U.S. patent application number 15/907147 was filed with the patent office on 2019-02-07 for 3d-printed articles of footwear with property gradients.
This patent application is currently assigned to Voxel8, Inc.. The applicant listed for this patent is Voxel8, Inc.. Invention is credited to Travis Alexander Busbee, Avin Dhoble, David John Herman, Andrew Marschner, John Eugene Minardi, II, Richard Rininger, Sean Christopher Troiano.
Application Number | 20190037961 15/907147 |
Document ID | / |
Family ID | 63253022 |
Filed Date | 2019-02-07 |
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United States Patent
Application |
20190037961 |
Kind Code |
A1 |
Busbee; Travis Alexander ;
et al. |
February 7, 2019 |
3D-PRINTED ARTICLES OF FOOTWEAR WITH PROPERTY GRADIENTS
Abstract
The present disclosure is related to three-dimensionally printed
articles for use in footwear and associated systems and methods. In
some embodiments, a three-dimensionally printed article may
comprise a closed-cell foam. The closed-cell foam may have a
gradient in and/or may be a single integrated material. In some
embodiments, a three-dimensionally printed article may comprise a
sensor. The use of such arrangements can, according to certain
embodiments, allow for the production of improved articles of
footwear and/or customized articles of footwear.
Inventors: |
Busbee; Travis Alexander;
(Somerville, MA) ; Marschner; Andrew; (Chicago,
IL) ; Minardi, II; John Eugene; (Somerville, MA)
; Troiano; Sean Christopher; (Somerville, MA) ;
Dhoble; Avin; (Waltham, MA) ; Rininger; Richard;
(Somerville, MA) ; Herman; David John; (Boston,
MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Voxel8, Inc. |
Somerville |
MA |
US |
|
|
Assignee: |
Voxel8, Inc.
Somerville
MA
|
Family ID: |
63253022 |
Appl. No.: |
15/907147 |
Filed: |
February 27, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62555897 |
Sep 8, 2017 |
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62555904 |
Sep 8, 2017 |
|
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62555916 |
Sep 8, 2017 |
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62464364 |
Feb 27, 2017 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B29C 64/393 20170801;
A43B 23/0215 20130101; B29C 64/112 20170801; A43B 1/14 20130101;
A43B 13/04 20130101; A43B 17/003 20130101; B29L 2031/50 20130101;
A43B 17/14 20130101; B29C 64/336 20170801; B29D 35/00 20130101;
B29D 35/12 20130101; B29K 2105/04 20130101; B33Y 80/00 20141201;
A43D 999/00 20130101; B33Y 70/00 20141201; A43B 5/00 20130101; B33Y
30/00 20141201; B29C 64/209 20170801; B33Y 50/02 20141201; A43D
1/00 20130101; A43D 1/02 20130101; B33Y 10/00 20141201; A43B 3/0005
20130101; A43D 2200/60 20130101; B29K 2075/00 20130101; B29K
2713/00 20130101 |
International
Class: |
A43B 1/14 20060101
A43B001/14; B33Y 10/00 20060101 B33Y010/00; B33Y 30/00 20060101
B33Y030/00; B33Y 50/02 20060101 B33Y050/02; B33Y 70/00 20060101
B33Y070/00; B29C 64/112 20060101 B29C064/112; B29C 64/209 20060101
B29C064/209; B29C 64/336 20060101 B29C064/336; B29C 64/393 20060101
B29C064/393; A43B 13/04 20060101 A43B013/04; A43B 23/02 20060101
A43B023/02; A43B 17/00 20060101 A43B017/00; A43B 3/00 20060101
A43B003/00 |
Claims
1. A 3D-printed article for use in footwear, comprising: a
3D-printed article having a gradient in a property between a first
portion and a second portion, wherein the 3D-printed article is a
single integrated material, and wherein the property is selected
from the group consisting of average stiffness, average Shore A
hardness, average Shore D hardness, average Asker C hardness,
average pore size, average density, color, average surface
roughness, average reflectivity, average strength, average
elongation at break, average tensile elastic modulus, and average
modulus at 100% strain.
2. A 3D-printed article for use in footwear, comprising: a
3D-printed article having a gradient in a property between a first
portion and a second portion, wherein the 3D-printed article is a
single integrated material, and wherein the property is a
mechanical property.
3. A 3D-printed article for use in footwear, comprising: a
3D-printed article having a gradient in a property between a first
portion and a second portion, wherein the 3D-printed article is a
single integrated material, and wherein the property is an optical
property.
4. (canceled)
5. A 3D-printed article for use in footwear as in claim 1, wherein
the property is average pore size.
6. (canceled)
7. A 3D-printed article for use in footwear as in claim 1, wherein
the property is average stiffness.
8-10. (canceled)
11. A 3D-printed article for use in footwear as in claim 1, wherein
the property is average Shore A hardness.
12. (canceled)
13. A 3D-printed article for use in footwear as in claim 1, wherein
the property is average microindentation hardness.
14. (canceled)
15. A 3D-printed article for use in footwear as in claim 1, wherein
the property is average density.
16-17. (canceled)
18. A 3D-printed article for use in footwear as in claim 1, wherein
the first portion is positioned above the second portion.
19. A 3D-printed article for use in footwear as in claim 1, wherein
the first portion is positioned beside the second portion.
20. A 3D-printed article for use in footwear as in claim 1, wherein
the first portion and the second portion are directly adjacent.
21. (canceled)
22. A 3D-printed article for use in footwear as in claim 1, wherein
the first portion is positioned closer to a sensor than the second
portion.
23. A 3D-printed article for use in footwear as in any claim 1,
wherein the 3D-printed article is a component of one or more of a
sole, an upper, a midsole, an outsole, an insole, a toe box, an
eyestay, a heel counter, a logo, an eyelet, a quarter panel, and a
no sew overlay feature.
24. (canceled)
25. An article of footwear comprising the 3D-printed article for
use in footwear of claim 1.
26-28. (canceled)
29. A 3D-printed article for use in footwear as in claim 1, wherein
the 3D-printed article comprises a foam.
30-31. (canceled)
32. A 3D-printed article for use in footwear as in claim 1, wherein
the first portion is positioned above the second portion, and
wherein the first portion has a lower average density than the
second portion.
33-35. (canceled)
36. A 3D-printed article for use in footwear as in claim 1, wherein
the 3D-printed article comprises an elastomer.
37. A 3D-printed article for use in footwear as in claim 1, wherein
the gradient is present over a distance of greater than or equal to
2 mm.
38. A 3D-printed article for use in footwear as in claim 1, wherein
the 3D-printed article comprises a pathway along which the
3D-printed article lacks an interface over which the property
undergoes a step change, and wherein the pathway has a length of at
least 5 mm.
39-41. (canceled)
42. A 3D-printed article for use in footwear as in claim 1, wherein
the property varies smoothly throughout the 3D-printed article.
43-51. (canceled)
Description
RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. .sctn.
119(e) to U.S. Provisional Application No. 62/464,364, filed Feb.
27, 2017, and entitled "Systems and Methods for Three-Dimensional
Printing of Footwear and Other Articles", which is incorporated
herein by reference in its entirety for all purposes. This
application also claims priority under 35 U.S.C. .sctn. 119(e) to
U.S. Provisional Application No. 62/555,897, filed Sep. 8, 2017,
and entitled "Systems and Methods of 3D Printing Articles of
Footwear with Property Gradients," which is incorporated herein by
reference in its entirety for all purposes. This application also
claims priority under 35 U.S.C. .sctn. 119(e) to U.S. Provisional
Application No. 62/555,904, filed Sep. 8, 2017, and entitled "3D
Printed Articles of Footwear with Property Gradients," which is
incorporated herein by reference in its entirety for all purposes.
This application also claims priority under 35 U.S.C. .sctn. 119(e)
to U.S. Provisional Application No. 62/555,916, filed Sep. 8, 2017,
and entitled "3D Printed Articles of Footwear with Sensors and
Methods of Forming the Same," which is incorporated herein by
reference in its entirety for all purposes.
FIELD
[0002] The present invention relates generally to
three-dimensionally printed articles for use in footwear and
associated systems and methods.
BACKGROUND
[0003] Footwear is typically mass produced from in large batches
and with the use of complex supply chains. As a result, portions of
a single article of footwear with different properties are
typically formed from uniform components with standard sizes and
properties which are adhered together or disposed on one another.
This lowers the quality of the resultant footwear and makes its
customization for specific users challenging. Accordingly, improved
articles for use in footwear that allow greater integration and/or
customization of different components and associated methods may be
advantageous.
SUMMARY
[0004] The present invention generally relates to systems and
methods involving three-dimensionally printed articles for use in
footwear. The present subject matter of the present invention
involves, in some cases, interrelated products, alternative
solutions to a particular problem, and/or a plurality of different
uses of one or more systems and/or articles.
[0005] In one set of embodiments, 3D-printed articles for use in
footwear are provided. The 3D-printed article may have a gradient
in a property between a first portion and a second portion. In some
embodiments, the property may be selected from the group consisting
of average stiffness, average Shore A hardness, average pore size,
average density, color, average surface roughness, average
reflectivity, average strength, average elongation at break,
average tensile elastic modulus, average modulus at 100% strain,
average opacity, and average dimensional change upon heat
activation. In some embodiments, the 3D-printed article may be a
single integrated material.
[0006] In some embodiments, a method may comprise 3D-printing an
article having a gradient in a property between a first portion and
a second portion. The property may be a mechanical property. The
article may be a single integrated material.
[0007] In some embodiments, a method may comprise 3D-printing an
article having a gradient in a property between a first portion and
a second portion. The property may be an optical property. The
article may be a single integrated material.
[0008] In some embodiments, a method may comprise 3D-printing an
article having a gradient in a property between a first portion and
a second portion. The property may be a structural property. The
article may be a single integrated material.
[0009] In some embodiments, a 3D-printed article for use in
footwear may comprise a plurality of sensors. In some embodiments,
the sensors may be pressure sensors.
[0010] In another set of embodiments, methods are provided. A
method may comprise 3D-printing an article having a gradient in a
property between a first portion and a second portion. In some
embodiments, the property may be selected from the group consisting
of average stiffness, average Shore A hardness, average pore size,
and average density. In some embodiments, the article foam may be a
single integrated material.
[0011] In some embodiments, a method for designing a personalized
3D-printed article for use in footwear may comprise acquiring
information from a plurality of pressure sensors distributed within
a first 3D-printed article. The method may also comprise printing a
second 3D-printed article having a gradient in a property based on
the information. In some embodiments, the property may be selected
from the group consisting of average stiffness, average Shore A
hardness, average pore size, and average density.
[0012] Other advantages and novel features of the present invention
will become apparent from the following detailed description of
various non-limiting embodiments of the invention when considered
in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Non-limiting embodiments of the present invention will be
described by way of example with reference to the accompanying
figures, which are schematic and are not intended to be drawn to
scale. In the figures, each identical or nearly identical component
illustrated is typically represented by a single numeral. For
purposes of clarity, not every component is labeled in every
figure, nor is every component of each embodiment of the invention
shown where illustration is not necessary to allow those of
ordinary skill in the art to understand the invention. In the
figures:
[0014] FIGS. 1A-1C illustrate 3D-printed articles according to
certain embodiments of the invention;
[0015] FIG. 2 illustrates an article of footwear according to
certain embodiments of the invention;
[0016] FIG. 3A illustrates a 3D-printed article comprising a sensor
according to certain embodiments of the invention;
[0017] FIG. 3B illustrates a 3D-printed article comprising a
plurality of sensors according to certain embodiments of the
invention;
[0018] FIG. 4 illustrates a 3D-printed article in communication
with a computing device according to certain embodiments of the
invention;
[0019] FIG. 5 illustrates an implementation of a computing device
according to certain embodiments of the invention;
[0020] FIG. 6 is a flow chart illustrating a method according to
certain embodiments of the invention;
[0021] FIGS. 7A and 7B are schematic illustrations of meanders,
according to some embodiments of the invention;
[0022] FIG. 8A is a schematic illustration of meanders parallel and
perpendicular to gradients, according to some embodiments of the
invention;
[0023] FIG. 8B is a plot showing a stepped gradient, according to
some embodiments of the invention;
[0024] FIG. 8C is a plot showing a smooth gradient, according to
some embodiments of the invention;
[0025] FIG. 9 is a schematic depiction of a print head and a
substrate, according to certain embodiments of the invention;
[0026] FIGS. 10-12 are schematic depictions of a multi-axis
deposition system, according to certain embodiments of the
invention;
[0027] FIG. 13 illustrates an implementation of a computer program
according to certain embodiments of the invention;
[0028] FIG. 14 illustrates a method for 3D printing an article
according to certain embodiments of the invention;
[0029] FIG. 15 is a schematic of an illustrative reactive spray
print head with an integrated UV curing mechanism, in accordance
with some embodiments;
[0030] FIG. 16 is a schematic of an illustrative spray print head
with an integrated UV curing mechanism, in accordance with some
embodiments;
[0031] FIG. 17 is a schematic of an illustrative print head with an
integrated UV curing mechanism, in accordance with some
embodiments; and
[0032] FIGS. 18-21 show several 3D-printed articles according to
certain embodiments of the invention.
DETAILED DESCRIPTION
[0033] Inventive three-dimensionally printed (3D-printed) articles
for use in footwear or other applications, and associated methods,
are generally described herein. In some embodiments, the 3D-printed
article may comprise one or more features that are challenging or
impossible to obtain in articles manufactured by other techniques.
As an example, the 3D-printed article may be a single integrated
material which comprises a gradient in one or more properties
(e.g., average pore size, density, stiffness, stiffness of solid
components of the article, Shore A hardness, degree of
cross-linking, chemical composition, color, abrasion resistance,
thermal conductivity, electrical conductivity, stiffness
anisotropy, elastic modulus, flexural modulus, filler content,
opacity, conductivity, breathability) between two or more portions
of the material. This may be achieved using a 3D printing process
by printing the 3D-printed article using an ink that can be
dynamically changed as the article is printed (by, e.g., changing
the ratios of different components that make up the ink, changing
the temperature of the ink, and the like). In some embodiments, the
3D-printed article may have one or more features that are preferred
by users of the 3D-printed article or footwear of which the
3D-printed article is one component. For example, the 3D-printed
article may be a single integrated material and/or may lack seams,
adhesives, and other features that are typically used to join two
or more materials together. These and other 3D-printed articles may
be more comfortable for users, and/or may be less subject to
degradation or damage during normal usage of the article.
[0034] It should be understood that references herein to 3D-printed
articles may encompass articles that include more than one layer
(e.g., articles that comprise multiple layers printed on top of
each other) and/or may encompass articles that include a single
layer (e.g., articles in which a single layer of material has been
printed). 3D-printed articles may encompass articles printed from
3D-printers and/or articles that extend macroscopically in three
dimensions (e.g., with a minimal extent in each dimension of 50
microns, 100 microns, 200 microns, 500 microns, or 1 mm).
Similarly, 3D-printing may encompass printing articles that include
more than one layer and/or printing articles that include a single
layer. 3D-printing may encompass printing articles on 3D-printers,
printing articles extend macroscopically in three dimensions (e.g.,
with a minimal extent in each dimension of 50 microns, 100 microns,
200 microns, 500 microns, or 1 mm).
[0035] It should also be understood that articles other than
3D-printed articles and printing methods other than 3D-printing are
also contemplated. For example, some embodiments relate to articles
that have one or more of the features of the 3D-printed articles
described herein (e.g., a gradient in one or more properties) but
are not 3D-printed articles. Some articles may include both one or
more 3D-printed components and one or more non-3D-printed
components. Similarly, some embodiments relate to methods that have
one or more features of the methods described herein (e.g., may
comprise employing a multi-axis deposition system) but which do not
include a 3D-printing step. Some methods may include both one or
more 3D-printing steps and one or more non-3D-printing steps.
[0036] Certain methods (e.g., methods including exclusively
3D-printing steps, methods including exclusively non-3D printing
steps, methods including both 3D-printing steps and non-3D-printing
steps) comprise depositing one or more film(s) onto a 3D-surface.
Some or all of the films, if more than one are deposited, may be
thin film(s).
[0037] Certain methods (e.g., methods including exclusively
3D-printing steps, methods including exclusively non-3D printing
steps, methods including both 3D-printing steps and non-3D-printing
steps) comprise depositing a material that does not form a film on
a substrate. For instance, a material may be deposited onto a
substrate into which it infiltrates. As an example, a material may
be deposited onto a porous substrate (e.g., a porous textile) and
then infiltrate into at least a portion of the pores of the porous
substrate. After it has been deposited onto the porous substrate,
it may fill a portion of the pores of the porous substrate. The
material may enhance the mechanical properties of the substrate. In
some embodiments, a material deposited onto a substrate into which
it infiltrates, such as a porous substrate, does not extend an
appreciable distance (or at all) beyond the surface of the porous
substrate.
[0038] In some embodiments, certain articles and/or methods
described herein may include 3D-printed articles capable of sensing
one or more properties of a user of the 3D-printed article, of an
article of which the 3D-printed article forms one component, and/or
of the 3D-printed article itself. Information sensed by the
3D-printed article may be used to recommend one or more properties
of a second 3D-printed article for use in footwear and/or to may be
used to provide a user of the 3D-printed article with information
about themselves (e.g., health information, fitness information).
Such methods and articles may allow individual users of footwear to
learn about footwear designs that may be especially advantageous
for them (e.g., footwear that is beneficial for a medical condition
experienced by the user, footwear that is optimized for one or more
sports engaged in by the user, footwear that has sufficient
durability to undergo no or minimal damage during activities
typically engaged in by the user, footwear that is inexpensive yet
meets the needs of the user, etc.), which may enable a user to seek
medical care and/or training guidance, and/or may allow the
manufacture of customized 3D-printed articles of footwear that are
advantageous for individual users.
[0039] In one set of embodiments, one or more methods for
manufacturing 3D-printed articles as described herein may be
advantageous in comparison to other methods for making articles for
use in footwear. For example, a footwear manufacturer employing a
method as described herein may be able to use fewer processes to
create the article than would be employed in other comparable
processes (e.g., the manufacturer may use a three-dimensional
printer (3D printer) in a single process to make a component that
would otherwise be made by a combination of several processes such
as injection molding, lamination, and the like). This may allow for
more rapid and/or more facile manufacturing. As another example,
one or more of the methods described herein may not necessarily
require the use equipment that is expensive to manufacture and
whose cost is typically recovered only after repeated use (e.g.,
molds). Some of the methods described herein may instead employ a
3D printer to create articles whose design can be modified as
desired with little or no added cost. In some embodiments, it may
be economical for methods as described herein to create small
batches of 3D-printed articles (e.g., batches of less than 100,
less than 50, or less than 10). It is thus possible for
manufacturers may employ some of the methods described herein to
respond to changing market conditions, to create articles for use
in footwear that are designed for individual users or groups of
users, etc. In some embodiments, it may be advantageous to use one
or more of the methods described herein to fabricate a 3D-printed
article at the point of sale and/or to avoid long distance
shipping.
[0040] A non-limiting example of a 3D-printed article for use in
footwear is shown in FIG. 1A. In this figure, 3D-printed article
100 comprises first portion 110 and second portion 120. As used
herein, a portion of an article may refer to any collection of
points within the article (i.e., points that are within the portion
of space bounded by the external surfaces of the article). Portions
of the article are typically, but not always, volumes of space
within the article (in some embodiments, a portion may be a surface
within an article, a line within an article, or a point within an
article). Portions of the article may be continuous (i.e., each
point within the portion may be connected by a pathway that does
not pass through any points external to the portion) or may be
discontinuous (i.e., the portion may comprise at least one point
that cannot be connected to at least one other point within the
article by a pathway that does not pass through any points external
to the portion). Portions of an article may be substantially
homogeneous with respect to one or more properties (e.g., one or
more properties of the portion may vary with a standard deviation
of less than or equal to 1%, 2%, 5%, or 10% throughout the
portion), and/or may be heterogeneous with respect to one or more
properties (e.g., one or more properties of the portion may vary
with a standard deviation of greater than or equal to 1%, 2%, 5%,
or 10% throughout the portion).
[0041] Portions of an article may have any suitable size. In some
embodiments, a portion may have a largest dimension and/or may
comprise one or more features with a size of greater than or equal
to 100 microns, greater than or equal to 200 microns, greater than
or equal to 500 microns, greater than or equal to 1 mm, greater
than or equal to 2 mm, greater than or equal to 5 mm, greater than
or equal to 10 mm, greater than or equal to 20 mm, greater than or
equal to 50 mm, greater than or equal to 1 cm, or greater than or
equal to 2 cm. In some embodiments, a portion may have a largest
dimension and/or may comprise one or more features with a size of
less than or equal to 5 cm, less than or equal to 2 cm, less than
or equal to 1 cm, less than or equal to 5 mm, less than or equal to
2 mm, less than or equal to 1 mm, less than or equal to 500
microns, or less than or equal to 200 microns. Combinations of the
above-referenced ranges are also possible (e.g., greater than or
equal to 100 microns and less than or equal to 5 cm). Other ranges
are also possible.
[0042] In some embodiments, a 3D-printed article may comprise two
or more portions, where one or more properties (e.g., average pore
size, density, stiffness, stiffness of solid components of the
article, Shore A hardness, degree of cross-linking, chemical
composition, color, abrasion resistance, thermal conductivity,
electrical conductivity, stiffness anisotropy, elastic modulus,
flexural modulus, filler content, opacity, conductivity,
breathability) of a first portion may differ from one or more
properties of a second portion. The one or more properties may be
structural properties (e.g., average pore size, density, surface
roughness, filler content), chemical properties (e.g., average
degree of cross-linking, chemical composition), mechanical
properties (e.g., average stiffness, stiffness of solid components,
Shore A hardness, abrasion resistance, stiffness anisotropy,
elastic modulus, flexural modulus, strength, elongation at break,
tensile elastic modulus, modulus at 100% strain), optical
properties (e.g., color, opacity, reflectivity), and/or other
properties (e.g., average thermal conductivity, electrical
conductivity, conductivity, breathability, dimensional change upon
heat activation). In some embodiments, the difference in properties
between the first portion and the second portion may comprise a
gradient of the one or more properties (e.g., the property or
properties may vary relatively smoothly from a first value in the
first portion to a second value in the second portion). In other
embodiments, there may be a sharp change in one or more of the
properties at a boundary of one or more of the first portion and
the second portion.
[0043] It should be understood that while FIG. 1A shows the second
portion positioned above the first portion, other arrangements of
the first portion with respect to the second portion are also
contemplated. For example, the first portion may be positioned
beside the second portion, the first portion may surround the
second portion, the first portion and the second portion may
interpenetrate (e.g., a first portion may comprise a foam that
interpenetrates with a second portion that comprises an elastomer),
etc. It should also be noted that while FIG. 1A shows the second
portion directly adjacent the first portion, this configuration
should not be understood to be limiting. In some embodiments, the
first portion may be separated from the second portion by one or
more intervening portions positioned between the first portion and
the second portion. As used herein, a portion that is positioned
"between" two portions may be directly between the two portions
such that no intervening portion is present, or an intervening
portion may be present.
