate after printing is complete.
[0062] Contrary to what is known in the art, FIGS. 10 and 11, and
likewise 12 and 13, illustrate a portion of a 3D printing technique
consistent with an embodiment. For example, FIGS. 10 and 11 show a
cross sectional view of upper 20 placed on tray 90. Upper 20 is
depicted as comprising threads 22, which may be placed in different
directions, although threads 22 could be configured in any manner,
such as any density or thickness, to form upper 20. Printed
material 70 may comprise one or more layers of material
sequentially printed onto upper 20. Consistent with an embodiment,
printed material 70 may be at least partially absorbed into a
surface region 110 of upper 20 after printing and prior to curing.
Partial absorption in surface region 110 of printed material 70 may
aid in adhesion/bonding of printed material 70 to upper 20. FIGS.
12 and 13 likewise illustrate a perspective view of upper 20 placed
on tray 90 and having printed material 70 printed thereon.
[0063] As shown in FIGS. 11 and 13, and consistent with an
embodiment, removal of upper 20 containing printed material 70 may
be accomplished by simply lifting upper 20 away from tray 90, as
shown by motion 115. Because printed material 70 is
printed/deposited onto upper 20, and may be at least partially
absorbed into a surface region 110, upper 20 may thus serve as a
"substrate" such that there is no need for a release layer
interspersed between upper 20 and printed material 70, or between
tray 90 and upper 20. That is, wetting and adhering/bonding/curing
of printed material 70 to upper 20 is desirable and accomplished.
After printing, upper 20 may be removed from tray 90 with printed
material 70 adhered/bonded/cured to upper 20, and without concern
for adhesion of upper 20 or printed material 70 to tray 90.
Consistent with an embodiment, a release layer may be optionally
used, however unlikely, for example if upper 20 is so thin or
contains a particularly low density of threads 22 such that
portions of printed material 70 might pass between individual
threads 22 of upper 20 and directly contact tray 90.
[0064] Consistent with an embodiment, FIGS. 14-17 illustrate cross
sectional views of a printing sequence of multiple 3D layers of
printed material 70 on upper 20. For example, FIG. 14 illustrates
first layer 71 of printed material 70 deposited onto upper 20.
Printed material 70 may be ejected or otherwise emitted from
printhead 120 via nozzle 122 in the form of droplets 124. One of
ordinary skill in the art will recognize that the form of droplets
124 may vary depending on the actual material ejected or otherwise
emitted from nozzle 122. Droplets 124 may thus be any viscosity
liquid material, or even a semi-solid material. Consistent with an
embodiment, droplets 124 may be any desired material or phase of
material suitable for use in 3D printing system 80.
[0065] Still referring to FIG. 14, in some embodiments, first layer
71 may be cured by UV light 126, however, in other embodiments,
first layer 71 may be deposited without the need to cure the
deposited material. Depending on the material used for printing of
printed material 70, the material may be deposited in a liquid,
semi-liquid, or otherwise gel-like or viscous phase. The material
may then be solidified, at least partially, or cured, for various
reasons, or to achieve desired properties, for example, to enhance
durability, adhesion, or bonding of printed material 70 to upper
20. FIGS. 14-17 thus illustrate UV light 126 as an exemplary curing
agent for use after deposition of printed material 70. One of
ordinary skill in the art will understand that UV light 126 may be
activated/applied either immediately after deposition of first
layer 71, or at any desired time thereafter, depending on the
nature of the desired patterns/chemistry/thickness of printed
material 70. For simplicity, exemplary FIGS. 14-17 illustrate UV
light 126 applied to cure printed material 70 after deposition of
each layer. Depending on the material used for printing of printed
material 70, one of ordinary skill in the art will recognize that
curing of printed material 70 may be optional.