[0044] Similarly, while FIG. 1A only depicts two portions, it
should also be understood that an article may comprise three
portions, four portions, or more portions. In some embodiments,
portions within a 3D-printed article as described herein may also
further comprise sub-portions. Each portion and/or sub-portion may
differ from each other (sub-)portion in at least one way (e.g., any
two (sub-)portions may comprise at least one property that is
different), or one or more (sub-)portions may be substantially
similar to other (sub-)portion(s) of the 3D-printed article.
[0045] In some embodiments, two or more portions may be disposed
relative to each other such that they may be connected by a pathway
along which the 3D-printed article lacks an interface along which
one or more properties (e.g., average pore size, density,
stiffness, stiffness of solid components of the article, Shore A
hardness, degree of cross-linking, chemical composition, color,
abrasion resistance, thermal conductivity, electrical conductivity,
stiffness anisotropy, elastic modulus, flexural modulus, filler
content, opacity, conductivity, breathability) undergo step
changes. In other words, the property or properties may vary
smoothly along the pathway. The pathway may be a straight path
pathway (e.g., it may be a line segment), or it may include one or
more curves or corners (e.g., it may be a meander, as described
more fully below). In some embodiments, the pathway may be a
pathway along which material was deposited during formation of the
3D-printed article, such as a pathway travelled by a print head (or
by a substrate with respect to the print head) during
3D-printing.
[0046] When two or more portions are connected by a pathway, the
pathway may have any suitable length. In some embodiments, the
pathway has a length of greater than or equal to 0.5 mm, greater
than or equal to 1 mm, greater than or equal to 2 mm, greater than
or equal to 5 mm, greater than or equal to 10 mm, greater than or
equal to 20 mm, greater than or equal to 50 mm, greater than or
equal to 100 mm, greater than or equal to 200 mm, greater than or
equal to 500 mm, greater than or equal to 1 m, greater than or
equal to 2 m, or greater than or equal to 5 m. In some embodiments,
the pathway has a length of less than or equal to 10 m, less than
or equal to 5 m, less than or equal to 2 m, less than or equal to 1
m, less than or equal to 500 mm, less than or equal to 200 mm, less
than or equal to 100 mm, less than or equal to 50 mm, less than or
equal to 20 mm, less than or equal to 10 mm, less than or equal to
5 mm, less than or equal to 2 mm, or less than or equal to 1 mm.
Combinations of the above-referenced ranges are also possible
(e.g., greater than or equal to 0.5 mm and less than or equal to 10
m, or greater than or equal to 0.5 mm and less than or equal to 50
mm). In some embodiments, the length of the pathway may have a
certain relationship to the 3D-printed article (e.g., if the
3D-printed article is an article of footwear, the length of the
pathway may be the length of the article of footwear). Other ranges
are also possible.
[0047] When a first portion and a second portion are connected by a
pathway, a property (e.g., average pore size, density, stiffness,
stiffness of solid components of the article, Shore A hardness,
degree of cross-linking, chemical composition, color, abrasion
resistance, thermal conductivity, electrical conductivity,
stiffness anisotropy, elastic modulus, flexural modulus, filler
content, opacity, conductivity, breathability) may change along the
pathway at a rate that is advantageous. The average rate of change
of the property may be greater than or equal to 0.05% of the
average of the property in the first portion per mm, greater than
or equal to 0.1% of the average of the property in the first
portion per mm, greater than or equal to 0.2% of the average of the
property in the first portion per mm, greater than or equal to 0.5%
of the average of the property in the first portion per mm, greater
than or equal to 1% of the average of the property in the first
portion per mm, or greater than or equal to 2% of the average of
the property in the first portion per mm. The average rate of
change of the property may be less than or equal to 5% of the
average of the property in the first portion per mm, less than or
equal to 2% of the average of the property in the first portion per
mm, less than or equal to 1% of the average of the property in the
first portion per mm, less than or equal to 0.5% of the average of
the property in the first portion per mm, less than or equal to
0.2% of the average of the property in the first portion per mm, or
less than or equal to 0.1% of the average of the property in the
first portion per mm. Combinations of the above-referenced ranges
are also possible (e.g., greater than or equal to 0.05% and less
than or equal to 5%). Other ranges are also possible. It should be
understood that the average rates of changed described above may
apply to pathways that straight (e.g., pathways that are line
segments), or to pathways that are curved.
[0048] In some embodiments, a first portion and a second portion as
described herein may be components of a 3D-printed article that is
a single integrated material. As used herein, two or more portions
that together form a single integrated material are not separated
by a separable interface. In some embodiments, a single integrated
material may not separate into discrete parts during the course of
normal use, and/or may be separated into discrete parts whose
morphologies would not be predictable prior to normal use and/or
along interfaces that would not be predictable prior to normal use.
For instance, a single integrated material may lack seams and/or
lack an adhesive that bonds two or more portions together. In some
cases, the 3D-printed article as a whole may lack an interface at
which one or more properties (e.g., average pore size, density,
stiffness, stiffness of solid components of the article, Shore A
hardness, degree of cross-linking, chemical composition, color,
abrasion resistance, thermal conductivity, electrical conductivity,
stiffness anisotropy, elastic modulus, flexural modulus, filler
content, opacity, conductivity, breathability) undergo step changes
as described above. In some cases, the property or properties may
vary smoothly throughout the 3D-printed article.
[0049] In some embodiments, one or more portions may together form
an 3D-printed article with one or more of the following features:
macrovoids embedded within the article (e.g., a midsole) without an
intersecting interface from overmolding, lamination, or ultrasonic
welding; one or more open cell lattices; variations in density
across geometries that would be challenging to form by molding;
interpenetrating foams and elastomers that may, in some
embodiments, not be separated by an interface due to molding or
lamination; and/or one or more interfaces between different
materials with extreme undercuts (e.g., materials with a negative
draft angle, materials which cannot be injection molded using a
single mold because they would be unable to slide out of the
mold).
[0050] In some embodiments, a 3D-printed article (e.g., a
3D-printed article comprising two or more portions) may be a foam
(e.g., a closed cell foam). For instance, FIG. 1B shows one
non-limiting embodiment of a 3D-printed article 100 which is a foam
comprising pores 130. The foam may be a material comprising a
matrix and pores disposed within the matrix. Pores may be randomly
distributed throughout the foam, or may be positioned at regular
and/or pre-determined intervals. The material present within the
pores of a foam is typically of a different phase than the material
forming the matrix of the foam (e.g., a foam may comprise pores
that comprise gas within a matrix that comprises a liquid and/or a
solid). As would be understood to one of ordinary skill in the art,
in a closed-cell foam, the cells of the foam are typically isolated
or separated from each other. By contrast, in an open-cell foam,
the cells of the foam are interconnected with each other; for
example, they may be formed in an interconnected fashion, or the
cells may be ruptured or become interconnected during or after
formation of the foam. These conditions are typically more violent
foaming conditions than those resulting in a closed-cell foam. The
foam may be formed from a variety of polymers and gases. The gases
may be introduced into the foam during formation (e.g.,
physically), and/or generated during formation (e.g., via chemical
reaction). In addition, in some cases, a gas may be introduced by
providing a liquid that forms a gas, e.g., upon a decrease in
pressure or an increase in temperature. For instance, a liquid such
as butane may be kept under pressure and/or cooled prior to
introduction into the nozzle or the mixing chamber; a change in
temperature and/or pressure may cause the liquid to form a gas.
Without wishing to be bound by theory, closed cell foams and open
cell foams may have different properties (e.g., closed cell foams
may have different values of density, stiffness, Shore A hardness,
and the like than otherwise equivalent open cell foams) and may be
suitable for different applications. In some embodiments, closed
cell foams may have properties that are better suited to footwear
applications than open cell foams. In some embodiments, a
3D-printed article or a portion thereof may comprise an enclosed
open cell foam, or an open cell foam surrounded by a layer of
continuous material. In some cases, an enclosed open cell foam may
be suitable for use as an air cushion, and/or may have tactile
properties that may be varied by varying infill density.
[0051] It should also be understood that certain 3D-printed
articles described herein may not be foams (i.e., they may not
include any pores). For instance, certain embodiments may relate to
3D-printed articles that are not foams and that comprise one or
more elastomers. In addition, in some cases, an article may be
printed that can then be formed into a foam, e.g., using a chemical
reaction to produce a gas within the article.
[0052] As shown in FIG. 1C, in some but not necessarily all
embodiments, a 3D-printed article that is a foam (e.g., a
closed-cell foam that is optionally a single integrated material)
may comprise one or more portions having different properties. FIG.
1C shows 3D-printed article 100 comprising first portion 110,
second portion 120, and pores 130. Although FIG. 1C depicts a
3D-printed article comprising an average pore (or cell) size in the
first portion (i.e. a first average pore size) that is different
from an average pore (or cell) size in the second portion (i.e., a
second average pore size), in some embodiments the first portion
and the second portion may have the same average pore size but may
comprise differences in other properties (e.g., one or more of the
density, stiffness, Shore A hardness, degree of cross-linking,
chemical composition may be different in the first portion than in
the second portion). Thus the pore sizes are presented here for
illustrative portions only. Similarly, although FIG. 1C shows an
average pore size in the first portion that is larger than the
average pore size in the second portion, in some embodiments the
average pore size of the first portion may be smaller than the
average pore size of the second portion.
[0053] In some embodiments, a 3D-printed article as designed herein
may be suitable for use as a component of one or more articles of
footwear. FIG. 2 shows one non-limiting embodiment of an article of
footwear 100. The article of footwear comprises a sole, a toe box,
an upper; lacing, a heel counter, and a pull tab. It should be
understood that 3D-printed articles suitable for use in footwear
may form any of the components or be a portion of any or all of the
components shown in FIG. 2. In some embodiments, multiple
3D-printed articles may be positioned on a single article of
footwear (e.g., a single article of footwear may comprise a
3D-printed article that is disposed on a sole or is a sole and a
3D-printed article that is disposed on an upper). In some
embodiments, the 3D-printed article may be a sole or a sole
component, such as an outsole, a midsole, or an insole. In some
embodiments, the 3D-printed article may be an article that is
printed onto a sole component, such as a midsole and/or insole that
is printed onto an outsole (e.g., a commercially available outsole,
an outsole produced by a non-3D printing process). In some
embodiments, the 3D-printed article may be an upper. In some
embodiments, the 3D-printed article may be an article that is
printed onto an upper, such as a toe box, a heel counter, an ankle
support, an eyestay, an article comprising a logo and/or embodying
a logo, an eyelet, a quarter panel, a no sew overlay feature,
and/or a pull tab. The upper may be one component of a fully
assembled shoe which lacks the part(s) to be printed, or it may be
an upper that has not been assembled with other footwear
components. In some embodiments, a 3D-printed article may be a
combination of two or more footwear components that are typically
provided as separate articles. For example, the 3D-printed article
may be able to serve as both a midsole and an insole, or may
comprise a midsole and an insole that are a single integrated
material. As another example, the 3D-printed article may be able to
serve as both an outsole and an insole, or may comprise an outsole
and an insole that are a single integrated material. In some
embodiments, a 3D-printed article comprising two or more footwear
components (e.g., a 3D-printed article comprising a midsole and an
insole, a 3D-printed article comprising an outsole and an insole)
may be printed using a single integrated process. Although FIG. 2
shows an athletic shoe, 3D-printed articles suitable for use in
other types of footwear are also contemplated as described in
further detail below. In some embodiments, the 3D-printed article
may also or instead be suitable for one or more non-footwear
components, such as orthotics and/or prosthetics.
[0054] In some embodiments, a 3D-printed article (e.g., a foam that
optionally is a closed-cell foam, is a single integrated material,
and/or comprises two or more portions; an article that is not a
foam; an article that comprises an elastomer, etc.) may comprise
one sensor or may comprise a plurality of sensors. FIG. 3A shows
one non-limiting embodiment where 3D-printed article 100 further
comprises sensor 140. As described above, the sensor may be capable
of sensing one or more properties of an article of footwear of
which it is a component and/or of a user of an article of footwear
of which it is a component. When present, the plurality of sensors
may comprise sensors that are each identical to each other (e.g.,
the plurality of sensors may comprise identical sensors dispersed
throughout the 3D-printed article) and/or may comprise different
and/or complementary sensors (e.g., the plurality of sensors may
comprise sensors that are capable of measuring different
properties).
[0055] In some, but not necessarily all, embodiments, one or more
properties of the 3D-printed article may vary with distance from
one or more sensors. As an example, a 3D-printed article may
comprise one portion adjacent a sensor or positioned near a sensor
(e.g., positioned within 1 cm of the sensor) for which one or more
properties are different than for a portion positioned further from
the sensor (e.g., positioned at least 3 cm from the sensor). While
FIG. 3A shows a 3D-printed article comprising pores with an average
pore size varying with distance from the sensor, it should be
understood that the 3D-printed article may not comprise pores
(i.e., it may not be a foam) or that the average pore size may not
vary with distance from the sensor, and/or one or more other
properties (e.g., one or more of the density, stiffness, Shore A
hardness, degree of cross-linking, chemical composition may be
different in the first portion than in the second portion) may vary
with distance from the sensor. For example, the 3D-printed article
could have a first stiffness in a first portion adjacent the sensor
that is different from a second stiffness in a second portion
positioned further from the sensor. Without wishing to be bound by
theory, a higher stiffness adjacent a sensor may prevent the sensor
from undergoing significant strain, which may be beneficial for
certain types of sensors. For other types of sensors, such as
strain sensors, it may be beneficial for the sensor to undergo
significant strain. Similarly, although FIG. 3A shows average pore
size increasing with distance from the sensor, it is also possible
for average pore size to decrease with distance from the
sensor.
[0056] When present, the plurality of sensors may be disposed with
respect to each other in any suitable manner. In some embodiments,
it may be advantageous for certain sensors to be positioned in
specific locations or in predetermined locations. For instance, as
shown in FIG. 3B, in some embodiments it may be beneficial for
sensors 140 to be positioned along the outer edge of sole 150. As
another example, in some embodiments it may be advantageous for one
or more sensors to be positioned in the heel of an article of
footwear, in the arch of an article of footwear, on the bottom of a
sole, or in any other location in an article of footwear. Without
wishing to be bound by theory, sensors in different locations may
be capable of sensing different properties and/or being useful for
different applications. For example, pressure sensors positioned
around the outer edge of a sole may be able to determine whether a
user is pronating, where on their foot the user is placing the
majority of their weight, whether the user is running and/or
walking with good form, and/or the weight of the user. Such data
may be useful in, e.g., fitness and athletic applications. As
another example, one or more strain sensors positioned within an
arch may be able to determine whether the arch is beginning to
degrade. Data obtained from such sensors may be used to alert users
that footwear replacement is recommended. As a third example, one
or more sensors disposed on the bottom of a sole may be able to
sense characteristics of the environment that the user is walking
over (e.g., temperature, roughness, incline, and the like).
[0057] Non-limiting examples of suitable sensors include strain
sensors, force sensors, position sensors, and capacitance sensors.
In some embodiments, a single sensor may be capable of sensing two
or more properties (e.g., a single sensor may be capable of sensing
both velocity and acceleration, both position and force, and the
like). In some embodiments, the plurality of sensors may be capable
of sensing one or more properties as a function of time.
In some embodiments, the plurality of sensors may comprise one or
more sensors (e.g., strain sensors) formed by a 3D-printing process
as described herein. For example, a sensor may be formed by
3D-printing a conductive material, such as an ionic liquid and/or a
material that comprises conductive particles. In some embodiments,
the plurality of sensors may comprise one or more sensors that are
stretchable (e.g., a sensor that can undergo an elastic strain of
greater than or equal to 100%, 200%, 300%, 400%, or more).
[0058] As described above, certain inventive articles and methods
relate to 3D-printed articles (e.g., 3D-printed articles for use in
footwear) which comprise a plurality of electronic devices (e.g.,
sensors) which are capable of transmitting information to a
computing device. These articles and methods may relate to
electronic devices. For example, one or more sensors may be
integrated into the shoe and information from the sensors may be
transmitted to a computing device over a wireless communication
link. An example of such a shoe in communication with a computing
device is shown in FIG. 4 by article of footwear 402. As shown,
article of footwear 402 comprises a sensor 404, a wireless
transmitter 406, and a power source 408. The wireless transmitter
406 may be configured to establish a wireless communication link
with a computing device 410 comprising a display 412 and a
transducer 414.
[0059] The wireless transmitter 406 may receive sensor information
from the sensor 404 indicative of the particular parameter sensed
by the sensor 404 and communicate the received sensor information
to the computing device 410 over a wireless communication link. For
example, the wireless transmitter 406 may be implemented as a
BLUETOOTH transmitter and establish a BLUETOOTH wireless
communication link with the computing device 410.
[0060] The power source 408 may provide power to the wireless
transmitter 406. The power source 408 may comprise an energy
storage device, such as a battery, to store energy and provide the
stored energy to the wireless transmitter 406. Additionally (or
alternatively), the power source 408 may comprise an energy
harvester device that are configured to capture energy from
environmental sources, such as sunlight, temperature changes, and
movement. The energy generated by the energy harvester device may
be employed to charger an energy storage device and/or directly
power the wireless transmitter 406. Example energy harvesting
devices include photovoltaic devices, piezoelectric devices, and
thermoelectric devices.
[0061] The computing device 410 may receive sensor information from
the wireless transmitter 406 and interpret the received sensor
information. This process will be described in further detail below
in relation to FIG. 6.
[0062] The computing device 410 may be implemented in any of a
variety of ways. For example, the computing device 410 may be
implemented as a tablet, a mobile phone, a laptop, a desktop, or a
server. An example implementation of the computing device 410 is
shown in FIG. 5 by computer system 500. As shown in FIG. 5, the
computer system 500 includes a processor 506 connected to a memory
device 510 and a storage device 512. The processor 506 may
manipulate data within the memory 510 and copy the data to storage
512 after processing is completed. The memory 510 may be used for
storing programs and data during operation of the computer system
500. Storage 512 may include a computer readable and writeable
nonvolatile recording medium in which computer executable
instructions are stored that define a program to be executed by the
processor 506. According to one embodiment, storage 512 comprises a
non-transient storage medium (e.g., a non-transitory computer
readable medium) on which computer executable instructions are
retained.
[0063] Components of computer system 500 can be coupled by an
interconnection mechanism 508, which may include one or more busses
(e.g., between components that are integrated within a same
machine) and/or a network (e.g., between components that reside on
separate discrete machines). The interconnection mechanism enables
communications (e.g., data, instructions) to be exchanged between
system components of system 500. The computer system 500 may also
include one or more input/output (I/O) devices 502 and 504, for
example, a keyboard, mouse, trackball, microphone, touch screen, a
printing device, display screen, speaker, wireless communication
components, etc. to facilitate communication with other systems
and/or a user.
[0064] The computer system 500 may include specially-programmed,
special-purpose hardware, for example, an application-specific
integrated circuit (ASIC). Aspects of the present disclosure can be
implemented in software, hardware or firmware, or any combination
thereof. Although computer system 500 is shown by way of example,
as one type of computer system upon which various aspects of the
present disclosure can be practiced, it should be appreciated that
aspects of the present disclosure are not limited to being
implemented on the computer system as shown in FIG. 5. Various
aspects of the present disclosure can be practiced on one or more
computers having a different architectures or components than that
shown in FIG. 5.
[0065] Various embodiments described above can be implemented using
an object-oriented programming language, such as Java, C++, Ada, or
C# (C-Sharp). Other programming languages may also be used.
Alternatively, functional, scripting, and/or logical programming
languages can be used. Various aspects of the present disclosure
can be implemented in a non-programmed environment (e.g., documents
created in HTML, XML or other format that, when viewed in a window
of a browser program, render aspects of a graphical-user interface
(GUI) or perform other functions). The system libraries of the
programming languages are incorporated herein by reference. Various
aspects of the present disclosure can be implemented as programmed
or non-programmed elements, or any combination thereof.
[0066] As described above, in certain embodiments a computing
device may receive and/or process information obtained from a
plurality of sensors. FIG. 6 shows one non-limiting example of a
process that could be employed. As shown therein, the process may
comprise a first step 601 of sensing one or more properties using
the plurality of sensors. Next, as in step 602, information may be
acquired from the sensors by, for example, receiving data
transmitted from the plurality of sensors. Then, the information
gathered in step 602 may be used in one or more ways. For instance,
as in step 603, the information may be used to print a second
3D-printed article. As another example, as in step 604, the
information may be used to generate a recommendation for one or
more properties of a second 3D-printed article. Step 604 may
optionally be followed by step 605, in which a second 3D-printed
article is formed based on the recommendation generated in step
604. As a third example, shown as step 606, the computing device
may alert a user of one or more conclusions derived from
information acquired from the plurality of sensors. The information
may be related to the health and/or fitness of the user (e.g.,
weight, distance traveled, running form), related to an article of
footwear of which the 3D-printed article forms one part (e.g.,
whether or not the article of footwear has worn out), and/or
related to a recommendation for footwear designs or footwear
component designs that may be suitable for the user (e.g., designs
for insoles). It should be understood that methods for fabricating
3D-printed articles informed by data gathered from one or more
sensors may possibly additional steps not shown in FIG. 6 and/or
may not comprise one or more steps shown in FIG. 6. In some
embodiments, information used as described herein may be obtained
from several different 3D-printed articles worn by a single user at
different times. For instance, a user may test 3D-printed articles
with different designs (e.g., insoles with different designs) which
each are capable of transmitting data to a computing device.
[0067] For the methods described above, it should be appreciated
that a second 3D-printed article if printed or recommended may be
the same type of article as the first article (e.g., both the first
article and the second article may be midsoles), or the second
3D-printed article may be a different type of article than the
first article (e.g., the second 3D-printed article may be a sole
and the first 3D-printed article may be an insole, the second
3D-printed article may be a midsole and the first 3D-printed
article may be an insole). In some embodiments, the second
3D-printed article may be the same type of article as the first
3D-printed article, but may be an employed in a different type of
footwear than the first 3D-printed article (e.g., the second
3D-printed article may be an insole for a dress shoe and the first
3D-printed article may be an insole for an athletic shoe). In some
embodiments, it may be possible to 3D print identical or
substantially similar articles for use in different types of
footwear (e.g., identical or substantially similar insoles may be
printed for dress shoes, sandals, athletic shoes, etc.).
[0068] As described above, certain articles as described herein may
be formed by a process involving one or more 3D-printing steps. In
some embodiments, an article may be formed by a process involving
both one or more 3D-printing steps and one or more non-3D-printing
steps. For example, an article may be formed by a first 3D-printing
step followed by a first non-3D-printing step which is optionally
followed by one or more further 3D-printing steps or
non-3D-printing steps. For example, a sole or sole component may be
3D-printed into a mold to form a first portion and then a material
may be injection molded or compression molded above the first
portion to form the second portion. Third, fourth, fifth, and/or
higher numbered portions may then optionally be formed on the
second portion (by, e.g., 3D-printing). As another example, a
non-3D printing step may comprise directly bonding two materials by
pressing a first material (e.g., a non-3D-printed material, an
upper) into a second 3D-printed material (e.g., a 3D-printed
midsole) prior to full curing of the second material. As a third
example, an inkjet finishing process may be applied to deposit one
or more materials (e.g., one more pigments) on a 3D-printed article
or on a material disposed on a 3D-printed article (e.g., a material
injection molded or compression molded on a 3D-printed article). In
some embodiments, an inkjet finishing process may enhance the
surface quality of the article that is subject to it.