[0066] Still referring to FIG. 14, and consistent with an
embodiment, printed material 70 may be at least partially absorbed
into a surface region 110 of upper 20 prior to curing. For example,
printed material 70 may be allowed to absorb into upper 20 for a
predetermined amount of time after deposition and prior to curing
with UV light 126. One of ordinary skill in the art will understand
that such a predetermined amount of time will vary depending on the
material used for printed material 70, as an absorption rate may be
affected by the wettability or permeability of upper 20 to the
deposited material, the viscosity or temperature of the material
during printing, and the pressure or speed at which the material is
ejected from printhead 92 onto upper 20. Consistent with an
embodiment, therefore, such a predetermined amount of time after
deposition and prior to optional curing with UV light 126 may be
essentially immediately after deposition, or may be contemplated
seconds or minutes thereafter.
[0067] Consistent with an embodiment, FIG. 15 illustrates second
layer 72 of printed material 70 deposited onto layer 71, and cured
by UV light 126. Second layer 72 may or may not be partially
absorbed into a portion of first layer 71 prior to curing.
Consistent with an embodiment, second layer 72 (and any subsequent
layers) need not be deposited solely on the immediately underlying
layer. One of ordinary skill in the art will understand that
variations in printing patterns/thicknesses layers are
contemplated. For example, second layer 72 may be deposited on any
desired portion of upper 20, which may include partial or complete
coverage of layer 71, or may include no coverage of layer 71. For
example, if second layer 72 is partially deposited on layer 71 and
partially deposited on upper 20, second layer 72 may or may not be
partially absorbed into a portion of first layer 71 and a portion
of upper 20 prior to optional curing.
[0068] Consistent with an embodiment, FIG. 16 illustrates a third
layer 73 of printed material 70 deposited onto layer 72, and
optionally cured by UV light 126. Third layer 73 may or may not be
partially absorbed into at least a portion of second layer 72, at
least a portion of first layer 71, and/or at least a portion of
upper 20 if so printed, prior to curing. FIG. 17 likewise
illustrates a fourth layer 74 of printed material 70 deposited onto
layer 73, and optionally cured by UV light 126. Fourth layer 74 may
or may not be partially absorbed into at least a portion of third
layer 73, at least a portion of second layer 72, at least a portion
of first layer 71, and/or at least a portion of upper 20 if so
printed, prior to optional curing. Consistent with an embodiment,
any number of layers may be printed to form printed material 70.
Also consistent with an embodiment, upper 20 may be removed from
tray 90 upon completion of printing, as shown in FIG. 13.
[0069] One of ordinary skill in the art will recognize that the
printed layers forming printed material 70 may originate with
different materials, colors, chemistries, optional fillers, etc.,
in order to fully customize the desired properties of upper 20.
Printed material may also comprise layers having gradients of
colors blended amongst the layers, or may comprise gradients of
elasticity due to variations in material ejected from printhead 92
during printing of printed material 70. For example, printed
material 70 may comprise layers of low elasticity printed material
alternated or in conjunction with layers of high elasticity
material. Consistent with an embodiment, exemplary moduli of
elasticity for printed material 70 may range from about 10 MPa to
about 4,000 MPa. Consistent with an embodiment, exemplary flexural
strength for printed material 70 may range from about 35 MPa to
about 300 MPa. Consistent with an embodiment, exemplary flexural
moduli for printed material 70 may range from about 1,200 MPa to
about 12,000 MPa. And, consistent with an embodiment, exemplary
tensile strength for printed material 70 may range from about 0.5
MPa to about 150 MPa.
[0070] One of ordinary skill in the art will also recognize that
the printed layers forming printed material 70 may comprise layers
of material having at least a first color alternated or in
conjunction with layers having at least a second color. For
example, printed material 70 may be designed to impart high
strength and low elasticity in heel region 13, while maintaining
high elasticity and flexibility in toe region 11, and such
properties may be accomplished by varying the properties of printed
material 70 through printing of different combinations of materials
and layers in any desired manner on any surface of upper 20.