[0069] A variety of suitable inkjet processes may be combined with
3D-printing processes described herein. In some embodiments, an
inkjet process may be employed to deposit one or more layers of
material onto a 3D-printed article. For instance, two or more
layers may be deposited consecutively to increase the thickness of
a surface finishing layer and/or to form a 3D structure on the
surface of the 3D-printed article. The layer(s), or other
structure(s) formed by an inkjet process, may comprise one or more
translucent portions (e.g., may be translucent) and/or may comprise
one or more non-translucent portions (e.g., may be
non-translucent). The layer(s) or other structure(s) may cover one
or more portions of the 3D-printed article (e.g., may cover one or
more portions of the 3D-printed article and not cover one or more
portions of the 3D-printed article) or may cover the entirety of
the 3D-printed article. The layer(s) or structure(s) may have a
variety of surface properties. In certain embodiments, the layer(s)
or other structure(s) may increase the surface roughness of the
article, cause the article to have a matte finish, and/or reduce
the reflectivity of the article (e.g., reduce the reflectivity of
its surface).
[0070] As will be described in further detail below, in 3D-printed
articles may be formed by depositing a material from a nozzle onto
a substrate. The nozzle may be translated with respect to the
substrate (and/or the substrate translated with respect to the
nozzle) during this process. In certain cases, the nozzle and/or
substrate may be translated such that the deposited material
meanders (i.e., forms a meander on the substrate). Meanders
typically have a length, width, and repeat period. FIG. 7A shows
one non-limiting example of a meander 900, with length 910, width
920, and repeat period 930. The meander may have other relative
proportions of length, width, and repeat period. For example, FIG.
7B shows a meander 901 with a relatively larger width and smaller
length than meander 900. It should be noted that meanders may have
different shapes than those shown in FIGS. 7A and 7B (e.g., they
may have repeat periods along two or more distinct axes). In some
cases material may be deposited in meanders that do not have a
repeat period, or have a repeat period including some
irregularities. For example, the meander may be a meander where the
width and/or repeat period changes (e.g., with position, such as
along the length of the meander), the meander may be an irregular
curve, etc. If the width and/or repeat period of the meander
changes, it may do so monotonically or may increase in some
portions of the meander and decrease in other portions of the
meander.
[0071] In some cases, one or more properties of the material being
deposited by the nozzle may change as a function of time and/or
position, which may result in changes in one or more properties of
the 3D-printed article as a function of printing time and/or
position. As one example, a gradient in a property (e.g., average
pore size, density, stiffness, stiffness of solid components of the
article, Shore A hardness, degree of cross-linking, chemical
composition, color, abrasion resistance, thermal conductivity,
electrical conductivity, stiffness anisotropy, elastic modulus,
flexural modulus, filler content, opacity, conductivity,
breathability, etc.) may be generated by varying one or more
properties of the material being deposited by the nozzle. In some
cases, a material may be deposited on a substrate in a meander
(which may be regular or irregular) and a gradient may be formed
along the meander or perpendicular to the meander. FIG. 8A shows a
non-limiting schematic depiction of a gradient that is parallel to
a meander and a non-limiting schematic depiction of a gradient that
is perpendicular to a meander. FIG. 8B shows a non-limiting example
of the change in the value of a property as a function of distance
along the gradient when the gradient is formed perpendicular to the
meander. Gradients of this type are stepped gradients, or gradients
encompassing step changes. FIG. 8C shows a non-limiting example of
the change in the value of a property as a function of distance
along the gradient when the gradient is formed parallel to the
meander. Gradients of this type are smooth gradients, or gradients
that lack step changes. The rate of change of the gradient, in a
smooth gradient, may be constant (i.e., a linear gradient), or the
rate of change may result in a non-linear smooth gradient. It
should be understood that both smooth and stepped gradients are
encompassed by the use of the term gradient, and that gradients
referenced herein, if not otherwise specified, should be understood
to include smooth gradients in some embodiments and stepped
gradients in other embodiments. In addition, some gradients may
comprise one or more smooth portions and one or more stepped
portions.
[0072] In certain embodiments, an article (e.g., a portion, an
article of footwear, a component of an article of footwear) as
described herein may be produced on a multi-axis deposition system,
and/or a method as described herein may include at least one step
(e.g., a 3D-printing step, a non 3D-printing step) that is
performed on a multi-axis deposition system. It should be
understood that articles of apparel (e.g., an article of apparel
such as a sports bra, a component of an article of apparel such as
a sports bra) may also be produced on a multi-axis deposition
system as described herein. In general, and as described further
below, multi-axis deposition systems include a print head and a
substrate. The print head may be any suitable print head configured
to deposit a material onto the substrate. The substrate may be any
suitable substrate onto which a material may be deposited; in some
embodiments, one or more articles (e.g., a component of an article
of footwear, an upper, a sock liner) may be disposed on the
substrate. In certain embodiments, one or both of the print head
and substrate may be translated along one or more axes and/or
rotated around one or more axes. Translation and/or rotation of the
print head and/or substrate may enable the position of the print
head with respect to the substrate to be changed prior to, during,
and/or after a printing process. In some cases, translation and/or
rotation of the print head and/or the substrate may allow the print
head to deposit material onto a wide variety of substrate surfaces
and/or allow the print head to deposit material onto the substrate
at a wide variety of angles. In some embodiments, the print head
may be configured to be rotated and/or translated such that it can
deposit material onto each surface of the substrate.
[0073] FIG. 9 shows one non-limiting embodiment of a multi-axis
deposition system 1000 comprising print head 1010 and substrate
1020. The print head, substrate, and multi-axis deposition system
will be described in further detail below.
[0074] A print head in a multi-axis deposition system may be any
suitable print head configured to deposit a material of interest
onto the substrate. In some embodiments a multi-axis deposition
system may comprise two or more print heads. Non-limiting examples
of suitable print heads include a direct write head, a mixing
nozzle as described further below, an ink jet head, a spray valve,
an aerosol jet print head, a laser cutting head, a hot air gun, a
hot knife, an ultrasonic knife, a sanding head, a polishing head, a
UV curing device, an engraver, an embosser, and the like. In some
embodiments, it may be advantageous for the multi-axis deposition
system to comprise a first print head that comprises a mixing
nozzle and a second print head that does not comprise a mixing
nozzle. As also described below, in some embodiments, the print
head may be configured to accept one or more material inputs (e.g.,
one material input, two material inputs, etc.). When two or more
material inputs are present, the inputs may be substantially the
same or they may differ. In some embodiments, the print head may be
configured to mix two or more reactive material inputs to form a
reactive mixture that may be deposited onto a substrate while the
first and second material inputs are reacting and/or after the
first and second material inputs have reacted. For example, the
print head may be configured to mix a polyol and an isocyanate to
form a reactive polyurethane mixture. Other examples of suitable
reactive mixtures include reactive polyurea mixtures, reactive
mixtures comprising reactive polyurethane and reactive polyurea
blends (e.g., polyurethane/polyurea hybrid formulations), reactive
mixtures comprising epoxy groups and amine groups, and reactive
silicone mixtures.
[0075] A substrate in a multi-axis deposition system may be any
suitable substrate capable of receiving the material deposited by
the print head. In some cases, the substrate may have a shape that
enables facile deposition of the material of interest in a
morphology of interest by the print head. As an example, the
substrate may have a shape that substantially corresponds to the
morphology of interest, such as a footwear last for footwear
applications (e.g., as shown in FIG. 9). In other embodiments, the
substrate may have a shape that substantially corresponds to a
morphology of interest for an article of apparel (e.g., a bra cup
for sports bra applications and/or for bra lining applications, an
article substantially corresponding to the shape of a knee for knee
brace applications, an article substantially corresponding to the
shape of an ankle for ankle brace applications, an article
substantially corresponding to the shape of a wrist for wrist brace
applications, an article substantially corresponding to the shape
of a shoulder for shoulder brace applications, and/or an article
substantially corresponding to the shape of an arm for arm band
applications). As another example, the substrate may be a mold or a
portion of a mold. As a third example, the substrate may comprise a
portion that is curved, and/or the substrate as a whole may be
curved. For instance, the substrate may have a spherical shape, or
a hemispherical shape. As a fourth example, the substrate may
comprise two or more surfaces that are joined at facets. In some
such cases, the substrate may be a platonic solid or may comprise a
portion that is a platonic solid. In some embodiments, the
substrate may be substantially flat. Other types of substrates are
also possible.
[0076] In some embodiments, a multi-axis deposition system may
comprise a substrate that is removable. The substrate may be
configured to be positioned in the multi-axis deposition system
during material deposition and removed after material deposition.
In some embodiments, a multi-axis deposition system may comprise
multiple substrates that may be added to the multi-axis deposition
system prior to material deposition and/or removed from the
multi-axis deposition system after material deposition. Each
substrate may have a different shape (e.g., a different shoe size,
a different cup size, a mold for a different type of apparel), or
two or more substrates may have substantially the same shape.
[0077] As described above, one or more articles may be disposed on
the substrate prior to material deposition and/or during material
deposition using the a multi-axis deposition system. The article(s)
disposed on the substrate may be configured to be positioned on the
substrate during material deposition and, optionally, removed from
the substrate after material deposition. In some embodiments, a
multi-axis deposition system may be configured to deposit material
onto a multiple articles successively, each of which may be added
to the multi-axis deposition system prior to material deposition
and/or removed from the multi-axis deposition system after material
deposition. For example, a textile (e.g., a non-flat textile, an
upper, a woven textile, a knit textile) may be disposed on the
substrate prior to material deposition, during material deposition,
and/or after material deposition. In some embodiments, a multi-axis
deposition system may be employed to deposit a reactive mixture as
described above onto a textile to form a 3D-printed material on the
textile and/or on a succession of textiles sequentially added to
the substrate.
[0078] It should be noted that the print head(s) and the substrate
in a multi-axis deposition system comprising both a print head and
a substrate may be oriented with respect to each other in other
ways than that shown in FIG. 9. As an example, the a print head may
be disposed over the center of the substrate in some embodiments
and over the edge of the substrate in other embodiments. As another
example, the a print head may be oriented so that it deposits
material on the substrate at a 90.degree. angle to the substrate in
some embodiments and so that it deposits material on the substrate
at another angle to the substrate (e.g., 45.degree., 30.degree., or
other angles) in other embodiments. As a third example, the
substrate may present a bottom surface (e.g., a portion of a last
on which a sole would be disposed) to the a print head in some
embodiments and may present a side or top surface (e.g., a portion
of a last on which an upper would be disposed) in other
embodiments. In some cases, the print head(s) and/or the substrate
may be configured to be translated and/or rotated around one or
more axes, as described further below. In such cases, the absolute
positions of the print head(s) and the substrate may be varied
during operation of the multi-axis system, and/or the relative
position of the print head(s) with respect to the substrate may be
varied during operation of the multi-axis system.
[0079] As described above, a multi-axis deposition system may
comprise a print head that may be configured to be translated along
one or more axes. In some embodiments, the print head may be
configured to be translated along one axis, along two axes, or
along three axes. In certain cases, the axes may be perpendicular
to each other. In other cases two or more of the axes are not
perpendicular to each other (e.g., they may intersect at an angle
between 45.degree. and) 90.degree.. For example, in some
embodiments the print head may be configured to be translated
vertically, and/or translated in one or more directions
perpendicular to the vertical direction. As another example, in
some embodiments the print head may be configured to be translated
in a direction perpendicular to the substrate, and/or in one or
more directions parallel to the substrate. As a third example, in
some embodiments the print head may be configured to be translated
at a 45.degree. angle with respect to the substrate. In some cases,
each axis of translation may independently be controlled by
separate motors. In some embodiments, the print head may not be
configured to be translated.
[0080] In some embodiments, one or more print heads in a multi-axis
system may be configured to be rotated around one axis, around two
axes, or around three axes. In some embodiments, one or more print
heads may be configured to be rotated around more than three axes
(e.g., around more than four axes, around more than six axes,
around more than eight axes, around more than 10 axes, or around
more than 12 axes). In certain cases, the axes may be perpendicular
to each other. For example, in some embodiments the print head may
be configured to be rotated around a vertical axis, and/or rotated
around one or more axes perpendicular to the vertical axis. As
another example, in some embodiments one or more print heads may be
configured to be rotated around an axis perpendicular to the
substrate, and/or around one or more axes parallel to the
substrate. In some cases, each axis of rotation may independently
be controlled by separate motors. In some embodiments, one or more
print heads may not be configured to be rotated. In some
embodiments, the print head may be configured to be stationary.
[0081] In some embodiments, a substrate in a multi-axis system may
be configured to be translated along one axis, along two axes, or
along three axes. In certain cases, the axes may be perpendicular
to each other. In other cases two or more of the axes are
perpendicular to each other (e.g., they may intersect at an angle
between 45.degree. and 90.degree.). For example, in some
embodiments the substrate may be configured to be translated
vertically, and/or translated in one or more directions
perpendicular to the vertical direction. As another example, in
some embodiments the substrate may be configured to be translated
in a direction perpendicular to the print head, and/or in one or
more directions parallel to the print head. As a third example, in
some embodiments the print head may be configured to be translated
at a 45.degree. angle with respect to the substrate. In some cases,
each axis of translation may independently be controlled by
separate motors. In some embodiments, the substrate may not be
configured to be translated.
[0082] In some embodiments, a substrate in a multi-axis system may
be configured to be rotated around one axis, around two axes, or
around three axes. In certain cases, the axes may be perpendicular
to each other. In some embodiments, the substrate may be configured
to be rotated around more than three axes (e.g., around more than
four axes, around more than six axes, around more than eight axes,
around more than 10 axes, or around more than 12 axes). For
example, in some embodiments the substrate may be configured to be
rotated around a vertical axis, and/or rotated around one or more
axes perpendicular to the vertical axis. As another example, in
some embodiments the substrate may be configured to be rotated
around an axis perpendicular to the print head, and/or around one
or more axes parallel to the print head. In some cases, each axis
of rotation may independently be controlled by separate motors. In
some embodiments, the substrate may not be configured to be
rotated. In some embodiments, the substrate may be configured to be
stationary.
[0083] In some embodiments, a multi-axis deposition system may
comprise one or more features that aid rotation and/or translation
of a print head and/or a substrate. As an example, in some cases
the print head may be attached to a print head arm that facilitates
motion. When two or more print heads are present, each print head
may be positioned separate print head arms or two or more print
heads may be positioned on the same print head arm. In some cases,
two or more print head arms may be attached to a single gantry. The
print head arm(s) may be capable of facilitating translation and/or
rotation of the print head(s). In some embodiments, the print
head(s) may be attached to single print head arms; in other
embodiments, the print head(s) may be attached to multiple print
head arms that are attached at joints that allow for rotation
and/or translation. In some cases, one or more motors may
facilitate motion of one or more components of the print head
arm(s). As another example, in some cases the substrate may be
attached to a substrate arm that facilitates motion. The substrate
arm may be capable of facilitating translation and/or rotation of
the substrate. In some embodiments, the support substrate may be
attached to a single substrate arm; in other embodiments, the
substrate may be attached to multiple substrate arms that are
attached at joints that allow for rotation and/or translation. In
some cases, the substrate may be attached to a robot arm. In some
cases, one or more motors may facilitate motion of one or more
components of the substrate arm(s). In certain embodiments, the
print head may be attached to a print head arm and the substrate
may be attached to a substrate arm.
[0084] FIGS. 10-12 show various views of a non-limiting embodiment
of a multi-axis deposition system showing various combinations of
axes around which a print head and substrate therein may be
configured to be rotated and/or translated. FIG. 10 shows a
perspective view of the system as a whole, FIG. 11 shows a
cross-sectional view of the system as a whole, and FIG. 12 shows a
close up perspective view of the print head and the substrate. It
should be understood that these figures do not show all possible
combinations of print head and substrate motion, and that all
combinations of print head motion and substrate motion described
above are contemplated.
[0085] In FIGS. 10-12, the multi-axis deposition system includes
print head 1010 and substrate 1020. Print head 1010 in FIGS. 10-12
is attached to first print head arm 1031, which is attached to
second print head arm 1032 by a first print head joint configured
to allow translation of first print head arm 1031 along a first
print head translation axis and along a second print head
translation axis. Second print head arm 1032 is also attached to
gantry 1050, which supports the second print head arm. In some
embodiments, the second print head arm is attached to the gantry by
screws and held in a stationary position (as is shown in FIGS.
10-12). In other embodiments, the second print head arm is
configured to be translated along one or more axes and/or rotated
around one or more axes. The print head may be translated along the
first print head translation axis by translating the first print
head arm along the first print head translation axis, and the print
head may be translated along the second print head translation axis
by translating the first print head arm along the second print head
translation axis. In certain cases, such as that shown in FIGS.
10-12, the second print head arm may be a track along which the
first print head arm may be translated and/or the first print head
joint may comprise a track along which the first print head arm may
be translated. In other embodiments, other types of joints and
print head arms may be employed.
[0086] Substrate 1010 in FIGS. 10-12 is attached to first substrate
arm 1041, which is attached to second substrate arm 1042 by a first
substrate joint configured to allow rotation of first substrate arm
1041 around a first substrate rotation axis. Second substrate arm
1042 is attached to third substrate arm 1043 by a second substrate
joint configured to allow rotation of second substrate arm 1042
around a second substrate rotation axis. The substrate may be
rotated around the first substrate rotation axis by rotating the
first substrate arm around the first substrate rotation axis, and
around the second substrate rotation axis by rotating the second
substrate arm around the second substrate rotation axis. In some
embodiments, one or more of the substrate arms may curved (e.g.,
second substrate arm as shown in FIGS. 10-12). Third substrate arm
1043 is attached to support 1044 by a third substrate joint
configured to allow translation of the third arm along a first
substrate translation axis. The substrate may be translated along
the first substrate translation axis by translating the third arm
along the first substrate translation axis. In certain cases, such
as that shown in FIGS. 10-12, the third substrate arm may be a
track along which the second substrate arm may be translated. In
other embodiments, other types substrate arms may be employed.
[0087] In some embodiments, a multi-axis system may comprise
further features in addition to some or all of those described
above. For example, the multi-axis system may be encased in a frame
or enclosure. FIG. 11 includes frame 1060 with feet 1070 and wheels
1080. The feet may aid stable positioning of the frame on a surface
(e.g., a floor, a desktop, a lab bench). The wheels may promote
facile repositioning of the frame in different locations. In some
embodiments, one or more components (e.g., the frame, one or more
arms) may be formed from standardized parts, such as T-slotted
framing. Other types of standardized parts, and/or non-standard
parts, may also be employed.
[0088] Certain combinations of print head motion and substrate
motion may be especially advantageous. For example, as shown in
FIGS. 10-12, the a print head may be configured to be translated
vertically and in a first horizontal direction, and the substrate
may be configured to be translated along a second horizontal
direction perpendicular to the first horizontal direction and
rotated around two distinct axes. As another example, the a print
head may be configured to be translated in three perpendicular
directions and the substrate may be configured to be rotated around
two distinct axes. As a third example, the a print head may be
configured to be stationary and the substrate may be configured to
be translated in three perpendicular directions and rotated around
two distinct axes. As a fourth example, the a print head may be
configured to be translated around three distinct rotation axes and
along three distinct translation axes, and the substrate may be
configured to be stationary. Other combinations of print head
motion and substrate motion are also possible.
[0089] In some embodiments, a multi-axis system may have one or
more features that make it suitable for 3D-printing materials of
interest. For example, the multi-axis system may be configured to
deposit a material onto a substrate as a continuous stream or as a
continuous filament. In other words, the substrate may be in fluid
communication with the print head via the material during
deposition. In certain cases, the multi-axis system may be employed
to deposit a continuous stream or filament that extends from a
first side of a last or a material disposed on the last (e.g., an
upper, a 3D-printed material disposed on an upper) across the
bottom of the last or material disposed on the last to the opposing
side of the last or material disposed on the last. In some cases,
the multi-axis system may be employed to print each portion of an
article of footwear except for the upper.
[0090] In some embodiments, a multi-axis system may be configured
to 3D-print materials with one or more advantageous properties. For
example, the multi-axis system may be configured to 3D-print
materials with a feature size of greater than or equal to 100
microns, greater than or equal to 200 microns, greater than or
equal to 500 microns, greater than or equal to 1 mm, greater than
or equal to 2 mm, greater than or equal to 5 mm, greater than or
equal to 10 mm, greater than or equal to 20 mm, greater than or
equal to 50 mm, greater than or equal to 1 cm, or greater than or
equal to 2 cm. In some embodiments, the multi-axis system may be
configured to 3D-print materials with a feature size of less than
or equal to 5 cm, less than or equal to 2 cm, less than or equal to
1 cm, less than or equal to 5 mm, less than or equal to 2 mm, less
than or equal to 1 mm, less than or equal to 500 microns, or less
than or equal to 200 microns. Combinations of the above-referenced
ranges are also possible (e.g., greater than or equal to 100
microns and less than or equal to 5 cm). Other ranges are also
possible.
[0091] In some embodiments, a 3D-printed material may be formed on
an article disposed on a substrate that is configured to interact
with a detection system in a manner that promotes alignment of the
3D-printed article (and/or portions thereof) with respect to the
article disposed on the substrate and/or precision in the
positioning of the 3D-printed article (and/or portions thereof)
onto the article disposed on the substrate. For example, the
article may comprise one or more features that may be detected by a
detector. The detector may be in electronic communication (e.g., by
use of a wired and/or wireless connection) with a print head
configured to deposit a material onto the substrate and article
disposed thereon, and/or may be configured to transmit information
to the print head configured to deposit a material onto the
substrate and article disposed thereon. In certain cases, the
detector may be configured to detect information about the article
disposed on the substrate, such as the location of the article
(and/or a portion thereof) in space, with respect to the substrate,
and/or with respect to the print head; the orientation of the
article (and/or a portion thereof) in space, with respect to the
substrate, and/or with respect to the print head; and/or one or
more qualities associated with the article (e.g., the scale of the
article, the skew of the article, the mirroring of the article,
whether or not the article has undergone an affine transformation).
The detector may send instructions to the print head and/or the
substrate based on some or all of the information it detects. For
example, the detector may detect that the article is located in an
undesirable position, and may send an instruction to the substrate
to translate and/or rotate so that the article is located in a
desirable position. As a second example, the detector may detect
that the article is located in a desirable position, and may send
instructions to the print head to print onto the article and/or to
translate and/or rotate to a desired position and then print onto
the article. As a third example, the detector may detect that the
article has undergone a certain amount of skew, and send
instructions to the print head to modify its motion with respect to
the article to account for the skew. Other types of instructions
may also be sent.
[0092] When present, a detector configured to detect one of more
features of an article disposed on a substrate may be located in
any suitable position. The detector may be configured to be
stationary (e.g., it may be mounted above the substrate at a fixed
position), or may be configured to be translated and/or rotated
(e.g., it may be mounted on a gantry on which one or more other
features such as the print head may also be positioned). The
detector may be configured to have a known position with respect to
one or more other components of a deposition system (e.g., a print
head, a substrate), and/or may be configured to detect its location
with respect to one or more components of the deposition system
(e.g., the print head, the substrate). For example, the detector
may detect its position with respect to the print head by
depositing a material onto the substrate (or an article disposed
thereon) and detecting the location of the deposited material.