[0071] Consistent with an embodiment, FIG. 18 illustrates an
overhead view of upper 20 placed on tray 90 prior to 3D printing in
system 80, and FIG. 19 illustrates a cross sectional view of the
indicated portion of FIG. 14 showing upper 20 on tray 90. As shown
in FIGS. 18 and 19, upper 20 may be positioned substantially flat
on tray 90 in 3D printer 81. Upper 20 may further be positioned and
aligned with fiduciary marks (not shown) to coordinate alignment
with CAD representation 89 from computer 82 to facilitate accurate
printing.
[0072] Consistent with an embodiment, FIG. 20 illustrates an
overhead view of upper 20 placed on tray 90 after 3D printing in
system 80, and FIG. 21 illustrates a cross sectional view of the
indicated portion of FIG. 20 showing exemplary printed material 70
on upper 20. As shown in FIGS. 20 and 21, printed material 70 is
deposited on upper 20 in any desired pattern or number of layers,
in accordance with a desired CAD representation 89 from computer 82
in implementation of system 80 shown in FIG. 6. It will be
recognized that printed material 70, shown in FIG. 21, may appear
to be one continuous deposit of material as shown, although it may
actually comprise multiple layers of sequentially printed material
to form a desired printed pattern resulting in printed material 70
as shown.
[0073] For example, consistent with an embodiment, FIG. 22
illustrates an exemplary printing job 300 using system 80 to
produce printed material 70 as shown and described with reference
to FIGS. 20 and 21. Printing job 300 in FIG. 22 will be further
described consistent with exemplary process flow 400 shown in FIG.
23.
[0074] FIG. 23 shows an exemplary process 400 for 3D printing onto
upper 20, consistent with an embodiment. It will be appreciated
that some or all steps in the process may be completed by a
footwear, apparel, or equipment manufacturer or proprietor. In
other cases, some steps could be accomplished by a manufacturer and
other steps could be accomplished by another party including
another manufacturer, proprietor, retailer, or any other entity. In
some cases, one or more of the steps may be optional. In other
cases, some steps may be completed in a different order.
[0075] As shown in FIG. 23, exemplary process 400 for 3D printing
onto upper 20 begins with step 410. In step 410, computer 82 may be
used to design a print pattern and form CAD representation 89 shown
in FIG. 22. CAD representation 89 may be any desired printing job
on any surface, such as upper 20.
[0076] In step 415, CAD representation 89 may be provided to print
server 83 via optional switching device 84. Print server 83 may
process CAD representation 89 into any number of slices 310
designed to accomplish 3D printing of print material 70 to any
desired pattern or thickness in 3D printer 81. One of ordinary
skill in the art will recognize that slices 310 may be
representations designed to correspond to actual printed layers of
material forming printed material 70, such as, for example, layers
71-74 shown and described with reference to FIGS. 14-17.
[0077] In step 420, a fabric material such as upper 20 may be
positioned in 3D printer device 81 on tray 90, as shown in FIG. 7.
In step 425, fabric material such as upper 20 may be aligned as
described above with respect to FIG. 18 to facilitate accurate
printing of any desired CAD representation 89 and any number of
slices 310.
[0078] In step 430, 3D printer 81 executes printing onto fabric
material such as upper 20, using slices 310 provided by computer 82
and print server 83 as guides for printing and curing multiple
layers of material to form printed material 70, such as those shown
in FIGS. 10-13. As discussed above, printing may include printing a
resin, acrylic, or ink material onto a fabric, where the material
is adhered/bonded to the fabric and where the material does not
generally delaminate when flexed, rolled, worked, or subject to
additional assembly processes/steps. Consistent with step 430,
printed material 70 may be an ink, a resin, an acrylic, a polymer,
a thermoplastic material, a thermosetting material, a light-curable
material, or combinations thereof. Printed material 70 may also
include a filler material (not shown) to impart a strengthening or
aesthetic aspect to printed material 70 in one or more layers
printed using slices 310. For example, the filler material
incorporated in printed material 70 may be a powdered material or
dye designed to impart desired color or color patterns or
transitions, metallic or plastic particles or shavings, or any
other powdered mineral, metal, or plastic. Consistent with an
embodiment, printed material 70 printed in step 430 may thus be a
composite material.