[0093] In some embodiments, a detector configured to detect a
feature is an optical detector and an article disposed on a
substrate comprises features that may be detected optically. For
example, the features may be patterns printed onto an article
disposed on the substrate, portions of an article disposed on a
substrate that scatter light in a detectable manner, portions of an
article disposed on a substrate that absorb light in a detectable
manner, and/or portions of an article disposed on a substrate that
reflect light in a detectable manner. Other types of features that
may be detected optically are also contemplated. One example of a
suitable type of optical detector is an optical camera.
[0094] In some embodiments, as also described elsewhere herein, an
article disposed on a substrate may be a fabric, such as a knitted
fabric or a woven fabric. The fabrics may comprise one or more
features which include one or more portions that are knitted or
woven to form a pattern that may be detectable optically. The
feature(s) may either be created inline (e.g., during the knitting
or weaving process used to form the fabric), or may be added to the
fabric after it has been formed. In some embodiments, the
feature(s) may comprise portion(s) of a pattern (e.g., a repeating
motif) knitted or woven into the fabric or printed onto the
fabric.
[0095] As discussed herein, a 3D printer may be provided that is
capable of printing 3D articles with non-uniform material
compositions, such as a shoe sole and/or a shoe upper. Such 3D
articles may comprise a gradient structure with at least one
non-uniform property (e.g., color, average stiffness, average Shore
A hardness, average pore size, average density, surface roughness,
reflectivity, strength, elongation at break, tensile elastic
modulus, and 100% modulus). These gradient structures may be formed
by varying one or more printer settings (e.g., a ratio of two or
more input materials to a mixing chamber, a spin speed of an
impeller in the mixing chamber, a sequence of materials into a
mixing chamber, and a position of one or more valves to control
material inputs into the mixing chamber, total combined volumetric
flow rate of one or more input materials to a mixing chamber,
nozzle tip height relative to the substrate, target temperature of
the mixing chamber and/or the substrate, target catalyst
concentration of the resulting mixed material, target line width of
the printed material, target fumed silica concentration of the
printed composite, target viscosity of the printed composite at the
point of exiting the nozzle, and target concentration of an
additive) while a 3D printer is printing the part. For example, the
gradient structure may be formed by varying the ratio of two
material inputs into a mixing nozzle. The inventors have
appreciated that existing techniques for generating printer
instructions for a 3D printer, such as those implemented in
conventional slicer software applications, may be unable to
recreate these gradient structures. Accordingly, aspects of the
present disclosure relate to a computer program that is configured
to generate print instructions that comprise changes to printer
settings while the print heard is moving along a print path to
accurately create these gradient structures.
[0096] The computer program may be configured to receive object
information, such as a design file for a 3D article comprising a
gradient structure (e.g., from a computer-aided design (CAD)
program) and/or a print path for printing a 3D article (e.g., from
a slicer application) with metadata indicative of material
properties at various points along the print path, and output print
instructions that may be provided to a 3D printer to accurately
create the 3D article. The computer program may generate these
print instructions by identifying gradient structures in the 3D
article (e.g., a bounded volume in the 3D structure where the
material properties are non-uniform) and identifying the
appropriate set of printer settings for various points along the
print path to create the gradient structure. In some embodiments,
identifying the appropriate set of printer settings comprises
identifying one or more material inputs to the 3D-printer and/or
calculating a set of ratios of two or more material inputs. For
example, the computer program may identify a bounded volume in the
3D article where a color transition occurs from a first color
formed by a first pigment to a second color formed by a second
pigment. In this example, the computer program may identify the
printer settings required to reduce (e.g., ramp down) the
deposition rate of the first pigment and increase (e.g., ramp up)
the deposition rate of the second pigment to achieve the color
transition. Once the appropriate set of printer settings have been
identified, print instructions may be generated using the
identified set of printer settings. For example, print instructions
may be generated that comprise a print path for the print head to
follow and printer settings information indicative of the
appropriate printer settings at a plurality of points along the
print path. In certain cases, the print instructions may be in
machine readable code.
[0097] In some embodiments, a computer program may be configured to
receive information related to the status of one or more parts of
the 3D-printer. The computer program may be configured to output
print instructions based on the status information. For example,
the computer program may identify a volume of material occupying a
mixing chamber (and/or a volume of material that the mixing chamber
contains when full), and output print instructions based, at least
in part, upon that volume. The print instructions may be applied at
a point in time in advance of the point in time at which the
material to which they apply is deposited by a nozzle. Similarly,
the print instructions may be applied when a nozzle depositing the
material to which they apply is at a position in space different
than the position it will occupy when the material to which the
print instructions are applied is deposited. In other words, the
print instructions may be volume shifted. Because the mixing
chamber has a finite volume, material that is input into the mixing
chamber will not be printed until the material already in the
mixing chamber has been printed. Thus, it may be beneficial to
apply print instructions in advance of the point in time at which
their effect is desired. Volume shifted print instructions may
result in variations in the composition of the material in the
mixing chamber as a function of position. In other words, a
3D-printer receiving volume shifted print instructions may include
a mixing chamber comprising material with a spatial variation in
composition (e.g., from top to bottom).
[0098] The computer program may comprise a set of instructions that
may be executed by a computer system comprising a processor (e.g.,
a hardware processor or a virtual processor) and a memory (e.g., a
non-transitory computer readable medium). For example, the computer
program may comprise a set of instructions stored in a
non-transitory computer readable medium that programs at least one
processor coupled to the non-transitory computer readable medium.
It should be appreciated that the computer system may be
communicatively coupled to a 3D printer and/or integrated with the
3D printer.
[0099] In some embodiments, the computer program may comprise a
plurality of instructions that program at least one processor to
perform a method 2000 in FIG. 13. As shown, the method 2000
comprises an act 2002 of receiving object information, an act 2004
of identifying a gradient structure, an act 2006 of identifying
input materials to form the gradient structure, an act 2008 of
identifying printer settings for the gradient structure, and an act
2010 of generating print instructions.
[0100] In act 2002, the system may receive object information
associated with a 3D article that comprises a gradient structure.
The object information may be, for example, a design file for a 3D
article to be printed. The design file may comprise information
indicative of one or more properties of the 3D article such as
shape, material composition, and/or color. The design file may be
in any of a variety of formats. Example formats include: Drawing
Interchange Format (DXF), COLLAborative Design Activity (COLLADA),
STereoLithography (STL), Initial Graphics Exchange Specification
(IGES), Virtual Reality Modeling Language (VRML), PDF, EPS, and AI.
Alternatively (or additionally), the object information may
comprise a print path for a print head to follow to print the 3D
article (e.g., generated by a slicer application) and information
indicative of the desired material properties at various points
along the print path. For example, the object information may
comprise a print path comprising a plurality of points and metadata
associated with one or more (or all of) the plurality of points
indicative of a desired material property at the point (e.g.,
color, average stiffness, average Shore A hardness, average pore
size, average density, surface roughness, reflectivity, strength,
elongation at break, tensile elastic modulus, and 100% modulus,
etc.). In some implementations, the metadata may be directly
associated with one or more points in the plurality of points. In
other implementations, the metadata may be stored in another format
and overlaid onto the print path to determine the material
properties at a given point. For example, the metadata may be
desired color information stored in an image comprising a plurality
of pixel values that may be overlaid onto the print path. In this
example, the pixel value that aligns with a given point in the
print path may be the metadata associated with the respective
point.
[0101] In act 2004, the system may identify a gradient structure in
the object information. A gradient structure may be identified by,
for example, identifying a volume (e.g., a bounded volume) in the
3D article that has at least one non-uniform material property.
Thereby, portions of the 3D article with uniform material
properties may be separated from portions of the 3D article with
non-uniform material properties. Once the portions of the 3D
article with non-uniform material properties have been identified,
the system may identify a constant set of printer settings for
printing the remaining portions (e.g., the uniform portions) of the
3D article. In one implementation for illustration, the system may
read metadata associated with one or more points in a print path to
identify a subset of points (e.g., a continuous and/or contiguous
subset of points) along the print path with non-uniform metadata to
identify a gradient structure.
[0102] In act 2006, the system may identify input material(s) to
create the gradient structure. For example, the 3D printer may
print the material in the gradient structure by mixing a first
material with a second material. In this example, the system may
identify the first and second materials. The system may identify
this information by, for example, identifying a material in the
gradient structure and retrieving information stored in a memory of
the computer system regarding the input materials required to
create the identified material in the gradient structure.
[0103] In act 2008, the system identifies one or more printer
settings for the gradient structure using the identified input
materials. In some embodiments, the system may identify one or more
printer settings required to achieve the desired material
properties at a plurality of discrete points in the gradient
structure. Once the printer settings for the plurality of discrete
points have been identified, the system may employ interpolation
techniques (e.g., linear interpolation and cubic interpolation) to
smooth shifts in printer settings between the discrete points.
Thereby, the system may generate a set of printer settings that may
be employed to create the gradient structure. In one example for
illustration, the system may identify that the mixing ratio of two
materials needs to be 40/60 at a first point in the gradient
structure and a 50/50 ratio at a second point in the gradient
structure. In this example, the system may fit a linear curve
between the first and second points to create a smooth ramp between
a 40/60 ratio and a 50/50 ratio. Thereby, the system may create a
set of printer settings to employ along the print path as the print
head moves from the first point to the second point.
[0104] In act 2010, the system may generate the print instructions
using the identified printer settings in act 2008. The print
instructions may comprise, for example, a print path for a print
head to follow to print the 3D article along with printer settings
at a plurality of points along the print path (e.g., generated in
act 2008). The print instructions may be, for example, G-code
instructions. Once the print instructions have been generated, the
system may transmit the print instructions to a 3D printer (and/or
one or more other components of a 3D printer in embodiments where
the computer system is integrated with the 3D printer).
[0105] FIG. 14 shows an example of a method for 3D-printing an
article in accordance with some embodiments (e.g., on a multi-axis
system as described above). In this figure, a device 10 for
printing an article is shown, using techniques such as 3D printing.
The device may include a nozzle 15, through which material is
directed at a substrate through outlet 18. In some embodiments, the
material may conformally coat the substrate after exiting through
the nozzle. As described above, the substrate may be planar, or in
some cases, the substrate may have a different shape (e.g., a
curved shape). The substrate may thus be any suitable target for a
material exiting the nozzle. For instance, the substrate may
include a mold to which the material is applied or may be a
component of an article of footwear (e.g., an upper). In some
embodiments, the substrate itself may be produced by a 3D-printing
process prior to 3D-printing the article. Without wishing to be
bound by theory, printing onto 3D-printed substrates (e.g.,
3D-printed molds) may yield 3D-printed articles that are smooth
and/or have curved surfaces. In some embodiments, the substrate may
be scanned using one or more sensors prior to printing. In some
embodiments, data received during scanning may at least partially
determine one or more movements of the nozzle during printing.
[0106] Nozzle 15 in FIG. 14 is generally depicted as being conical
or funnel-shaped, although it should be understood that this is by
way of example only, and the nozzle may have any suitable shape
able to direct a material at a substrate. Further non-limiting
examples of methods for 3D printing may be seen in a U.S.
provisional patent application filed on Feb. 27, 2017, entitled
"Techniques and Systems for Three-Dimensional Printing of Foam and
other Materials," incorporated herein by reference in its
entirety.
[0107] In some embodiments, a substrate may be translated and/or
rotated with respect to a nozzle as described above during a
3D-printing process (e.g., a multi-axis robot may translate the
substrate with respect to the nozzle, which may allow material to
be extruded onto various portions of the substrate). In some
embodiments, the nozzle may be translated and/or with respect to
the substrate as described above.
[0108] In addition, in some embodiments, the material within the
nozzle may be subjected to heating or cooling. This may, for
example, be used to control mixing and/or reaction within the
material, to keep the temperature at substantially the temperature
of the surrounding environment (e.g., at room temperature), to
prevent the surrounding environmental conditions and/or the heat
generated by friction of the impeller and exotherm of the material
curing from affecting the reaction or the printing parameters, or
the like. In some cases, the temperature may be altered by at least
5.degree. C., at least 10.degree. C., or by other ranges such as
those discussed herein. Any method may be used to heat or cool the
material within the nozzle. For example, heating or cooling may be
applied to the nozzle itself, and/or to material within the nozzle.
Non-limiting examples include electrical heating, Peltier cooling,
application of infrared light, or other techniques such as those
discussed herein.
[0109] As mentioned, one or more fluids may enter the nozzle to be
mixed together. The fluids may enter via a common inlet, and/or via
separate inlets, for example, as is illustrated in FIG. 14 with
inlets 31, 32, and 33. Although 3 inlets are illustrated in this
figure, this is by way of example only, and in other embodiments,
more or fewer inlets are also possible. The inlets may
independently be at the same or different distances away from an
outlet of the nozzle. In some cases, the fluids may react upon
contact with each other; thus, the fluids are kept separate prior
to entrance into the nozzle, for example, using one or more inputs
and/or valves to control contact of the fluids with each other. For
example, one or more valves may be present on one or more of the
inlets to control the flow of fluid through the inlets, e.g., into
the nozzle. Examples of valves that can be used include needle
valves, ball valves, gate valves, butterfly valves, or other
suitable types of valves. Additionally, other types of apparatuses
to control fluid flow may also be used, in addition to and/or
instead of valves.
[0110] Fluids entering a mixing nozzle may be provided to the
mixing nozzle in a variety of suitable manners. In some
embodiments, fluids enter a mixing nozzle by flowing therein from a
material supply tube. Material supply tubes may be connected to
sources of the material, such as material reservoirs. In some
embodiments, material supply tubes and/or material reservoirs may
be configured to be held at a desired temperature. For instance,
fluid may enter a mixing nozzle from a heated material supply tube
and/or from a material supply tube fluidically connected to a
heated material reservoir. As another example, fluid may enter a
mixing nozzle from a cooled material supply tube and/or from a
material supply tube fluidically connected to a cooled material
reservoir. Without wishing to be bound by any particular theory, it
is believed that temperature control may advantageously prevent
and/or reduce crystallization of one or more components of one or
more of the fluids entering the mixing nozzle and/or prevent and/or
reduce phase separation of two or more components of one or more of
the fluids entering the mixing nozzle. It may also allow materials
that are solid at room temperature to be printed in liquid
form.
[0111] Some embodiments are directed to methods of printing an
article, which may include flowing at least two materials into a
mixing chamber. In some embodiments, at least one of the materials
is polymeric. The method may involve in some embodiments mixing the
at least two materials in the mixing chamber containing an impeller
to form a mixture. The method may also include depositing the
mixture onto a textile. In some embodiments, the mixed material
flows through an orifice and onto the surface of a textile.
[0112] In some embodiments, the method may involve flowing the at
least two materials into the mixing chamber while rotating the
impeller in the mixing chamber. The impeller may cause two or more
materials in the mixing chamber to mix. In some embodiments, the
mixing chamber contains at least a portion of the impeller. The
term "mixing chamber" may refer to the volume in which the at least
two materials that are mixed together occupy from when they first
touch each other, to when they stop being mechanically influenced
by active motion of a mixing part (e.g., impeller). In some
embodiments, the mixing chamber and the impeller share at least
some volume, e.g. the impeller occupies at least some of the dead
volume of the mixing chamber.
[0113] In some embodiments, the method may involve flowing the at
least two materials into the mixing chamber through at least three
discrete material inlets. In such embodiments, there may be at
least three materials flowed into the mixing chamber. In some
embodiments, the method may involve flowing the at least two
materials into the mixing chamber through at least four discrete
material inlets. In such embodiments, there may be at least three
or four materials flowed into the mixing chamber.
[0114] In some embodiments, the mixture is a liquid. In some
embodiments the mixture is in direct fluid communication with the
mixing chamber during the time of deposition onto the substrate
(e.g., textile). As a non-limiting example, the mixture is not
jetted into discrete droplets from a standoff distance from the
substrate (e.g., textile), but instead contacts simultaneously an
outlet from the mixing chamber (e.g., nozzle orifice) and the
substrate (e.g., textile) while the mixture is continuous with
itself.
[0115] In some embodiments, the method may involve controlling the
execution of the method using a controller. The method may involve
varying the volumetric flow ratios of the at least two materials
based on the spatial location of the mixing chamber with respect to
the textile. In some embodiments, the change in the volumetric flow
ratios between the at least two materials changes at least one
property of the deposited mixture. In some embodiments, at least
two of the at least two materials undergo a chemical reaction that
changes at least one property of the deposited mixture. In some
embodiments, the change in the volumetric flow ratios between the
at least two materials changes at least one property of the
deposited mixture after a chemical reaction has occurred in the
deposited mixture. The change in the volumetric flow ratios between
the two or more materials may influence the properties of the
deposited structure before all chemical reactions have occurred,
after all chemical reactions have occurred, or both before and
after chemical reactions. In some embodiments, the at least one
property that has changed is selected from the group consisting of
tensile elastic modulus, tensile strength, tensile 100% modulus,
hardness, viscosity, dynamic yield stress, static yield stress,
density, particle concentration, color, opacity, and surface
roughness, or a combination thereof.
[0116] In some embodiments, the textile onto which the mixture is
deposited is substantially flat (e.g., it may be a flat plate). In
some embodiments, the textile conforms to a substrate that is
curved in one or more dimensions (e.g., two or three dimensions).
Without wishing to be bound by any particular theory, it is
believed that substrates that are curved in one or more dimensions
may promote curing of material deposited thereon (e.g., polymeric
material deposited thereon) in an advantageous shape (e.g., a shape
similar to a final shape desired for an application, a shape more
similar to the final shape desired for the application than the
shape formed by the material if cured on a flat substrate). The
textile may be disposed on a fixture, such as a fixture configured
to interact with a 3D-printer. In some embodiments, the textile is
supported by a belt that can translate the textile in one or more
dimensions (e.g., two or three dimensions) and/or through a
sequence of one or more processes. In some embodiments, the textile
is handled in a roll to roll process. In some embodiments, the
textile itself acts as a belt that can move the textile surface
with respect to the mixing chamber. In some embodiments, the
textile is a component of a footwear upper (e.g., a shoe upper). In
some embodiments, the textile is a component of apparel, a
component of an article of sportswear, a component of an article of
sporting goods (e.g., a glove, a grip, a tent), a component of an
article of clothing (e.g., a shirt), and/or a component of a bag.
In some embodiments, the textile is a component of a knit shoe
upper. In some embodiments, the textile is an article of apparel,
an article of sportswear, an article of sporting goods, an article
of clothing (e.g., a shirt), and/or a bag.
[0117] In certain cases, a mixture may be deposited onto an article
disposed on a substrate. The article may be a component of an
article of footwear (e.g., an upper), or may be an article of
footwear (e.g., a shoe). The substrate may be configured to hold
the article in an advantageous shape, such as an advantageous shape
for footwear applications. In some embodiments, the substrate may
be a shoe last. Non-limiting examples of suitable combinations of
substrates and articles include lasted three dimensional shoe
uppers on shoe lasts, lasted full shoes on shoe lasts, textiles cut
into the shape of upper flat patterns in a flat form factor, and
textiles cut into the shape of upper flat patterns disposed on a
substrate that is curved in at least one dimension. Other types of
articles and substrates are also possible.
[0118] In some embodiments, at least one of the at least two
materials comprises a filler and the article is a polymeric
composite. In some embodiments, at least one of the at least two
materials comprises isocyanate groups. In some embodiments, at
least one of the at least two materials have functional groups
(e.g., chemical functional groups) selected from the group
consisting of alcohol groups, amine groups, or combinations
thereof. In some cases, more than two materials may be flowed into
a mixing chamber (e.g., three materials, four materials, or more
materials). When two or more materials are flowed into the mixing
chamber, each material may comprise different functional groups
from each other material, or two or more materials may comprise the
same functional group. For example, a first material may have an
isocyanate functional group and a second material may have an
alcohol functional group. As another example, three materials
comprising an alcohol functional group (e.g., polyols) and one
material comprising an isocyanate functional group may be flowed
into a mixing chamber. As a third example, two materials comprising
a first functional group (e.g., an alcohol functional group) and
two materials comprising a second functional group (e.g., an
isocyanate functional group) may be flowed into the mixing
chamber.
[0119] In some embodiments, the method may involve flowing a
material comprising an isocyanate group through an inlet into the
mixing chamber. In some embodiments, the material comprising an
isocyanate group is selected from the group consisting of an
isocyanate, an isocyanate prepolymer, and a quasi-isocyanate
prepolymer, or a combination thereof. In some embodiments, the
method may involve flowing a short chain extender through an inlet
into the mixing chamber. In some embodiments, the short chain
extender has a number average molecular weight of e.g. less than
5000 Dalton, less than 4000 Dalton, less than 3000 Dalton, less
than 2000 Dalton, less than 1000 Dalton, less than 500 Dalton, less
than 100 Dalton, or less than 90 Dalton. In some embodiments, the
short chain extender has a number average molecular weight of less
than 1000 Dalton. In some embodiments the chain extender is
butanediol with a molecular weight of 90.12 g/mol. In some
embodiments, e.g. at least 20%, at least 30%, at least 40%, at
least 50%, at least 60%, at least 70%, at least 80%, or at least
90%, or at least 99% of the molecules of the short chain extender
have at least two functional groups per molecule. In some
embodiments, at least 70%, of the molecules of the short chain
extender have at least two functional groups per molecule. In some
embodiments, the at least two functional groups per molecule
comprise at least two alcohol groups. In some embodiments, the at
least two functional groups per molecule comprise at least two
amine groups. In some embodiments, the at least two functional
groups per molecule comprise at least one alcohol group and one
amine group. In some embodiments the short chain extender may
comprise a blend comprising molecules with two alcohol groups and
comprising molecules with two amine groups. In some embodiments,
the method may involve flowing a higher molecular weight (e.g.,
number average molecular weight) polyol and/or polyamine through an
inlet into the mixing chamber (e.g., molecular weight e.g. greater
than 100 Daltons, greater than 200 Daltons, greater than 300
Daltons, greater than 400 Daltons, or greater than 500 Daltons). In
some embodiments, e.g. at least 20%, at least 30%, at least 40%, at
least 50%, at least 60%, at least 70%, at least 80%, or at least
90%, or at least 99% of the molecules have a molecular weight
greater than 90 Daltons. In some embodiments, at least 70% of the
molecules have a molecular weight greater than 90 Daltons. In some
embodiments, e.g. at least 20%, at least 30%, at least 40%, at
least 50%, at least 60%, at least 70%, at least 80%, or at least
90%, or at least 99% of the molecules have a molecular weight
greater than 200 Daltons. In some embodiments, at least 70% of the
molecules have a molecular weight greater than 200 Daltons. In some
embodiments, the method may involve flowing polyols with a
concentration of added fumed silica e.g. greater than 0.1 percent
by weight, greater than 0.2 percent by weight, greater than 0.5
percent by weight, greater than 1 percent by weight, greater than 2
percent by weight, greater than 3 percent by weight, greater than 4
percent by weight, greater than 5 percent by weight, greater than
10 percent by weight, greater than 20 percent by weight, greater
than 30 percent by weight, greater than 40 percent by weight,
greater than 50 percent by weight, greater than 60 percent by
weight, greater than 70 percent by weight through an inlet into the
mixing chamber. In some embodiments, the method may involve flowing
polyols with a concentration of added fumed silica greater than 3
percent by weight through an inlet into the mixing chamber.
[0120] In some embodiments, additional material inlets may be
utilized to control the insertion of pigments of dyes to control
the RGB color of the deposited material. In some embodiments, the
method may involve flowing a pigment and/or a particle through an
inlet into the mixing chamber. Any of the materials flowed into the
mixing chamber may also contain pigments and/or particles. In some
embodiments, the pigments and/or particles may be flowed into the
mixing chamber while contained in a fluid in a pigment and/or
particle concentration of e.g. greater than 1 percent by weight,
greater than 2 percent by weight, greater than 3 percent by weight,
greater than 4 percent by weight, greater than 5 percent by weight,
greater than 10 percent by weight, greater than 20 percent by
weight, greater than 30 percent by weight, greater than 40 percent
by weight, greater than 50 percent by weight, greater than 60
percent by weight, greater than 70 percent by weight.
[0121] In one non-limiting set of embodiments, one material that is
flowed into the mixing chamber, Part A, is the curing agent that
binds another three materials together. One or more of the
materials bound together by Part A may affect the properties of the
mixture of the four materials (i.e., the uncured material) and/or
the properties of the deposited material after curing has completed
(i.e., the cured material). In one non-limiting set of embodiments,
there are three different Part B's flowed into the mixing chamber
along with Part A: Part B1, which makes the cured material stiff;
Part B2, which reduces the viscosity of the uncured material and
makes the cured material soft; and Part B3, which increases the
viscosity of the uncured material and makes the cured material
soft. The volumetric flow rate ratios for B1 to B2 to B3 into the
mixing chamber can be controlled to control properties (e.g.,
stiffness and viscosity) of the mixture. The volumetric flow rate
of A into the mixing chamber can be determined, e.g. based on what
is necessary to complete all chemical reactions for the ratio of
Part B's, and controlled by a controller.
[0122] As a non-limiting example, in one set of embodiments, two or
more fluids may be mixed together to form product on a substrate,
for example, a foam. In some cases, a material (e.g., a precursor
to the foam) may be deposited on a substrate in a partially fluid
state, where the material is able to harden to form the product on
the substrate. For instance, the material may have a viscosity of
less than 1,000,000 cP, less than 500,000 cP, less than 300,000 cP,
less than 100,000 cP, less than 50,000 cP, less than 30,000 cP,
less than 10,000 cP, less than 5,000 cP, less than 3,000 cP, less
than 1,000 cP, less than 500 cP, less than 300 cP, less than 100
cP, less than 50 cP, less than 30 cP, or less than 10 cP. In some
cases, the material may have a viscosity of at least 10 cP, at
least 30 cP, at least 50 cP, at least 100 cP, at least 300 cP, at
least 500 cP, at least 1,000 cP, at least 3,000 cP, at least 5,000
cP, at least 10,000 cP, at least 30,000 cP, at least 50,000 cP, at
least 100,000 cP, at least 300,000 cP, at least 500,000 cP, or at
least 1,000,000 cP. Combinations of any of these viscosities are
also possible; for example, the viscosity of a material may be
between 100 cP and 500 cP. The material may form a product
passively (e.g., upon drying of the material, completion of a
reaction forming the product, etc.), and/or additional steps may be
taken to encourage formation of the product. As various
non-limiting examples, heat may be applied to the material and/or
to the substrate, light (e.g., ultraviolet light) may be applied to
the material to cause a chemical reaction, etc.
[0123] For instance, in some embodiments, a foam may be prepared by
mixing a polymer, a cross-linking reagent, and a cell-forming
agent, e.g., within a printing nozzle such as is shown in FIG. 14.
These may be added sequentially or simultaneously in various
embodiments, e.g., as discussed herein. For instance, in FIG. 14, a
cross-linking agent may be added to the nozzle via inlet 31, a
cell-forming agent may be added via inlet 32, and a polymer may be
added via inlet 33. In some cases, these may be flowable at the
temperatures in which they enter the nozzle. In some cases, control
of these may be controlled using one or more valves or other
apparatuses on any of these inlets, optionally controlled by a
computer or other controller.
[0124] One example of a suitable polymer is polyurethane; one
example of a cross-linking reagent is isocyanate; and one example
of a cell-forming agent is water (which can react with the
isocyanate to produce carbon dioxide as the foam forms). Other
examples of each of these are discussed in more detail below. In
addition, it should be understood that other fluids or reactants
may be combined to form a foam, and the invention is not limited to
only embodiments that include a polymer, a cross-linking reagent,
and a cell-forming agent; see below for additional non-limiting
examples. For example, as discussed below, a foam may be prepared
using a polymer and a cell-forming agent, but not necessarily a
cross-linking agent. In some embodiments, other additives may also
be introduced, for example, surfactant, silicone surfactant, UV
stabilizer, catalyst, pigment, nucleation promotors, fillers for
better abrasion resistance, chemical foaming agents, etc. In
addition, other products besides foam may be formed in other
embodiments.
[0125] As mentioned, if more than two fluids or reactants are used,
they may, in some embodiments, be introduced into the same nozzle,
as is shown in FIG. 14. However, in other embodiments, one or more
of the fluids or reactants may be mixed to form a mixture (for
example, in a first mixing chamber), which can then be mixed with
another fluid or reactant (e.g., in a nozzle such as discussed
herein).
[0126] In some cases, 3D-printed foams (e.g., closed-cell foams,
open-cell foams, etc.) may be prepared as discussed herein using
various inputs, as described herein. For instance, the foam density
may be varied by varying the amount of added gas, the amount of
added water (e.g., in water-blown foam applications), the amount of
added chemical blowing agent, etc. As another example, the foam
density constant may be held constant, but the cross-link density
or isocyanate content may be varied to change properties such as
the elasticity, elongation, or stiffness of the foam.
[0127] In some embodiments, one or more materials that are flowed
into a mixing chamber may comprise a latent curing agent, or a
curing agent that is activated by exposure to a stimulus (e.g.,
light and/or heat). In certain cases, two or more materials are
flowed into a mixing chamber, and at least one of the two or more
materials comprises a latent curing agent. For instance, at least
one material comprising a latent curing agent may be flowed into
the mixing chamber and at least one additional material (e.g.,
another material comprising a latent curing agent, a material
lacking a latent curing agent) may also be flowed into the mixing
chamber. The mixing chamber may blend together the materials
flowing therein (e.g., a material comprising a latent curing agent
and one or more further materials also flowing into the mixing
chamber). For example, both a photocureable resin and a 1K
polyurethane system may be flowed into a mixing chamber and mixed
therein.
[0128] When present, the latent curing agent may be activated at
any suitable time to cure the material(s). In some embodiments, a
latent curing agent may initially be present in a first fluid input
or second fluid input and may be incorporated into a mixture,
deposited material, and/or 3D-printed article in an uncured form.
The mixture, deposited material, and/or 3D-printed article may be
removed from a vessel (e.g., extruded from a mixing chamber and/or
mixing nozzle) and then exposed to a stimulus, such as light and/or
heat, that results in the curing of the latent curing agent. Curing
the latent curing agent may e.g. increase the strength of a
3D-printed article, increase the density of the 3D-printed article,
and/or may improve the surface finish of the 3D-printed article.
The latent curing agent may be a blocked isocyanate such as blocked
toluene diisocyanate. The latent curing agent may make up to 70% by
weight of a fluid input.
[0129] In some embodiments, an active mixing system may be applied
to one part latent curing polymer systems. In these one part latent
curing polymer systems, polymers may have little to no reactivity
in the storage state or in the cartridge. In some embodiments, it
is not until the one part latent curing polymer system is deposited
and experiences a stimulus that it will begin to polymerize into a
solid thermoset or elastomer. In such embodiments, multiple one
part systems that have compatibility with one another can be used
as inputs into the microfluidic active mixing nozzle system. In
some embodiments, each one part system may have a different
material property or properties, e.g. stiffness, density, filler
content, and/or blowing agent content. In some embodiments, the
ratios between two or more inputs can be varied to modulate these
properties. It should be understood that any of the embodiments
relating to multi-part reactive systems may also be applied to the
active mixing of one part systems to vary material properties. In
some embodiments, one or more inputs (e.g., materials, fluids;
e.g., to a microfluidic printing nozzle) comprises a one part resin
that is configured to polymerize in response to a stimulus. In some
embodiments, the resin comprises, e.g., polyols with blocked
isocyanates, and/or a polyurethane with silane terminal groups. In
some embodiments, the stimulus is e.g., heat, moisture, and/or
light.
[0130] There are several types of systems (e.g., 1K systems) that
could be blended using a one part latent curing polymer system. As
a non-limiting example of a system (e.g., 1K systems) that could be
blended using a one part latent curing polymer system, a polyol or
polyamine system with blocked isocyanate could be used. In some
embodiments, a polyol or polyamine system with blocked isocyanate
functions similarly to e.g. a standard polyurethane system, a
polyuria system, or a polyurethane/polyuria hybrid system. In the
case of a polyol or polyamine system with blocked isocyanate, the
curing agent is blocked with another functional group, so the
curing agent can be integrated directly into the polyol or
polyamine in the cartridge without curing. Heat can then be used to
deblock the isocyanate and drive rapid curing after all of the
materials have been deposited.
[0131] As another non-limiting example of a system (e.g., 1K
systems) that could be blended using a one part latent curing
polymer system, silane hybrid chemistry could be used. In the case
of silane hybrid chemistry, the polyols and/or isocyanates are
functionalized with a terminal silane group. The silane group may
be e.g. alpha-Dimethoxysilane, gamma-trimethoxy silane,
gamma-triethoxy silane, gamma-dimethoxy silane, or gamma diethoxy
silane. In these cases, the silanes polymerize with each other on
exposure to moisture, and the reaction is accelerated by heat.
After a part is printed, it may be exposed to high humidity and
high heat to accelerate the reaction. Another example of a material
that may be cured by exposure to moisture is an isocyanate
prepolymer.
[0132] As still another non-limiting example of a system (e.g., 1K
systems) that could be blended using a one part latent curing
polymer system, radiation curable formulations could be used. In
some embodiments, these radiation curable formulations may comprise
acrylates, and/or methacrylate functional polymers with free
radical photoinitiators. In some cases, the free radical photo
initiators can be activated by exposure to UV after the
formulations are deposited. Carbodiimides could be used, as still
another non-limiting example of a system (e.g., 1K systems) that
could be blended using a one part latent curing polymer system. In
some embodiments, carbodiimides can act as a latent curing agent
that forms chemical bonds with carboxylic acid groups or amine
groups on exposure to heat. In some cases, carbodiimides could be
used as a cross-linker for polyamine systems.
[0133] In another non-limiting example of a system (e.g., 1K
systems) that could be blended using a one part latent curing
polymer system, moisture cure polyurethane (PU) could be used. In
some cases isocyanate prepolymers, or polyols that have been capped
with free isocyanate groups, may be used as the one part system. In
some embodiments, the one part system will then be stable until it
is exposed to moisture in the air that will drive the reaction
between free isocyanate groups.
[0134] In some embodiments, one or more properties of a mixture
that is 3D-printed from a nozzle may change as a function of time
and/or nozzle position with respect to the substrate. For instance,
the composition of one or more components and/or the wt % of one or
more components within the mixture may change as a function of
time. In some embodiments, one or more physical parameters of the
nozzle and/or the substrate may change as a function of time. As an
example, the temperature of the nozzle and/or the substrate may
change as a function of time. Without wishing to be bound by
theory, the temperature of the nozzle and the temperature of the
substrate may affect the types of reactions that occur between
various components (e.g., cross-linking reactions, foaming
reactions, reactions within the nozzle, reactions on the substrate)
and/or the rates at which these reactions occur. This may in turn
affect the chemical structure of the mixture (e.g., the composition
of the mixture, the degree of cross-linking of the resultant foam)
during and/or after printing, and/or affect one or more physical
properties of the mixture (e.g., the viscosity of the mixture, the
average pore size of the resultant foam, the density of the
resultant foam, the stiffness of the resultant foam, the Shore A
hardness of the resultant foam) during and/or after printing. In
some embodiments, changes in substrate or nozzle temperature during
printing may allow for different portions of the 3D-printed article
(e.g., those printed at different times and/or in different
positions on the substrate) to have different chemical or physical
properties. In some embodiments, the portions with different
chemical and/or physical properties may be printed in a single
continuous process, and/or may together form a single integrated
material.
[0135] The Inventors recognized the problem that some particles
(e.g., fumed silica), which can be used to change the rheology
and/or mechanical properties of a material (e.g., a polymeric
material), are difficult to use in spraying methods for deposition
of material. The degree of particle incorporation may be useful,
for example, in controlling whether a material deposited onto a
fabric sits on top of the fabric (e.g., material with a sufficient
volume percent of the particles) or seeps into the fabric. As an
alternative to incorporating particles into a material, the
Inventors have determined that exposing a light-curable material to
light (e.g., UV light) of an appropriate curing wavelength upon the
material exiting a printing nozzle, or after a predetermined delay
between exiting the printing nozzle and light exposure, results in
a similar rigidifying effect on the material to that resulting from
particle incorporation. The Inventors have further determined that
light curing can be used to control the mechanical properties of
materials that can be deposited by spraying (e.g., using compressed
gas to aerosolize the material), which may result in both better
mechanical properties control and higher throughput relative to
other printing methods. In addition, the Inventors have determined
that combining a printing nozzle (e.g., having a mixing chamber and
an impeller disposed in the mixing chamber) configured to actively
mix small volumes of material with a compressed gas source, an
outlet of which printing nozzle intersects with an outlet in fluid
communication with the compressed gas source, a print head with
spraying capabilities results in which input ratios (e.g., volume
ratios) into the printing nozzle, and therefore material
composition of the sprayed material, can be changed on the fly.
[0136] In some embodiments, it can be useful deposit material onto
surfaces by spraying rather than by extrusion alone through a
nozzle. Advantages of spraying relative to extrusion alone may
include but are not limited to deposition of thinner films with no
extrusion lines; reduced sensitivity to nozzle standoff distance
from the substrate; and/or a capacity to create wider strips of
material in one pass to reduce cycle time. Other advantages of
spraying relative to extrusion alone may include limited
accumulation or no accumulation of cured material on the nozzle,
which may be because spraying may not require the spray nozzle to
come into direct fluid communication with material that has already
been deposited. In addition, coatings made by spraying can be
applied conformally to three-dimensional (3D) surfaces without
precise alignment or 3D tool-pathing.
[0137] In some embodiments, it is possible to make slight
modifications to a mixing nozzle (e.g., a 4-input dynamic mixing
nozzle) to convert it into a spray nozzle. In order to do this, a
compressed gas guiding sheath fluidly connected with a compressed
gas source may be attached around the outside of the nozzle. In
some embodiments, a configuration of an impeller disposed in the
mixing chamber of the mixing nozzle ensures that a small mixing
volume is retained such that rapid changes in the sprayed material
composition can be executed. In some embodiments, the compressed
gas guiding sheath (e.g., air guiding sheath) is configured to
guide the flow of compressed gas from a compressed gas source to
atomize the output of the nozzle into small droplets immediately
upon exiting the nozzle. In some embodiments, the small droplets
are then propelled through the air to land on a target substrate.
In some embodiments, ratio(s) (e.g., volume ratios) of the inputs
(e.g., 4 inputs) into the mixing chamber can be changed in space
and time to vary the composition of the material that is sprayed.
In some embodiments, the geometry of the compressed gas guiding
sheath and/or the applied pressure from the compressed gas can be
used to change the shape and velocity of the cone of atomized
material that is deposited. In some embodiments, the standoff
distance from the substrate can be used to control the width of the
sprayed strips.
[0138] A potential limitation of spraying (e.g., spraying a mixture
of chemically reactive materials) may be that depending on the
applied pressure from the compressed gas through the compressed gas
guiding sheath, the sprayed films that are deposited onto the
substrate can be deformed after deposition by the force of the
compressed gas blowing against them. In embodiments where spraying
a mixture of chemically reactive materials occurs, one solution to
this problem may be to induce the mixture of materials to react
more quickly and become solid very quickly so that the mixture can
withstand the forces of the compressed gas without permanent
deformation. However, this solution may create risks of
accumulating cured material inside of a mixing nozzle (e.g., inside
of a mixing chamber) during deposition. Another solution may be to
add a UV-curable component to one or more inputs that are mixed
together in the mixing chamber. As a non-limiting example, free
radical polymerization between materials with alkene functional
groups (e.g., acrylates, methacrylates, vinyls) may proceed very
rapidly (e.g., in fractions of a second) when exposed to high power
UV irradiation, but may also remain stable for months when not
exposed to UV irradiation. After adding a UV-curable component to
the mixture, the mixture can be exposed to UV irradiation directly
as it exits the mixing chamber. The exposure to UV irradiation may
increase the viscosity of the resulting material very rapidly to
the consistency of a non-flowing paste or gel that can withstand
forces from the compressed gas without deformation. This rapid
increase in viscosity may also prevent the deposited material from
soaking into porous fabrics, and may enable structures of
substantial thickness to be built up. Since the UV-curable
components of the system may represent only a fraction of the total
functional groups that have the capability of reacting to form a
solid polymer, the deposited material may continue to increase in
viscosity, and also may form chemical bonds with previously
deposited material as functional groups in the mixed material
(e.g., isocyanates and one or more of alcohol groups or amine
groups) curable by means other than UV exposure continue to react
with one another after the UV irradiation (e.g., high power UV
irradiation) is removed. In some cases, a UV-curable component of
the mixture may be a urethane acrylate that does not have any
alcohol or isocyanate groups present on it. In some cases,
UV-curable component(s) of the mixture may be present within the
same molecule that also has one or more functional groups curable
by means other than UV exposure (e.g., alcohol, amine, or
isocyanate groups). The mass percentage of molecules that contain
UV-curable functionality may be as high as 100% for any individual
input. The mass percentage of molecules that contain UV-curable
functionality may be as high as 60% for the final mixture in the
case that molecules containing UV-curable functional groups are
present on different molecules from the molecules containing one or
more functional groups curable by means other than UV exposure
(e.g., isocyanates, alcohols, or amines). In the case where
UV-curable functional groups are present on the same molecules that
also contain one or more functional groups curable by means other
than UV exposure (e.g., isocyanates, alcohols, or amines), as much
as 100% of the molecules may contain at least one UV-curable
functional group. In the case that a hybrid UV-curable mixture is
used, wherein UV-curable functional groups are present as well as
one or more functional groups curable by means other than UV
exposure, an irradiation source (e.g., a UV irradiation source, a
light source, a UV light source) may be integrated into (or
adjacent to) the print head, such that the hybrid UV-curable
mixture may be UV cured immediately upon exiting the nozzle. The
irradiation source (e.g., UV irradiation source) may comprise one
or more UV LEDs, each with a peak wavelength between or equal to
200 nm and 405 nm. The irradiation source (e.g., UV irradiation
source) may also comprise mercury lamps or bulbs. The irradiation
source may also comprise a light source with a peak wavelength
outside of the UV spectrum, provided that the intensity of
irradiation in the UV spectrum is sufficiently high to activate a
photoinitiator in the system. Additionally, the irradiation source
may be one or more DLP (Digital Light Projection) projectors. The
projectors may have lenses that direct the light (e.g., focus the
light) onto a small region, but enable the light in that region to
be patterned. The projectors can be used to change the shape of an
image that is projected so that the light is directed only onto
regions that require exposure.
[0139] In some cases, it may be advantageous for the hybrid
UV-curable mixture to experience a delay between exiting the nozzle
and initial exposure to the irradiation source (e.g., UV
irradiation source). This delay may allow the deposited material to
level and spread, and/or to soak into the surface of the substrate
(e.g., the fabric surface) to some degree before the viscosity of
the extruded material increases substantially. This leveling,
spreading, and/or soaking in can produce more uniform and flat
films deposited with this method, relative to immediate exposure of
the mixture to the irradiation source as it leaves the nozzle. In
other cases, it may be advantageous to have no delay in exposure of
the mixture to the irradiation source as it leaves the nozzle, such
that the material that is deposited holds its shape without
spreading or leveling. In some cases, a region surrounding the
nozzle tip may be exposed to irradiation (e.g., UV irradiation)
continuously, and the rate of increase of viscosity of the mixture
may be controlled by the mass fraction or volume fraction of
UV-curable material present in the mixture, which can be controlled
zonally by varying the ratios of two or more inputs into the mixing
chamber.
[0140] It should also be understood that while the scope of this
disclosure has focused on examples of functional groups curable by
means other than UV exposure directed to polyurethane formulations,
for spraying and/or extrusion of a hybrid UV-curable mixture, other
material chemistries may be used to replace the polyurethane
formulations. For example, a mixture for spraying and/or extrusion
may be made with epoxies where one component contains epoxide
functional groups, and another component contains amine functional
groups. In another example of a mixture, one component may include
siloxane functional silicone resins and a platinum catalyst, and
another component may include vinyl functional silicone resins,
which would react after mixing to form polydimethylsiloxane (PDMS)
elastomers. Polydimethylsiloxane resins that cross-link through
multiple chemistries may also be used (e.g., tin-cured, or
acetoxy-based systems). Polydimethylsiloxane resins may also be
partially or fully UV-curable, e.g., by adding acrylate functional
groups to the silicone resins, or by employing a catalyst that is
de-blocked by exposure to UV light.
[0141] Other variations of a nozzle include but are not limited to:
a spray nozzle with a compressed gas source and/or a compressed gas
guiding sheath without an irradiation source (e.g., without a UV
light source) with at least two inlets to the nozzle, for
depositing a reactive system having two or more parts without any
UV-curable components; or a nozzle with two inlets and (in some
cases without a compressed gas source or guiding sheath but)
including an irradiation source (e.g., a UV irradiation source),
for depositing by extrusion (in some cases without spray
functionality) a reactive system having two or more parts with some
irradiation-curable (e.g., UV-curable) components.
[0142] In any variation of the nozzle (e.g., mixing nozzle), the
nozzle may have one input or two inputs or more than two inputs
(e.g., 3, 4, 5, 6, 7, 8, 9, 10, or more inputs).
[0143] In some embodiments, a print head is provided.
[0144] The print head can have a printing nozzle, which can have a
mixing chamber, an impeller disposed in the mixing chamber, and two
or more material inlets in fluid communication with the mixing
chamber (see, e.g., FIG. 15). In some embodiments, a tip of the
impeller is less than 5 mm from an outlet of the printing nozzle.
In some embodiments, an outlet of the printing nozzle (e.g., of the
mixing chamber) is configured to intersect with an outlet fluidly
connected to the compressed gas source (see, e.g., FIG. 15, FIG.
16). In some embodiments, a volume of the mixing chamber is less
than 1 mL. In some embodiments, the volume of the mixing chamber is
less than 250 microliters. In some embodiments, the mixing chamber
is in fluid communication with three or more material inlets. In
some embodiments, the mixing chamber is in fluid communication with
four or more material inlets. In some embodiments, one or more of
the material inlets is in fluid communication with a respective
in-line rotary pump.
[0145] The print head can have a light source (e.g., an ultraviolet
(UV) light source) adjacent to the printing nozzle (see, e.g., FIG.