[0079] In step 435, progress of printing in 3D printer 81 may be
periodically evaluated. For example, one may evaluate the progress
of printing after several layers of material are printed and cured,
as shown, for example, in FIGS. 14-17.
[0080] In step 440, if desired printing is not complete, or if
adjustments are desired during printing, fabric material such as
upper 20 may be repositioned on tray 90 and realigned to facilitate
printing of desired CAD representation 89 by proceeding back to
step 430.
[0081] In step 445, if desired printing is complete, fabric
material such as upper 20 may be inspected and removed from 3D
printer 81 by lifting upper 20 off of tray 90 by motion 115 shown
in FIGS. 11 and 13. In step 445, desired printing may appear as
shown in FIGS. 20 and 21, where printed material 70 is formed to
any desired pattern and thickness, and may or may not be partially
absorbed into a portion 110 of the surface of upper 20.
[0082] In step 450, for example, shoe assembly may subsequently be
completed by securing a sole structure 30 to a lower portion of
upper 20 so as to be positioned between the foot and the ground, as
shown, for example, in FIGS. 1-5.
[0083] Consistent with an embodiment, FIG. 24 illustrates an
approximately plan view of upper 20 including tongue 60 and lace
apertures 41 laid substantially flat after printing of printed
material 70 and prior to assembly of footwear 10 shown in FIGS.
1-5. Similarly, FIG. 25 illustrates upper 20 including tongue 60,
lace apertures 41, and printed material 70 disposed on sockliner 33
during a portion of an exemplary assembly process of manufacturing
footwear 10. It will be appreciated that some illustrated elements
of assembly of footwear 10 may vary or not be shown in the interest
of simplifying illustrations throughout this disclosure.
Alternatively, other additional elements or assembly steps may be
included. For example, upper 20 may be joined to sockliner 33 using
thermoforming applications, such as polymer heat seal seam tapes as
disclosed in U.S. Pat. No. 8,028,440, which is incorporated herein
by reference.
[0084] Consistent with an embodiment, FIG. 26 illustrates a
perspective view of upper 20 after 3D printing of alternative
patterns and prior to completion of footwear assembly, similar to
FIGS. 7 and 24. FIG. 26 thus illustrates first printed material 510
and second printed material 520 on upper 20, printed using system
80 and process 400. For reference, exemplary printing directions XY
and Z are shown in FIG. 26. Consistent with an embodiment, first
printed material 510 and second printed material 520 may be
different materials. For example, first printed material 510 may be
a thin, abrasion-resistant material. Also, for example, second
printed material 520 may be a thicker, stiff material designed to
provide structural support to a portion of upper 20. First printed
material 510 and second printed material 520 may be disposed on any
desired portion or portions of upper 20.
[0085] First printed material 510 and second printed material 520
may be printed to upper 20 to impart customized properties such as
increased strength, rigidity, support, flexibility, abrasion
resistance, or variations thereof based on desired properties for
specific portions of the upper and the article of footwear as a
whole. For example, FIGS. 27-30 illustrate footwear 10 with first
printed material 510 and second printed material 520 disposed on
upper 20. Consistent with an embodiment, first printed material 510
and second printed material 520 may be formed by direct 3D printing
and curing of material onto upper 20 in any desired pattern, shape,
or coverage. Printing and curing of first printed material 510 and
second printed material 520 may be performed in accordance with
exemplary system 80 and exemplary process 400. Likewise, as
discussed with respect to FIGS. 1-5, various portions of first
printed material 510 and second printed material 520 may be
interconnected, but may also not be interconnected. While first
printed material 510 and second printed material 520 are generally
shown in FIGS. 27-30 in forefoot and heel regions, respectively, of
upper 20, one of ordinary skill in the art will recognize that
first printed material 510 and second printed material 520, or one
or more additional printed materials (not shown), may also be
printed in the midfoot region or any other region of footwear 10.