15, FIG. 16, FIG. 17). In some embodiments, the light source (e.g.,
UV light source) comprises an emission wavelength between or equal
to 200 nm and 405 nm. In some embodiments, the light source (e.g.,
UV light source) is configured to irradiate a material directly as
the material exits the printing nozzle (e.g., exits the mixing
chamber). In some embodiments, the light source (e.g., UV light
source) is configured to irradiate a material after the material
exits the mixing chamber with a predetermined delay. In some
embodiments, the light source (e.g., UV light source) comprises an
emission wavelength between or equal to 200 nm and 405 nm. In some
embodiments, the light source (e.g., UV light source) comprises one
or more light emitting diodes (LEDs) (e.g., UV LEDs). In some
embodiments, the light source (e.g., UV light source) is one or
more Digital Light Projectors (DLP).
[0146] The print head can have a compressed gas source (see, e.g.,
FIG. 15, FIG. 16). In some embodiments, the compressed gas source
is configured to atomize a material extruded from the printing
nozzle (e.g., from the mixing chamber). In some embodiments, the
compressed gas source is in fluid communication with an
electropneumatic regulator.
[0147] In some embodiments, the print head has a compressed gas
guiding sheath fluidly connected to the compressed gas source (see,
e.g., FIG. 15, FIG. 16). In some embodiments, an outlet of the
mixing chamber is configured to intersect with an outlet of the
compressed gas guiding sheath. In some embodiments, the compressed
gas guiding sheath is a microfluidic gas guiding sheath. In some
embodiments, the compressed gas guiding sheath (e.g., microfluidic
gas guiding sheath) is actuatable such the sheath can be moved with
respect to an outlet of the printing nozzle or vice versa. In some
embodiments, the compressed gas guiding sheath (e.g., microfluidic
gas guiding sheath) is coupled to the print head through magnetic
attachment such that it can be easily removed. In some embodiments,
the compressed gas guiding sheath (e.g., microfluidic gas guiding
sheath) has multiple gas channels coupled to valves that can be
addressed individually. In some embodiments, moving the sheath with
respect to the outlet of the printing nozzle changes channels
through which compressed gas is configured to flow, which changes
the shape of an atomized material cone that is deposited onto the
surface from the outlet of the printing nozzle.
[0148] In some embodiments, a method of printing a material is
provided.
[0149] The method may comprise passing a formulation through a
print head. In some embodiments, the method comprises mixing two or
more parts of the formulation in a printing nozzle of the print
head to form a mixture. In some embodiments, the method comprises
exposing the formulation to light (e.g., UV light) for e.g.,
between or equal to 0.01 seconds and 10 seconds, or between or
equal to 1 seconds and 3 seconds. In some embodiments, the method
comprises exposing the formulation (e.g., mixture) to light at a
wavelength within the absorption spectrum of the photoinitiator for
e.g., between or equal to 0.01 seconds and 10 seconds, or between
or equal to 1 seconds and 3 seconds. In some embodiments, the
method comprises flowing compressed gas from the compressed gas
source to atomize the formulation as it exits the nozzle. In some
embodiments, the method comprises flowing compressed gas from the
compressed gas source to atomize the formulation after it exits the
nozzle with a predetermined delay.
[0150] In some embodiments, the formulation comprises two or more
parts, and passing a formulation through the print head involves
flowing at least two of the two or more parts of the formulation
through a respective material inlet of the two or more material
inlets into the printing nozzle. In some embodiments, the
formulation comprises three or more parts, and passing a
formulation through the print head involves flowing at least three
of the three or more parts of the formulation through a respective
material inlet of three or more material inlets into the printing
nozzle. In some embodiments, the formulation comprises four or more
parts, and passing a formulation through the print head involves
flowing at least four of the four or more parts of the formulation
through a respective material inlet of four or more material inlets
into the printing nozzle.
[0151] In some embodiments, the formulation comprises molecules
that have a UV-curable functional group. In some embodiments, the
formulation comprises molecules that have a functional group
curable by means other than UV exposure. In some embodiments, the
formulation comprises molecules that have a UV-curable functional
group, and molecules that have a functional group curable by means
other than UV exposure. In some embodiments, some of the molecules
that have the UV-curable functional group also have a functional
group curable by means other than UV exposure. In some embodiments,
the formulation comprises molecules that have an isocyanate
functional group. In some embodiments, the formulation comprises
molecules that have one or more of an alcohol functional group or
an amine functional group. In some embodiments, the formulation
comprises molecules that have an alkene functional group and
molecules that have one or more of an alcohol functional group, an
amine functional group, or an isocyanate functional group. In some
embodiments, the formulation (e.g., mixture) comprises alkene
groups, isocyanate groups, a photoinitiator, and at least one of
alcohol groups or amine groups.
[0152] In some embodiments, the method comprises mixing two or more
parts of the formulation together to form a mixture that comprises
alkene groups (e.g., acrylates, methacrylates, vinyls, etc.),
isocyanate groups, a photoinitiator, and at least one of alcohol
groups or amine groups. In some embodiments, the method comprises
exposing the mixture to light (e.g., UV light) at a wavelength
within the absorption spectrum of the photoinitiator (e.g., between
or equal to 365 nm and 405 nm). In some such embodiments, the
alkene groups in the mixture react with one another to increase the
viscosity of the mixture.
[0153] The print head may comprise a compressed gas source, a
printing nozzle, and/or two or more material inlets in fluid
communication with the printing nozzle. In some embodiments, an
outlet of the printing nozzle is configured to intersect with an
outlet fluidly connected to the compressed gas source. In some
embodiments, the print head comprises an ultraviolet (UV) light
source adjacent to the printing nozzle. In some embodiments, the
printing nozzle comprises a mixing chamber and an impeller disposed
in the mixing chamber. In some embodiments, the two or more
material inlets are in fluid communication with the mixing
chamber.
[0154] In some embodiments, the mixture continues to increase in
one or more of viscosity, strength, yield stress, or stiffness
after UV exposure is finished as a result of reaction between
molecules in the mixture that have a functional group curable by
means other than UV exposure (e.g., between molecules in the
mixture that have isocyanate groups and one or more of alcohol
groups and amine groups). In some embodiments, the mixture does not
have a yield stress when it reaches an outlet of the printing
nozzle (e.g., outlet of the mixing chamber), prior to exposure to
UV light. In some embodiments, the mixture develops a yield stress
within 2 seconds after exposure to UV light. In some embodiments,
the formulation (e.g., the mixture) also includes a photo-latent
base, which may act as a catalyst that becomes more active upon
exposure to UV irradiation to induce faster reaction of any
functional groups in the formulation curable by means other than UV
irradiation. The term photo-latent base as used herein refers to a
molecule that changes structure in response to UV light to become a
new molecule with a larger pKa (logarithmic acid dissociation
constant).
[0155] In some cases, as discussed herein, a foam precursor, prior
to curing, may have different rheological properties than the
starting raw materials without gas content. For example, a mixture
of low viscosity fluids, gases, and/or surfactants, etc. having
Newtonian flow behavior before foaming can be used to produce a
precursor having non-Newtonian flow characteristics, e.g., with a
yield stress, or shear-thickening or shear-thinning behavior. This
may be used herein to produce a precursor having a rheological
profile suitable for printing, e.g., on a substrate. Fluids such as
incompressible Newtonian fluids or gases can be controlled
introduced into a nozzle (e.g., prior to mixing) and precisely
metered onto a substrate during deposition. In some cases, the
foaming process may start within the nozzle, and controlled to
control deposition of the precursor and/or the final mechanical
properties of the foam.
[0156] In some embodiments, one or more materials deposited onto a
substrate (e.g., a material deposited by a print head such as a
nozzle, a material printed by a 3D-printing process, a component of
a 3D-printed article, a portion of a 3D-printed article) may
comprise reactive functional groups for a period of time after
deposition. The reactive functional groups may be configured to
react with other articles to which the deposited material is
adjacent (e.g., articles of footwear, components of articles of
footwear, materials deposited by a print head such as a nozzle,
materials printed by a 3D-printing process, components of
3D-printed articles, portions of 3D-printed articles,), such as an
article onto which the material was deposited, an article added to
the deposited material, an article positioned beside the deposited
material, an article disposed on the same article onto which the
material was deposited, and/or an article that is positioned
partially above or below the deposited material and partially
beside the deposited material. Although many of the articles
referred to herein are articles of footwear or components thereof,
it should be understood that articles of apparel such as sports
bras and components of articles of apparel such as sports bras are
also contemplated herein. Reaction between the reactive functional
groups in the deposited material and one or more articles to which
it is adjacent may result in bond formation between the deposited
material and the articles(s), and/or may increase the adhesive
strength between the deposited material and the article(s).
Examples of such articles include textiles, molded parts, layers,
portions, further deposited materials with the same or different
chemistry, and the like. In some embodiments, the deposited
material may bond with two or more articles to which it is
adjacent, and may adhere these articles together through bonds
formed by reaction of the reactive functional groups in the
deposited material with the articles. Each article adhered together
may comprise a deposited material (e.g., a 3D-printed article may
be built up by successively depositing layers of materials
comprising reactive functional groups on top of each other), some
of the articles adhered together may comprise a deposited material
(e.g., a deposited material may adhere another deposited material
to which it is adjacent to a textile on which they are both
disposed), or none of the articles adhered together may comprise a
deposited material. In some cases, the articles adhered together
may have different physical or chemical properties (e.g., different
values of toughness, different values of Young's modulus, different
values of other properties described below).
[0157] In some embodiments, reactive functional groups that are
configured to react with an article to which a deposited material
(e.g., a material deposited by a print head such as a nozzle, a
material printed by a 3D-printing process, a component of a
3D-printed article, a portion of a 3D-printed article) is adjacent
(e.g., an article of footwear, a component of an article of
footwear, a material deposited by a print head such as a nozzle, a
material printed by a 3D-printing process, a component of a
3D-printed article, a portion of a 3D-printed article) may also be
configured to react with other reactive functional groups in the
deposited material. Reaction between two complementary sets of
functional groups within the deposited material may comprise curing
of the material. As the deposited material cures, the number of
reactive functional groups within the deposited material may be
reduced and the deposited material may become less reactive with
any articles to which it is adjacent. In certain cases, tuning the
curing time of the deposited material by varying one or more
parameters (e.g., temperature at which the deposited material is
held after deposition, composition of the deposited material) may
be advantageous because it may allow for tuning of the reactivity
of the deposited material as a function of time. For example, the
curing time may be tuned so that the deposited material is adhesive
upon deposition and upon further addition of a second article to
the deposited material, but is no longer adhesive during further
manufacturing steps and/or when an article of which the deposited
material is a part of is in use.
[0158] A variety of suitable reactive functional groups and
molecules comprising reactive functional groups may be included in
a deposited material (e.g., a material deposited by a print head
such as a nozzle, a material printed by a 3D-printing process, a
component of a 3D-printed article, a portion of a 3D-printed
article). In some embodiments, a deposited material may comprise
reactive functional groups that are alcohol groups and reactive
functional groups that are isocyanate groups, and the alcohol
groups and isocyanate groups may react to form a polyurethane. In
some embodiments, a deposited material may comprise reactive
functional groups that are amine groups and reactive functional
groups that are isocyanate groups, and the alcohol groups and
isocyanate groups may react to form polyureas. In some embodiments,
a deposited material may comprise reactive functional groups that
are amine groups, reactive functional groups that are alcohol
groups, and reactive functional groups that are isocyanate groups;
in this case, the isocyanate groups may react with the amine groups
and the alcohol groups to form a polyurethane/polyurea hybrid
formulation). Further non-limiting examples of suitable reactive
functional groups include hydroxyl groups, isocyanate groups, amine
groups, glycidyl groups, epoxide groups such as cycloaliphatic
epoxy groups, vinyl groups, methyl groups, siloxane groups,
catalysts such as platinum catalysts and tin catalysts, acrylate
groups, methacrylate groups, and photoinitiators.
[0159] The deposited material may have a composition as described
elsewhere herein (e.g., compositions for polyurethanes described
elsewhere herein). In some embodiments, the deposited material may
comprise one or more of a polyurethane, a polyurea, a
polyurethane/polyurea hybrid formulation, a silicone, and an epoxy.
Further non-limiting examples of molecules comprising reactive
functional groups are also listed below. Non-limiting examples of
suitable comprising molecules comprising alcohol groups include
difunctional hydroxyl compounds such as 1,4-butanediol,
hydroquinone bis(2-hydroxylethyl) ether, neopentyl glycol,
diethanolamine, and methyldiethanolamine; trifunctional hydroxyl
compounds such as trimethylolpropane, 1,2,6-hexanetriol, and
triethanolamine; tetrafunctional hydroxyl compounds such as
pentaerythritol; and polyols such as polyether polyols, polyester
polyols, polytetrahydrofuran, polycaprolactone polyols,
polycarbonate polyols, and polytetramethylene ether glycol-based
polyols. Non-limiting examples of suitable molecules comprising
amine groups include difunctional amine compounds such as
diethyltoluenediamine and dimethylthiotoluenediamine. Non-limiting
examples of suitable molecules comprising isocyanate groups include
methylenebis(phenyl isocyanate), toluene diisocyanate,
hexamethylene diisocyanate, naphthalene diisocyanate, methylene
bis-cyclohexylisocyanate, and isophorone diisocyanate. Other types
of reactive functional groups, and other types of molecules
comprising reactive functional groups are also possible.
[0160] In some embodiments, a deposited material (e.g., a material
deposited by a print head such as a nozzle, a material printed by a
3D-printing process, a component of a 3D-printed article, a portion
of a 3D-printed article) may be cured (and/or configured to be
cured) at room temperature. In some embodiments, the deposited
material may be cured (and/or configured to be cured) at a
temperature above room temperature. The deposited material may be
configured (and/or configured to be cured) to be cured at a
temperature of greater than or equal to 70.degree. C., greater than
or equal to 80.degree. C., greater than or equal to 90.degree. C.,
or greater than or equal to 100.degree. C. The deposited material
may be cured (and/or configured to be cured) at a temperature of
less than or equal to 110.degree. C., less than or equal to
100.degree. C., less than or equal to 90.degree. C., or less than
or equal to 80.degree. C. Combinations of the above-referenced
ranges are also possible (e.g., greater than or equal to 70.degree.
C. and less than or equal to 110.degree. C.). Other ranges are also
possible.
[0161] A deposited material (e.g., a material deposited by a print
head such as a nozzle, a material printed by a 3D-printing process,
a component of a 3D-printed article, a portion of a 3D-printed
article) may be cured (and/or configured to be fully cured) over
any suitable period of time. In some embodiments, the deposited
material is fully cured (and/or configured to be cured) over a
period of time of greater than or equal to 15 minutes, greater than
or equal to 30 minutes, greater than or equal to one hour, greater
than or equal to two hours, greater than or equal to four hours,
greater than or equal to eight hours, greater than or equal to 12
hours, greater than or equal to 20 hours, greater than or equal to
24 hours, greater than or equal to 36 hours, greater than or equal
to 48 hours, greater than or equal to three days, greater than or
equal to four days, greater than or equal to five days, or greater
than or equal to six days. In some embodiments, the deposited
material is fully cured (and/or configured to be fully cured) over
a period of time of less than or equal to one week, less than or
equal to six days, less than or equal to five days, less than or
equal to four days, less than or equal to three days, less than or
equal to 48 hours, less than or equal to 36 hours, less than or
equal to 24 hours, less than or equal to 20 hours, less than or
equal to 12 hours, less than or equal to eight hours, less than or
equal to four hours, less than or equal to two hours, less than or
equal to one hour, less than or equal to 30 minutes, or less than
or equal to 15 minutes. Combinations of the above-referenced ranges
are also possible (e.g., greater than or equal to 15 minutes and
less than or equal to one week, greater than or equal to two hours
and less than or equal to 20 hours, or greater than or equal to 24
hours and less than or equal to one week). Other ranges are also
possible. In general, higher curing temperatures result in faster
reactions between reactive functional groups. This may cause the
time over which the deposited material is fully cured (and/or
configured to be fully cured) to decrease. For example, a material
may be fully cured over a period of time of greater than or equal
to a few days and less than or equal to one week when cured at room
temperature but may be fully cured over a period of time of greater
than or equal to two hours and less than or equal to 20 hours at a
temperature of greater than or equal to 70.degree. C. and less than
or equal to 110.degree. C.
[0162] A deposited material (e.g., a material deposited by a print
head such as a nozzle, a material printed by a 3D-printing process,
a component of a 3D-printed article, a portion of a 3D-printed
article) may be deposited at any degree of curing. In some
embodiments, the deposited material is at least 25% uncured upon
deposition, at least 30% uncured upon deposition, at least 40%
uncured upon deposition, at least 50% uncured upon deposition, at
least 60% uncured upon deposition, at least 70% uncured upon
deposition, at least 80% uncured upon deposition, or at least 90%
uncured upon deposition. In some embodiments, the deposited
material is at most 95% uncured upon deposition, at most 90%
uncured upon deposition, at most 80% uncured upon deposition, at
most 70% uncured upon deposition, at most 60% uncured upon
deposition, at most 50% uncured upon deposition, or at most 40%
uncured upon deposition. Combinations of the above-referenced
ranges are also possible (e.g., at least 30% uncured upon
deposition and at most 95% uncured upon deposition). Other ranges
are also possible.
[0163] In some embodiments, an article (e.g., an article of
footwear, a component of an article of footwear) is positioned
adjacent to a deposited material (e.g., deposited on the deposited
material, deposited adjacent the deposited material, laminated to
the deposited material, etc.) before it has fully cured. The
article may be positioned adjacent to the deposited material (e.g.,
a material deposited by a print head such as a nozzle, a material
printed by a 3D-printing process, a component of a 3D-printed
article, a portion of a 3D-printed article) before at least 25% of
the deposited material has cured, before at least 30% of the
deposited material has cured, before at least 40% of the deposited
material has cured, before at least 50% of the deposited material
has cured, or before at least 60% of the deposited material has
cured. The article may be positioned adjacent to the deposited
material before at most 70% of the deposited material has cured,
before at most 60% of the deposited material has cured, before at
most 50% of the deposited material has cured, before at most 40% of
the deposited material has cured, or before at most 30% of the
deposited material has cured. Combinations of the above-referenced
ranges are also possible (e.g., before at least 25% of the
deposited material has cured and before at most 70% of the
deposited material has cured). Other ranges are also possible.
[0164] As described above, certain embodiments may relate to
3D-printed articles that are foams (e.g., 3D-printed articles that
are closed-cell foams). In some embodiments, the 3D-printed article
may be a foam with an average pore size of greater than or equal to
1 micron, greater than or equal to 2 microns, greater than or equal
to 5 microns, greater than or equal to 10 microns, greater than or
equal to 20 microns, greater than or equal to 50 microns, greater
than or equal to 100 microns, greater than or equal to 200 microns,
greater than or equal to 500 microns, greater than or equal to 1
mm, greater than or equal to 2 mm, or greater than or equal to 5
mm. In some embodiments, the 3D-printed article may be a foam with
an average pore size of less than or equal to 10 mm, less than or
equal to 5 mm, less than or equal to 2 mm, less than or equal to 1
mm, less than or equal to 500 microns, less than or equal to 200
microns, less than or equal to 100 microns, less than or equal to
50 microns, less than or equal to 20 microns, less than or equal to
10 microns, less than or equal to 5 microns, or less than or equal
to 2 microns. Combinations of the above-referenced ranges are also
possible (e.g., greater than or equal to 1 micron and less than or
equal to 10 mm). The average pore size of the foam may be measured
by microscopy or other suitable techniques.
[0165] In certain embodiments, a 3D-printed article that is a foam
comprises at least one portion (e.g., a 3D-printed article that is
a closed-cell foams which comprises at least a first portion). In
some embodiments, the first portion of the 3D-printed article may
have an average pore size of greater than or equal to 1 micron,
greater than or equal to 2 microns, greater than or equal to 5
microns, greater than or equal to 10 microns, greater than or equal
to 20 microns, greater than or equal to 50 microns, greater than or
equal to 100 microns, greater than or equal to 200 microns, greater
than or equal to 500 microns, greater than or equal to 1 mm,
greater than or equal to 2 mm, or greater than or equal to 5 mm. In
some embodiments, the first portion of the 3D-printed article may
have an average pore size of less than or equal to 10 mm, less than
or equal to 5 mm, less than or equal to 2 mm, less than or equal to
1 mm, less than or equal to 500 microns, less than or equal to 200
microns, less than or equal to 100 microns, less than or equal to
50 microns, less than or equal to 20 microns, less than or equal to
10 microns, less than or equal to 5 microns, or less than or equal
to 2 microns. Combinations of the above-referenced ranges are also
possible (e.g., greater than or equal to 1 micron and less than or
equal to 10 mm).
[0166] In certain embodiments, a 3D-printed article that is a foam
comprises at least two portions (e.g., a 3D-printed article that is
a closed-cell foams which comprises at least a first portion and a
second portion). In some embodiments, the second portion of the
3D-printed article may have an average pore size of greater than or
equal to 1 micron, greater than or equal to 2 microns, greater than
or equal to 5 microns, greater than or equal to 10 microns, greater
than or equal to 20 microns, greater than or equal to 50 microns,
greater than or equal to 100 microns, greater than or equal to 200
microns, greater than or equal to 500 microns, greater than or
equal to 1 mm, greater than or equal to 2 mm, or greater than or
equal to 5 mm. In some embodiments, the second portion of the
3D-printed article may have an average pore size of less than or
equal to 10 mm, less than or equal to 5 mm, less than or equal to 2
mm, less than or equal to 1 mm, less than or equal to 500 microns,
less than or equal to 200 microns, less than or equal to 100
microns, less than or equal to 50 microns, less than or equal to 20
microns, less than or equal to 10 microns, less than or equal to 5
microns, or less than or equal to 2 microns. Combinations of the
above-referenced ranges are also possible (e.g., greater than or
equal to 1 micron and less than or equal to 10 mm).
[0167] In certain embodiments, a 3D-printed article that is a foam
comprises at least two portions (e.g., a 3D-printed article that is
a closed-cell foams which comprises at least a first portion and a
second portion). In some embodiments, a ratio of the average pore
size of the second portion of the 3D-printed article to the first
portion of the 3D-printed article may be greater than or equal to
1.05, greater than or equal to 1.1, greater than or equal to 1.2,
greater than or equal to 1.3, greater than or equal to 1.5, greater
than or equal to 2, or greater than or equal to 5. In some
embodiments, a ratio of the average pore size of the second portion
of the 3D-printed article to the first portion of the 3D-printed
article may be less than or equal to 10, less than or equal to 5,
less than or equal to 2, less than or equal to 1.5, less than or
equal to 1.3, less than or equal to 1.2, or less than or equal to
1.1. Combinations of the above-referenced ranges are also possible
(e.g., greater than or equal to 1.05 and less than or equal to 10).
Other ranges are also possible. In some embodiments, the average
pore size may vary smoothly from the average pore size of the first
portion to the average pore size of the second portion.
[0168] In some embodiments, a 3D-printed article may not be a foam
(i.e., it may lack pores) or it may comprise at least one portion
that lacks pores.
[0169] In some embodiments, a 3D-printed article (e.g., a
3D-printed articles that is a foam such as a closed-cell foam, a
3D-printed article that is not a foam, a 3D-printed article that
comprises an elastomer) may have an average density of greater than
or equal to 0.1 pounds per cubic foot, greater than or equal to 0.2
pounds per cubic foot, greater than or equal to 0.5 pounds per
cubic foot, greater than or equal to 1 pound per cubic foot,
greater than or equal to 2 pounds per cubic foot, greater than or
equal to 5 pounds per cubic foot, greater than or equal to 10
pounds per cubic foot, or greater than or equal to 20 pounds per
cubic foot. In some embodiments, a 3D-printed article may have an
average density of less than or equal to 30 pounds per cubic foot,
less than or equal to 20 pounds per cubic foot, less than or equal
to 10 pounds per cubic foot, less than or equal to 5 pounds per
cubic foot, less than or equal to 2 pounds per cubic foot, less
than or equal to 1 pound per cubic foot, less than or equal to 0.5
pounds per cubic foot, or less than or equal to 0.2 pounds per
cubic foot. Combinations of the above-referenced ranges are also
possible (e.g., greater than or equal to 0.2 pounds per cubic foot
and less than or equal to 30 pounds per cubic foot). Other
densities and other ranges are also possible.
[0170] In certain embodiments, a 3D-printed article that comprises
at least one portion (e.g., a 3D-printed article that is a
closed-cell foam which comprises at least a first portion, a
3D-printed article that is not a foam which comprises at least a
first portion, a 3D-printed article that comprises an elastomer and
which comprises at least a first portion) may have an average
density of the first portion of greater than or equal to 0.1 pounds
per cubic foot, greater than or equal to 0.2 pounds per cubic foot,
greater than or equal to 0.5 pounds per cubic foot, greater than or
equal to 1 pound per cubic foot, greater than or equal to 2 pounds
per cubic foot, greater than or equal to 5 pounds per cubic foot,
greater than or equal to 10 pounds per cubic foot, or greater than
or equal to 20 pounds per cubic foot. In some embodiments, a
3D-printed article may have an average density in the first portion
of less than or equal to 30 pounds per cubic foot, less than or
equal to 20 pounds per cubic foot, less than or equal to 10 pounds
per cubic foot, less than or equal to 5 pounds per cubic foot, less
than or equal to 2 pounds per cubic foot, less than or equal to 1
pound per cubic foot, less than or equal to 0.5 pounds per cubic
foot, or less than or equal to 0.2 pounds per cubic foot.
Combinations of the above-referenced ranges are also possible
(e.g., greater than or equal to 0.2 pounds per cubic foot and less
than or equal to 30 pounds per cubic foot). Other densities and
other ranges are also possible.
[0171] In certain embodiments, a 3D-printed article that comprises
at least two portions (e.g., a 3D-printed article that is a
closed-cell foams which comprises at least a first portion and a
second portion, a 3D-printed article that is not a foam which
comprises at least a first portion and a second portion, a
3D-printed article that comprises an elastomer and comprises at
least a first portion and a second portion) may have an average
density of the second portion of greater than or equal to 0.1
pounds per cubic foot, greater than or equal to 0.2 pounds per
cubic foot, greater than or equal to 0.5 pounds per cubic foot,
greater than or equal to 1 pound per cubic foot, greater than or
equal to 2 pounds per cubic foot, greater than or equal to 5 pounds
per cubic foot, greater than or equal to 10 pounds per cubic foot,
or greater than or equal to 20 pounds per cubic foot. In some
embodiments, a 3D-printed article may have an average density in
the second portion of less than or equal to 30 pounds per cubic
foot, less than or equal to 20 pounds per cubic foot, less than or
equal to 10 pounds per cubic foot, less than or equal to 5 pounds
per cubic foot, less than or equal to 2 pounds per cubic foot, less
than or equal to 1 pound per cubic foot, less than or equal to 0.5
pounds per cubic foot, or less than or equal to 0.2 pounds per
cubic foot. Combinations of the above-referenced ranges are also
possible (e.g., greater than or equal to 0.2 pounds per cubic foot
and less than or equal to 30 pounds per cubic foot). Other
densities and other ranges are also possible.
[0172] In certain embodiments, a 3D-printed article that comprises
at least two portions (e.g., a 3D-printed article that is a
closed-cell foams which comprises at least a first portion and a
second portion, a 3D-printed article that is not a foam and
comprises at least a first portion and a second portion, a
3D-printed article that comprises an elastomer and comprises at
least a first portion and a second portion) may have a ratio of the
average density of the second portion of the to the first portion
of greater than or equal to 1.05, greater than or equal to 1.1,
greater than or equal to 1.2, greater than or equal to 1.3, greater
than or equal to 1.5, greater than or equal to 2, or greater than
or equal to 5. In some embodiments, a ratio of the average density
of the second portion of the 3D-printed article to the first
portion of the 3D-printed article may be less than or equal to 10,
less than or equal to 5, less than or equal to 2, less than or
equal to 1.5, less than or equal to 1.3, less than or equal to 1.2,
or less than or equal to 1.1. Combinations of the above-referenced
ranges are also possible (e.g., greater than or equal to 1.05 and
less than or equal to 10). Other densities and other ranges are
also possible.
[0173] In some embodiments, the first portion may be positioned
above the second portion, and the first portion may have a lower
density than the second portion. For example, the first portion may
comprise an upper surface of the 3D-printed article (or may be
adjacent or directly adjacent to the upper surface of the
3D-printed article) and the second portion may be positioned in
approximately the center of the 3D-printed article and the density
at, adjacent to, or directly adjacent to the upper surface of the
3D-printed article may be lower than the density in the center of
the 3D-printed article. In certain cases, the 3D-printed article
may be a foam with a lower density at an upper surface than in the
center. 3D-printed articles with this structure may be formed, in
some cases, by exposing a 3D-printed article comprising a blowing
agent to heat at its upper surface. If the heat exposure is
sufficiently rapid, the surface and, possibly, portions of the
3D-printed article adjacent to the surface may foam to a greater
extent than portions of the 3D-printed article further from the
surface (e.g., portions in the center of the 3D-printed article).
These portions may have a larger pore volume, and so may be less
dense.
[0174] In some embodiments, the average density may vary smoothly
from the average density of the first portion to the average
density of the second portion. In some embodiments, the average
density may vary in a way that would be challenging to obtain by
other fabrication techniques. As a non-limiting example, the
average density of a foam heel cup may vary from a minimum at the
center of the heel cup to maxima at the external surfaces of the
heel cup. This may be achieved by forming a higher density of pores
in the center of the heel cup and decreasing densities of pores as
distance from the center of the heel cup increases. In some
embodiments, a heel cup with this design may be softest and
lightest in the center and harder and heavier around the edges.
[0175] In certain embodiments, a 3D-printed article that comprises
at least two portions (e.g., a 3D-printed article that is a
closed-cell foam which comprises at least a first portion and a
second portion, a 3D-printed article that is not a foam which
comprises at least a first portion and a second portion, a
3D-printed article that comprises an elastomer and comprises at
least a first portion and a second portion) may have a ratio of the
average stiffness of the second portion of the to the first portion
of greater than or equal to 1.05, greater than or equal to 1.1,
greater than or equal to 1.2, greater than or equal to 1.3, greater
than or equal to 1.5, greater than or equal to 2, or greater than
or equal to 5. In some embodiments, a ratio of the average
stiffness of the second portion of the 3D-printed article to the
first portion of the 3D-printed article may be less than or equal
to 10, less than or equal to 5, less than or equal to 2, less than
or equal to 1.5, less than or equal to 1.3, less than or equal to
1.2, or less than or equal to 1.1. Combinations of the
above-referenced ranges are also possible (e.g., greater than or
equal to 1.05 and less than or equal to 10). Other ranges are also
possible. In some embodiments, the average stiffness may vary
smoothly from the average stiffness of the first portion to the
average stiffness of the second portion. References to stiffness
herein should be understood to refer to any, some, or all of the
following types of stiffnesses, unless otherwise specified:
compressive stiffness (i.e., compressive elastic modulus), tensile
elastic modulus (i.e., Young's modulus), modulus at 100% strain,
modulus at 300% strain, and flexural modulus.
[0176] In some embodiments, the first portion may comprise a region
of the 3D-printed article of footwear that would be positioned
adjacent to a toe, the second portion of the 3D-printed article of
footwear may be a heel, and the ratio of the average stiffness of
the first portion to the second portion may be greater than or
equal to 5 and less than or equal to 10.
[0177] In certain embodiments, a 3D-printed article that comprises
at least two portions (e.g., a 3D-printed article that is a
closed-cell foam which comprises at least a first portion and a
second portion, a 3D-printed article that is not a foam which
comprises at least a first portion and a second portion, a
3D-printed article that comprises an elastomer and comprises at
least a first portion and a second portion) may have a ratio of the
average stiffness of the solid components of the second portion to
the average stiffness of the solid components of first portion of
greater than or equal to 1.05, greater than or equal to 1.1,
greater than or equal to 1.2, greater than or equal to 1.3, greater
than or equal to 1.5, greater than or equal to 2, greater than or
equal to 5, greater than or equal to 10, greater than or equal to
20, greater than or equal to 50, greater than or equal to 100,
greater than or equal to 200, greater than or equal to 500, greater
than or equal to 1,000, greater than or equal to 2,000, greater
than or equal to 5,000, or greater than or equal to 10,000. In some
embodiments, a ratio of the average stiffness of the solid
components of the second portion of the 3D-printed article to the
first portion of the 3D-printed article may be less than or equal
to 20,000, less than or equal to 10,000, less than or equal to
5,000, less than or equal to 2,000, less than or equal to 1,000,
less than or equal to 500, less than or equal to 200, less than or
equal to 100, less than or equal to 50, less than or equal to 20,
or less than or equal to 10, less than or equal to 5, less than or
equal to 2, less than or equal to 1.5, less than or equal to 1.3,
less than or equal to 1.2, or less than or equal to 1.1.
Combinations of the above-referenced ranges are also possible
(e.g., greater than or equal to 1.05 and less than or equal to
20,000, or greater than or equal to 1.05 and less than or equal to
10). Other ranges are also possible. In some embodiments, the
average stiffness of the solid components of may vary smoothly from
the average stiffness of the solid components of first portion to
the average stiffness of the solid components of second
portion.
[0178] In certain embodiments, a 3D-printed article that comprises
at least two portions (e.g., a 3D-printed article that is a
closed-cell foam which comprises at least a first portion and a
second portion, a 3D-printed article that is not a foam which
comprises at least a first portion and a second portion, a
3D-printed article that comprises an elastomer and comprises at
least a first portion and a second portion) may have a ratio of the
average stiffness anisotropy of the second portion to the stiffness
anisotropy of first portion of greater than or equal to 1.05,
greater than or equal to 1.1, greater than or equal to 1.2, greater
than or equal to 1.3, greater than or equal to 1.5, greater than or
equal to 2, greater than or equal to 5, greater than or equal to
10, greater than or equal to 20, greater than or equal to 50,
greater than or equal to 100, greater than or equal to 200, greater
than or equal to 500, greater than or equal to 1,000, greater than
or equal to 2,000, greater than or equal to 5,000, or greater than
or equal to 10,000. In some embodiments, a ratio of the average
stiffness anisotropy of the second portion of the 3D-printed
article to the first portion of the 3D-printed article may be less
than or equal to 20,000, less than or equal to 10,000, less than or
equal to 5,000, less than or equal to 2,000, less than or equal to
1,000, less than or equal to 500, less than or equal to 200, less
than or equal to 100, less than or equal to 50, less than or equal
to 20, or less than or equal to 10, less than or equal to 5, less
than or equal to 2, less than or equal to 1.5, less than or equal
to 1.3, less than or equal to 1.2, or less than or equal to 1.1.
Combinations of the above-referenced ranges are also possible
(e.g., greater than or equal to 1.05 and less than or equal to
20,000, or greater than or equal to 1.05 and less than or equal to
10). Other ranges are also possible. In some embodiments, the
average stiffness of the solid components of may vary smoothly from
the average stiffness of the solid components of first portion to
the average stiffness of the solid components of second
portion.
[0179] In some embodiments, a 3D-printed article (e.g., a
3D-printed articles that is a foam such as a closed-cell foam, a
3D-printed article that is not a foam, a 3D-printed article that
comprises an elastomer) may have an average hardness (e.g., an
average Shore A hardness, an average Shore D hardness, an average
Asker C hardness, an average microindentation hardness) of greater
than or equal to 1, greater than or equal to 2, greater than or
equal to 5, greater than or equal to 10, greater than or equal to
15, greater than or equal to 20, greater than or equal to 25,
greater than or equal to 30, greater than or equal to 35, greater
than or equal to 40, greater than or equal to 45, greater than or
equal to 50, greater than or equal to 55, greater than or equal to
60, greater than or equal to 65, greater than or equal to 70,
greater than or equal to 75, greater than or equal to 80, greater
than or equal to 90, or greater than or equal to 100. In some
embodiments, a 3D-printed article may have an average hardness
(e.g., an average Shore A hardness, an average Shore D hardness, an
average Asker C hardness, an average microindentation hardness) of
less than or equal to 125, less than or equal to 100, less than or
equal to 90, less than or equal to 80, less than or equal to 75,
less than or equal to 70, less than or equal to 65, less than or
equal to 60, less than or equal to 55, less than or equal to 50,
less than or equal to 45, less than or equal to 40, less than or
equal to 35, less than or equal to 30, less than or equal to 25,
less than or equal to 20, less than or equal to 15, less than or
equal to 10, less than or equal to 5, or less than or equal to 2.
Combinations of the above-referenced ranges are also possible
(e.g., greater than or equal to 1 and less than or equal to 125).
The average hardness may be measured by the procedure described in
ASTM E384. The Shore A hardness of the 3D-printed article may
instead be measured, for example, by using a Shore A durometer.
[0180] In certain embodiments, a 3D-printed article that comprises
at least one portion (e.g., a 3D-printed article that is a
closed-cell foam which comprises at least a first portion, a
3D-printed article that is not a foam and comprises at least a
first portion, a 3D-printed article that comprises an elastomer and
at least a first portion) may have an average hardness (e.g., an
average Shore A hardness, an average Shore D hardness, an average
Asker C hardness, an average microindentation hardness) of the
first portion of greater than or equal to 5, greater than or equal
to 10, greater than or equal to 15, greater than or equal to 20,
greater than or equal to 25, greater than or equal to 30, greater
than or equal to 35, greater than or equal to 40, greater than or
equal to 45, greater than or equal to 50, greater than or equal to
55, greater than or equal to 60, greater than or equal to 65, or
greater than or equal to 70. In some embodiments, a 3D-printed
article may have an average hardness (e.g., an average Shore A
hardness, an average Shore D hardness, an average Asker C hardness,
an average microindentation hardness) of the first portion of less
than or equal to 75, less than or equal to 70, less than or equal
to 65, less than or equal to 60, less than or equal to 55, less
than or equal to 50, less than or equal to 45, less than or equal
to 40, less than or equal to 35, less than or equal to 30, less
than or equal to 25, less than or equal to 20, less than or equal
to 15, or less than or equal to 10. Combinations of the
above-referenced ranges are also possible.
[0181] In certain embodiments, a 3D-printed article that comprises
at least two portions (e.g., a 3D-printed article that is a
closed-cell foam which comprises at least a first portion and a
second portion, a 3D-printed article that is not a foam which
comprises at least a first portion and a second portion, a
3D-printed article that comprises an elastomer and comprises at
least a first portion and a second portion) may have an average
hardness (e.g., an average Shore A hardness, an average Shore D
hardness, an average Asker C hardness, an average microindentation
hardness) of the second portion of greater than or equal to 1,
greater than or equal to 2, greater than or equal to 5, greater
than or equal to 10, greater than or equal to 15, greater than or
equal to 20, greater than or equal to 25, greater than or equal to
30, greater than or equal to 35, greater than or equal to 40,
greater than or equal to 45, greater than or equal to 50, greater
than or equal to 55, greater than or equal to 60, greater than or
equal to 65, or greater than or equal to 70. In some embodiments, a
3D-printed article may have an average hardness (e.g., an average
Shore A hardness, an average Shore D hardness, an average Asker C
hardness, an average microindentation hardness) of the second
portion of less than or equal to 75, less than or equal to 70, less
than or equal to 65, less than or equal to 60, less than or equal
to 55, less than or equal to 50, less than or equal to 45, less
than or equal to 40, less than or equal to 35, less than or equal
to 30, less than or equal to 25, less than or equal to 20, less
than or equal to 15, less than or equal to 10, less than or equal
to 5, or less than or equal to 2. Combinations of the
above-referenced ranges are also possible (e.g., greater than or
equal to 1 and less than or equal to 75). Other ranges are also
possible.
[0182] In certain embodiments, a 3D-printed article that comprises
at least two portions (e.g., a 3D-printed article that is a
closed-cell foam which comprises at least a first portion and a
second portion, a 3D-printed article that is not a foam which
comprises at least a first portion and a second portion, a
3D-printed article that comprises an elastomer and comprises at
least a first portion and a second portion) may have a ratio of the
average hardness (e.g., average Shore A hardness, average Shore D
hardness, average Asker C hardness, average microindentation
hardness) of the second portion of the to the first portion of
greater than or equal to 1.05, greater than or equal to 1.1,
greater than or equal to 1.2, greater than or equal to 1.3, greater
than or equal to 1.5, greater than or equal to 2, or greater than
or equal to 5. In some embodiments, a ratio of the average hardness
(e.g., average Shore A hardness, average Shore D hardness, average
Asker C hardness, average microindentation hardness) of the second
portion of the 3D-printed article to the first portion of the
3D-printed article may be less than or equal to 10, less than or
equal to 5, less than or equal to 2, less than or equal to 1.5,
less than or equal to 1.3, less than or equal to 1.2, or less than
or equal to 1.1. Combinations of the above-referenced ranges are
also possible (e.g., greater than or equal to 1.05 and less than or
equal to 10). Other ranges are also possible. In some embodiments,
the average hardness (e.g., average Shore A hardness, average Shore
D hardness, average Asker C hardness, average microindentation
hardness) may vary smoothly from the average hardness (e.g.,
average Shore A hardness, average Shore D hardness, average Asker C
hardness, average microindentation hardness) of the first portion
to the average hardness (e.g., average Shore A hardness, average
Shore D hardness, average Asker C hardness, average
microindentation hardness) of the second portion.
[0183] In certain embodiments, a 3D-printed article that comprises
at least two portions (e.g., a 3D-printed article that is a
closed-cell foam which comprises at least a first portion and a
second portion, a 3D-printed article that is not a foam and
comprises at least a first portion and a second portion, a
3D-printed article that comprises an elastomer and comprises at
least a first portion and a second portion) may have a ratio of the
average cross-link density of the second portion of the to the
first portion of greater than or equal to 1.05, greater than or
equal to 1.1, greater than or equal to 1.2, greater than or equal
to 1.3, greater than or equal to 1.5, greater than or equal to 2,
or greater than or equal to 5. In some embodiments, a ratio of the
average cross-link density of the second portion of the 3D-printed
article to the first portion of the 3D-printed article may be less
than or equal to 10, less than or equal to 5, less than or equal to
2, less than or equal to 1.5, less than or equal to 1.3, less than
or equal to 1.2, or less than or equal to 1.1. Combinations of the
above-referenced ranges are also possible (e.g., greater than or
equal to 1.05 and less than or equal to 10). Other ranges are also
possible. In some embodiments, the average cross-link density may
vary smoothly from the average cross-link density of the first
portion to the average density of the second portion.
[0184] In certain embodiments in which a 3D-printed article that
comprises at least one portion (e.g., a 3D-printed article that is
a closed-cell foam which comprises at least a first portion, a
3D-printed article that is not a foam and comprises at least one
portion, a 3D-printed article that comprises an elastomer and
comprises at least one portion), the color in the first portion may
be one or more of red, orange, yellow, green, blue, indigo violet,
pink, purple, white, black, gray, etc. The color may be a pastel
color, a royal color, a light color, a dark color, or any other
color. The color may have any suitable saturation.
[0185] In certain embodiments in which a 3D-printed article that
comprises at least one portion (e.g., a 3D-printed article that is
a closed-cell foam which comprises at least a first portion and a
second portion, a 3D-printed article that is not a foam and
comprises at least a first portion and a second portion, a
3D-printed article that comprises an elastomer and comprises at
least a first portion and a second portion), the color in the
second portion may be one or more of red, orange, yellow, green,
blue, indigo violet, pink, purple, white, black, gray, etc. The
color may be a pastel color, a royal color, a light color, a dark
color, or any other color. The color may have any suitable
saturation.
[0186] In some embodiments, a 3D-printed article (e.g., a
3D-printed articles that is a foam such as a closed-cell foam, a
3D-printed article that is not a foam, a 3D-printed article that
comprises an elastomer) may have an average filler content of
greater than or equal to 0.1 wt %, greater than or equal to 0.2 wt
%, greater than or equal to 0.5 wt %, greater than or equal to 1 wt
%, greater than or equal to 2 wt %, greater than or equal to 5 wt
%, or greater than or equal to 10 wt %. In some embodiments, a
3D-printed article may have an average filler content of less than
or equal to 20 wt %, less than or equal to 10 wt %, less than or
equal to 5 wt %, less than or equal to 2 wt %, less than or equal
to 1 wt %, less than or equal to 0.5 wt %, or less than or equal to
0.2 wt %. Combinations of the above-referenced ranges are also
possible (e.g., greater than or equal to 0.1 wt % and less than or
equal to 20 wt %). Other ranges are also possible.
[0187] In certain embodiments, a 3D-printed article that comprises
at least one portion (e.g., a 3D-printed article that is a
closed-cell foam which comprises at least a first portion, a
3D-printed article that is not a foam and comprises at least a
first portion, a 3D-printed article that comprises an elastomer and
at least a first portion) may have an average filler content of the
first portion of greater than or equal to 0.1 wt %, greater than or
equal to 0.2 wt %, greater than or equal to 0.5 wt %, greater than
or equal to 1 wt %, greater than or equal to 2 wt %, greater than
or equal to 5 wt %, greater than or equal to 10 wt %, greater than
or equal to 20 wt %, greater than or equal to 50 wt %, or greater
than or equal to 80 wt %. In some embodiments, the first portion
may have an average filler content of less than or equal to 90 wt
%, less than or equal to 80 wt %, less than or equal to 50 wt %,
less than or equal to 20 wt %, less than or equal to 10 wt %, less
than or equal to 5 wt %, less than or equal to 2 wt %, less than or
equal to 1 wt %, less than or equal to 0.5 wt %, or less than or
equal to 0.2 wt %. Combinations of the above-referenced ranges are
also possible (e.g., greater than or equal to 0.1 wt % and less
than or equal to 90 wt %, or greater than or equal to 0.1 wt % and
less than or equal to 20 wt %). Other ranges are also possible.
[0188] In certain embodiments, a 3D-printed article that comprises
at least two portions (e.g., a 3D-printed article that is a
closed-cell foam which comprises at least a first portion and a
second portion, a 3D-printed article that is not a foam and
comprises at least a first portion and a second portion, a
3D-printed article that comprises an elastomer and at least a first
portion and a second portion) may have an average filler content of
the second portion of greater than or equal to 0.1 wt %, greater
than or equal to 0.2 wt %, greater than or equal to 0.5 wt %,
greater than or equal to 1 wt %, greater than or equal to 2 wt %,
greater than or equal to 5 wt %, greater than or equal to 10 wt %,
greater than or equal to 20 wt %, greater than or equal to 50 wt %,
or greater than or equal to 80 wt %. In some embodiments, the
second portion may have an average filler content of less than or
equal to 90 wt %, less than or equal to 80 wt %, less than or equal
to 50 wt %, less than or equal to 20 wt %, less than or equal to 10
wt %, less than or equal to 5 wt %, less than or equal to 2 wt %,
less than or equal to 1 wt %, less than or equal to 0.5 wt %, or
less than or equal to 0.2 wt %. Combinations of the
above-referenced ranges are also possible (e.g., greater than or
equal to 0.1 wt % and less than or equal to 90 wt %, or greater
than or equal to 0.1 wt % and less than or equal to 20 wt %). Other
ranges are also possible.