Consistent with an embodiment, first printed material 510 and
second printed material 520 are adhered or otherwise bonded to
upper 20, may be at least partially absorbed into a surface of
upper 20, and may be formed in one or more contiguous or disjointed
layers on upper 20. After printing, upper 20 may be shaped for
assembly of footwear 10 similar to the depiction in FIG. 25.
[0086] As shown in the various views of footwear 10 in FIGS. 27-30,
for example, footwear 10 may comprise first printed material 510 as
one or more abrasion resistant pads located in either or both of
forefoot region 11 and midfoot region 12, and may be useful for
protecting footwear 10, for example, while engaging in soccer.
Likewise, second printed material 520 may be a strengthening rigid
material customized to provide strength and support to heel region
13 of footwear 10. Consistent with an embodiment, moreover, first
printed material 510 may be thinner than second printed material
520. One of ordinary skill in the art will recognize that the
thickness of first printed material 510 and second printed material
520 may differ or be the same, however, depending on the desired
application or use of footwear 10.
[0087] One of ordinary skill in the art will recognize that printed
materials consistent with an embodiment may have a structural
aspect, a visual or aesthetic aspect, or both. For example, printed
materials consistent with an embodiment may be a visual or
decorative indicia, logo, graphic, or reflector in the midfoot
region or any other regions of footwear 10. Likewise, for example,
printed materials consistent with an embodiment may be a structural
material, to impart strength, abrasion resistance, protection, or
stiffness to one or more regions of footwear 10. Consistent with an
embodiment, printed materials may have a first characteristic for a
first portion of footwear 10, and a second, third, etc., or other
additional characteristics for one or more additional regions of
footwear 10.
[0088] Thus, for example, as shown in FIGS. 26-30 and generally in
the other figures, and consistent with an embodiment, footwear 10
may be fabricated by designing at least a first three-dimensional
pattern and a second three dimensional pattern (such as one or more
CAD representations 89 shown in FIG. 6) for printing onto upper 20;
providing the at least first and second three-dimensional patterns
to print server 83; positioning at least a first portion of upper
20 on tray 90 in 3D printer device 81 of system 80, the first
portion being positioned substantially flat on tray 90; aligning
the first portion of upper 20 with the first pattern (as shown, for
example, in FIG. 18); printing at least one layer of first printed
material 510 having a first material property directly onto the
first portion of upper 20 using the designed first pattern;
allowing the at least one layer of first printed material 510 to at
least partially absorb into a first portion of a surface of upper
20; curing the at least one layer of first printed material 510;
positioning at least a second portion of upper 20 on tray 90, the
second portion being positioned substantially flat on tray 90;
aligning the second portion of the upper with the second pattern
(as similarly shown, for example, in FIG. 18); printing at least
one layer of second printed material 520 having a second material
property directly onto the second portion of upper 20 using the
designed second pattern; allowing the at least one layer of second
printed material 520 to at least partially absorb into a second
portion of the surface of upper 20; curing the at least one layer
of second printed material 520; removing upper 20 from 3D printer
device 81; and assembling footwear 10 using the printed upper and
at least one footwear component chosen from sock liner 33, midsole
31, and outsole 32 (as similarly shown, for example, in FIGS. 5 and
25).
[0089] One of ordinary skill in the art will recognize that the
systems and methods described throughout this disclosure can be
used to 3D print any desired patterns, layers, or materials
directly onto a fabric material, which allows building of a
structure on the fabric for use in apparel applications.
[0090] While various embodiments have been described, the
description is intended to be exemplary, rather than limiting, and
it will be apparent to those of ordinary skill in the art that many
more embodiments and implementations are possible that are within
the scope of the disclosure. It is intended that all such
additional systems, methods, features and advantages be included
within this description and this summary, be within the scope of
the disclosure, and be protected by the following claims.
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