[0189] In certain embodiments, a 3D-printed article that comprises
at least two portions (e.g., a 3D-printed article that is a
closed-cell foams which comprises at least a first portion and a
second portion, a 3D-printed article that is not a foam and
comprises at least a first portion and a second portion, a
3D-printed article that comprises an elastomer and at least a first
portion and a second portion) may have a ratio of the average
filler content of the second portion to the first portion of
greater than or equal to 1.05, greater than or equal to 1.1,
greater than or equal to 1.2, greater than or equal to 1.3, greater
than or equal to 1.5, greater than or equal to 2, greater than or
equal to 5, greater than or equal to 10, greater than or equal to
20, greater than or equal to 50, greater than or equal to 100,
greater than or equal to 200, greater than or equal to 500, greater
than or equal to 1,000, greater than or equal to 2,000, greater
than or equal to 5,000, greater than or equal to 10,000, greater
than or equal to 20,000, greater than or equal to 50,000, or
greater than or equal to 100,000. In some embodiments, a ratio of
the average filler content of the second portion of the 3D-printed
article to the first portion of the 3D-printed article may be less
than or equal to 200,000, less than or equal to 100,000, less than
or equal to 50,000, less than or equal to 20,000, less than or
equal to 10,000, less than or equal to 5,000, less than or equal to
2,000, less than or equal to 1,000, less than or equal to 500, less
than or equal to 200, less than or equal to 100, less than or equal
to 50, less than or equal to 20, less than or equal to 10, less
than or equal to 5, less than or equal to 2, less than or equal to
1.5, less than or equal to 1.3, less than or equal to 1.2, or less
than or equal to 1.1. Combinations of the above-referenced ranges
are also possible (e.g., greater than or equal to 1.05 and less
than or equal to 200,000, or greater than or equal to 1.05 and less
than or equal to 10). Other ranges are also possible. In some
embodiments, the average filler content may vary smoothly from the
average filler content of the first portion to the average filler
content of the second portion. In some embodiments, a 3D-printed
article may comprise one portion including filler and one portion
lacking filler or containing minimal filler. The portion(s)
including filler may include up to 95 wt % filler.
[0190] In some embodiments, a 3D-printed article (e.g., a
3D-printed articles that is a foam such as a closed-cell foam, a
3D-printed article that is not a foam, a 3D-printed article that
comprises an elastomer) may have an average opacity of greater than
or equal to 0, greater than or equal to 0.1, greater than or equal
to 0.2, greater than or equal to 0.5, greater than or equal to 1,
greater than or equal to 2, or greater than or equal to 5. In some
embodiments, the 3D-printed article may have an average opacity of
less than or equal to 10, less than or equal to 5, less than or
equal to 2, less than or equal to 1, less than or equal to 0.5 less
than or equal to 0.2, or less than or equal to 0.1. Combinations of
the above-referenced ranges are also possible (e.g., greater than
or equal to 0 and less than or equal to 10). Other ranges are also
possible. The average opacity of the 3D-printed article may be
measured by UV-vis spectroscopy.
[0191] In certain embodiments, a 3D-printed article that comprises
at least one portion (e.g., a 3D-printed article that is a
closed-cell foam which comprises at least a first portion, a
3D-printed article that is not a foam and comprises at least a
first portion, a 3D-printed article that comprises an elastomer and
at least a first portion) may have an average opacity of the first
portion of greater than or equal to 0, greater than or equal to
0.1, greater than or equal to 0.2, greater than or equal to 0.5,
greater than or equal to 1, greater than or equal to 2, greater
than or equal to 5, greater than or equal to 10, greater than or
equal to 20, greater than or equal to 50, greater than or equal to
100, greater than or equal to 200, greater than or equal to 500, or
greater than or equal to 1,000. In some embodiments, the first
portion of the 3D-printed article may have an average opacity of
less than or equal to 2,000, less than or equal to 1,000, less than
or equal to 500, less than or equal to 200, less than or equal to
100, less than or equal to 50, less than or equal to 20, less than
or equal to 10, less than or equal to 5, less than or equal to 2,
less than or equal to 1, less than or equal to 0.5 less than or
equal to 0.2, or less than or equal to 0.1. Combinations of the
above-referenced ranges are also possible (e.g., greater than or
equal to 0 and less than or equal to 2,000, or greater than or
equal to 0 and less than or equal to 10). Other ranges are also
possible.
[0192] In certain embodiments, a 3D-printed article that comprises
at least two portions (e.g., a 3D-printed article that is a
closed-cell foams which comprises at least a first portion and a
second portion, a 3D-printed article that is not a foam and
comprises at least a first portion and a second portion, a
3D-printed article that comprises an elastomer and comprises at
least a first portion and a second portion) may have an average
opacity of the second portion of greater than or equal to 0,
greater than or equal to 0.1, greater than or equal to 0.2, greater
than or equal to 0.5, greater than or equal to 1, greater than or
equal to 2, or greater than or equal to 5. In some embodiments, the
second portion of the 3D-printed article may have an average
opacity of less than or equal to 10, less than or equal to 5, less
than or equal to 2, less than or equal to 1, less than or equal to
0.5 less than or equal to 0.2, or less than or equal to 0.1.
Combinations of the above-referenced ranges are also possible
(e.g., greater than or equal to 0 and less than or equal to 10).
Other ranges are also possible.
[0193] In certain embodiments, a 3D-printed article that comprises
at least two portions (e.g., a 3D-printed article that is a
closed-cell foams which comprises at least a first portion and a
second portion, a 3D-printed article that is not a foam and
comprises at least a first portion and a second portion, a
3D-printed article that comprises an elastomer and comprises at
least a first portion and a second portion) may have a ratio of the
average opacity of the second portion to the first portion of
greater than or equal to 1.05, greater than or equal to 1.1,
greater than or equal to 1.2, greater than or equal to 1.3, greater
than or equal to 1.5, greater than or equal to 2, greater than or
equal to 5, greater than or equal to 10, greater than or equal to
20, greater than or equal to 50, greater than or equal to 100,
greater than or equal to 200, greater than or equal to 1,000,
greater than or equal to 2,000, greater than or equal to 5,000,
greater than or equal to 10,000, greater than or equal to 20,000,
greater than or equal to 50,000, or greater than or equal to
100,000. In some embodiments, a ratio of the average opacity of the
second portion of the 3D-printed article to the first portion of
the 3D-printed article may be less than or equal to 200,000, less
than or equal to 100,000, less than or equal to 50,000, less than
or equal to 20,000, less than or equal to 10,000, less than or
equal to 5,000, less than or equal to 2,000, less than or equal to
1,000, less than or equal to 500, less than or equal to 200, less
than or equal to 100, less than or equal to 50, less than or equal
to 20, less than or equal to 10, less than or equal to 5, less than
or equal to 2, less than or equal to 1.5, less than or equal to
1.3, less than or equal to 1.2, or less than or equal to 1.1.
Combinations of the above-referenced ranges are also possible
(e.g., greater than or equal to 1.05 and less than or equal to
200,000, or greater than or equal to 1.05 and less than or equal to
10). Other ranges are also possible. In some embodiments, the
average opacity may vary smoothly from the average opacity of the
first portion to the average opacity of the second portion.
[0194] In certain embodiments, a 3D-printed article that comprises
at least two portions (e.g., a 3D-printed article that is a
closed-cell foams which comprises at least a first portion and a
second portion, a 3D-printed article that is not a foam and
comprises at least a first portion and a second portion, a
3D-printed article that comprises an elastomer and comprises at
least a first portion and a second portion) may have a ratio of the
average electrical conductivity of the second portion to the first
portion of greater than or equal to 1.05, greater than or equal to
1.1, greater than or equal to 1.2, greater than or equal to 1.3,
greater than or equal to 1.5, greater than or equal to 2, greater
than or equal to 5, greater than or equal to 10, greater than or
equal to 20, greater than or equal to 50, greater than or equal to
100, greater than or equal to 10.sup.3, greater than or equal to
10.sup.4, greater than or equal to 10.sup.5, greater than or equal
to 10.sup.6, or greater than or equal to 10.sup.7. In some
embodiments, a ratio of the average electrical conductivity of the
second portion of the 3D-printed article to the first portion of
the 3D-printed article may be less than or equal to 10.sup.8, less
than or equal to 10.sup.7, less than or equal to 10.sup.6, less
than or equal to 10.sup.5, less than or equal to 10.sup.4, less
than or equal to 10.sup.3, less than or equal to 100, less than or
equal to 50, less than or equal to 20, less than or equal to 10,
less than or equal to 5, less than or equal to 2, less than or
equal to 1.5, less than or equal to 1.3, less than or equal to 1.2,
or less than or equal to 1.1. Combinations of the above-referenced
ranges are also possible (e.g., greater than or equal to 1.05 and
less than or equal to 10.sup.8, or greater than or equal to 1.05
and less than or equal to 10). Other ranges are also possible. In
some embodiments, the average electrical conductivity may vary
smoothly from the average conductivity of the first portion to the
average electrical conductivity of the second portion.
[0195] In certain embodiments, a 3D-printed article that comprises
at least two portions (e.g., a 3D-printed article that is a
closed-cell foams which comprises at least a first portion and a
second portion, a 3D-printed article that is not a foam and
comprises at least a first portion and a second portion, a
3D-printed article that comprises an elastomer and comprises at
least a first portion and a second portion) may have a ratio of the
average thermal conductivity of the second portion to the first
portion of greater than or equal to 1.05, greater than or equal to
1.1, greater than or equal to 1.2, greater than or equal to 1.3,
greater than or equal to 1.5, greater than or equal to 2, greater
than or equal to 5, greater than or equal to 10, greater than or
equal to 20, greater than or equal to 50, greater than or equal to
100, greater than or equal to 10.sup.3, greater than or equal to
10.sup.4, greater than or equal to 10.sup.5, greater than or equal
to 10.sup.6, or greater than or equal to 10.sup.7. In some
embodiments, a ratio of the average thermal conductivity of the
second portion of the 3D-printed article to the first portion of
the 3D-printed article may be less than or equal to 10.sup.8, less
than or equal to 10.sup.7, less than or equal to 10.sup.6, less
than or equal to 10.sup.5, less than or equal to 10.sup.4, less
than or equal to 10.sup.3, less than or equal to 100, less than or
equal to 50, less than or equal to 20, less than or equal to 10,
less than or equal to 5, less than or equal to 2, less than or
equal to 1.5, less than or equal to 1.3, less than or equal to 1.2,
or less than or equal to 1.1. Combinations of the above-referenced
ranges are also possible (e.g., greater than or equal to 1.05 and
less than or equal to 108, or greater than or equal to 1.05 and
less than or equal to 10). Other ranges are also possible. In some
embodiments, the average thermal conductivity may vary smoothly
from the average thermal conductivity of the first portion to the
average thermal conductivity of the second portion.
[0196] In certain embodiments, a 3D-printed article that comprises
at least two portions (e.g., a 3D-printed article that is a
closed-cell foams which comprises at least a first portion and a
second portion, a 3D-printed article that is not a foam and
comprises at least a first portion and a second portion, a
3D-printed article that comprises an elastomer and at least a first
portion and a second portion) may have a ratio of the average
breathability of the second portion to the first portion of greater
than or equal to 1.05, greater than or equal to 1.1, greater than
or equal to 1.2, greater than or equal to 1.3, greater than or
equal to 1.5, greater than or equal to 2, or greater than or equal
to 5. In some embodiments, a ratio of the average breathability of
the second portion of the 3D-printed article to the first portion
of the 3D-printed article may be less than or equal to 10, less
than or equal to 5, less than or equal to 2, less than or equal to
1.5, less than or equal to 1.3, less than or equal to 1.2, or less
than or equal to 1.1. Combinations of the above-referenced ranges
are also possible (e.g., greater than or equal to 1.05 and less
than or equal to 10). Other ranges are also possible. In some
embodiments, the average breathability may vary smoothly from the
average breathability of the first portion to the average
breathability of the second portion.
[0197] In certain embodiments, a 3D-printed article that comprises
at least two portions (e.g., a 3D-printed article that is a
closed-cell foams which comprises at least a first portion and a
second portion, a 3D-printed article that is not a foam and
comprises at least a first portion and a second portion, a
3D-printed article that comprises an elastomer and at least a first
portion and a second portion) may have a ratio of the average
abrasion resistance of the second portion to the first portion of
greater than or equal to 1.05, greater than or equal to 1.1,
greater than or equal to 1.2, greater than or equal to 1.3, greater
than or equal to 1.5, greater than or equal to 2, or greater than
or equal to 5. In some embodiments, a ratio of the average abrasion
resistance of the second portion of the 3D-printed article to the
first portion of the 3D-printed article may be less than or equal
to 10, less than or equal to 5, less than or equal to 2, less than
or equal to 1.5, less than or equal to 1.3, less than or equal to
1.2, or less than or equal to 1.1. Combinations of the
above-referenced ranges are also possible (e.g., greater than or
equal to 1.05 and less than or equal to 10). Other ranges are also
possible. In some embodiments, the average abrasion resistance may
vary smoothly from the average abrasion resistance of the first
portion to the average abrasion resistance of the second portion.
The average abrasion resistance of a 3D-printed article or a
portion thereof may be determined, for example, in accordance with
ASTM standard D1630.
[0198] In certain embodiments, a 3D-printed article that comprises
at least two portions (e.g., a 3D-printed article that is a
closed-cell foams which comprises at least a first portion and a
second portion, a 3D-printed article that is not a foam and
comprises at least a first portion and a second portion, a
3D-printed article that comprises an elastomer and at least a first
portion and a second portion) may have a ratio of the average
flexural modulus of the second portion to the first portion of
greater than or equal to 1.05, greater than or equal to 1.1,
greater than or equal to 1.2, greater than or equal to 1.3, greater
than or equal to 1.5, greater than or equal to 2, greater than or
equal to 5, greater than or equal to 10, greater than or equal to
20, greater than or equal to 50, greater than or equal to 100,
greater than or equal to 200, greater than or equal to 500, greater
than or equal to 1,000, greater than or equal to 2,000, greater
than or equal to 5,000, or greater than or equal to 10,000. In some
embodiments, a ratio of the average flexural modulus of the second
portion of the 3D-printed article to the first portion of the
3D-printed article may be less than or equal to 20,000, less than
or equal to 10,000, less than or equal to 5,000, less than or equal
to 2,000, less than or equal to 1,000, less than or equal to 500,
less than or equal to 200, less than or equal to 100, less than or
equal to 50, less than or equal to 20, less than or equal to 10,
less than or equal to 5, less than or equal to 2, less than or
equal to 1.5, less than or equal to 1.3, less than or equal to 1.2,
or less than or equal to 1.1. Combinations of the above-referenced
ranges are also possible (e.g., greater than or equal to 1.05 and
less than or equal to 20,000, or greater than or equal to 1.05 and
less than or equal to 10). Other ranges are also possible. In some
embodiments, the average flexural modulus may vary smoothly from
the average flexural modulus of the first portion to the average
flexural modulus of the second portion.
[0199] In some embodiments, a 3D-printed article (e.g., a
3D-printed articles that is a foam such as a closed-cell foam, a
3D-printed article that is not a foam, a 3D-printed article that
comprises an elastomer) may have an average elastic modulus (i.e.,
Young's modulus) of greater than or equal to 1 kPa, greater than or
equal to 10 kPa, greater than or equal to 100 kPa, greater than or
equal to 1 MPa, greater than or equal to 10 MPa, greater than or
equal to 0.1 GPa, greater than or equal to 0.2 GPa, greater than or
equal to 0.5 GPa, greater than or equal to 1 GPa, greater than or
equal to 2 GPa, greater than or equal to 5 GPa. In some
embodiments, the 3D-printed article may have an average elastic
modulus of less than or equal to 10 GPa, less than or equal to 5
GPa, less than or equal to 2 GPa, less than or equal to 1 GPa, less
than or equal to 0.5 GPa, less than or equal to 0.2 GPa, less than
or equal to 0.1 GPa, less than or equal to 10 MPa, less than or
equal to 1 MPa, less than or equal to 100 kPa, or less than or
equal to 10 kPa. Combinations of the above-referenced ranges are
also possible (e.g., greater than or equal to 1 kPa and less than
or equal to 10 GPa, or greater than or equal to 0.1 GPa and less
than or equal to 10 GPa). Other ranges are also possible. Other
ranges are also possible. The average elastic modulus of the
3D-printed article may be measured by tensile testing or other
suitable techniques known to those of ordinary skill in the
art.
[0200] In certain embodiments, a 3D-printed article that comprises
at least one portion (e.g., a 3D-printed article that is a
closed-cell foam which comprises at least a first portion, a
3D-printed article that is not a foam and comprises at least a
first portion, a 3D-printed article that comprises an elastomer and
at least a first portion) may have an average elastic modulus
(i.e., Young's modulus) of the first portion of greater than or
equal to 1 kPa, greater than or equal to 10 kPa, greater than or
equal to 100 kPa, greater than or equal to 1 MPa, greater than or
equal to 10 MPa, greater than or equal to 0.1 GPa, greater than or
equal to 0.2 GPa, greater than or equal to 0.5 GPa, greater than or
equal to 1 GPa, greater than or equal to 2 GPa, greater than or
equal to 5 GPa. In some embodiments, the first portion of the
3D-printed article may have an average elastic modulus of less than
or equal to 10 GPa, less than or equal to 5 GPa, less than or equal
to 2 GPa, less than or equal to 1 GPa, less than or equal to 0.5
GPa, less than or equal to 0.2 GPa, less than or equal to 0.1 GPa,
less than or equal to 10 MPa, less than or equal to 1 MPa, less
than or equal to 100 kPa, or less than or equal to 10 kPa.
Combinations of the above-referenced ranges are also possible
(e.g., greater than or equal to 1 kPa and less than or equal to 10
GPa, or greater than or equal to 0.1 GPa and less than or equal to
10 GPa). Other ranges are also possible.
[0201] In certain embodiments, a 3D-printed article that comprises
at least two portions (e.g., a 3D-printed article that is a
closed-cell foams which comprises at least a first portion and a
second portion, a 3D-printed article that is not a foam and
comprises at least a first portion and a second portion, a
3D-printed article that comprises an elastomer and comprises at
least a first portion and a second portion) may have an average
elastic modulus (i.e., Young's modulus) of the second portion of
greater than or equal to 1 kPa, greater than or equal to 10 kPa,
greater than or equal to 100 kPa, greater than or equal to 1 MPa,
greater than or equal to 10 MPa, greater than or equal to 0.1 GPa,
greater than or equal to 0.2 GPa, greater than or equal to 0.5 GPa,
greater than or equal to 1 GPa, greater than or equal to 2 GPa,
greater than or equal to 5 GPa. In some embodiments, the second
portion of the 3D-printed article may have an average elastic
modulus of less than or equal to 10 GPa, less than or equal to 5
GPa, less than or equal to 2 GPa, less than or equal to 1 GPa, less
than or equal to 0.5 GPa, less than or equal to 0.2 GPa, less than
or equal to 0.1 GPa, less than or equal to 10 MPa, less than or
equal to 1 MPa, less than or equal to 100 kPa, or less than or
equal to 10 kPa. Combinations of the above-referenced ranges are
also possible (e.g., greater than or equal to 1 kPa and less than
or equal to 10 GPa, or greater than or equal to 0.1 GPa and less
than or equal to 10 GPa). Other ranges are also possible.
[0202] In certain embodiments, a 3D-printed article that comprises
at least two portions (e.g., a 3D-printed article that is a
closed-cell foams which comprises at least a first portion and a
second portion, a 3D-printed article that is not a foam and
comprises at least a first portion and a second portion, a
3D-printed article that comprises an elastomer and comprises at
least a first portion and a second portion) may have a ratio of the
average elastic modulus (i.e., Young's modulus) of the second
portion to the first portion of greater than or equal to 1.05,
greater than or equal to 1.1, greater than or equal to 1.2, greater
than or equal to 1.3, greater than or equal to 1.5, greater than or
equal to 2, or greater than or equal to 5. In some embodiments, a
ratio of the average elastic modulus of the second portion of the
3D-printed article to the first portion of the 3D-printed article
may be less than or equal to 10, less than or equal to 5, less than
or equal to 2, less than or equal to 1.5, less than or equal to
1.3, less than or equal to 1.2, or less than or equal to 1.1.
Combinations of the above-referenced ranges are also possible
(e.g., greater than or equal to 1.05 and less than or equal to 10).
Other ranges are also possible. In some embodiments, the average
elastic modulus may vary smoothly from the average elastic modulus
of the first portion to the average elastic modulus of the second
portion.
[0203] In certain embodiments, a 3D-printed article that comprises
at least two portions (e.g., a 3D-printed article that is a
closed-cell foams which comprises at least a first portion and a
second portion, a 3D-printed article that is not a foam and
comprises at least a first portion and a second portion, a
3D-printed article that comprises an elastomer and at least a first
portion and a second portion) may have a ratio of the average
surface roughness of the second portion to the first portion of
greater than or equal to 1.05, greater than or equal to 1.1,
greater than or equal to 1.2, greater than or equal to 1.3, greater
than or equal to 1.5, greater than or equal to 2, greater than or
equal to 5, greater than or equal to 10, greater than or equal to
20, greater than or equal to 50, greater than or equal to 100,
greater than or equal to 200, greater than or equal to 500, or
greater than or equal to 1,000. In some embodiments, a ratio of the
average surface roughness of the second portion of the 3D-printed
article to the first portion of the 3D-printed article may be less
than or equal to 2,000, less than or equal to 1,000, less than or
equal to 500, less than or equal to 200, less than or equal to 100,
less than or equal to 50, less than or equal to 20, less than or
equal to 10, less than or equal to 5, less than or equal to 2, less
than or equal to 1.5, less than or equal to 1.3, less than or equal
to 1.2, or less than or equal to 1.1. Combinations of the
above-referenced ranges are also possible (e.g., greater than or
equal to 1.05 and less than or equal to 2,000, or greater than or
equal to 1.05 and less than or equal to 10). Other ranges are also
possible. In some embodiments, the average surface roughness may
vary smoothly from the average surface roughness of the first
portion to the average surface roughness of the second portion.
[0204] In certain embodiments, a 3D-printed article that comprises
at least two portions (e.g., a 3D-printed article that is a
closed-cell foams which comprises at least a first portion and a
second portion, a 3D-printed article that is not a foam and
comprises at least a first portion and a second portion, a
3D-printed article that comprises an elastomer and at least a first
portion and a second portion) may have a ratio of the average
reflectivity of the second portion to the first portion of greater
than or equal to 1.05, greater than or equal to 1.1, greater than
or equal to 1.2, greater than or equal to 1.3, greater than or
equal to 1.5, greater than or equal to 2, greater than or equal to
5, greater than or equal to 10, greater than or equal to 20,
greater than or equal to 50, or greater than or equal to 100. In
some embodiments, a ratio of the average reflectivity of the second
portion of the 3D-printed article to the first portion of the
3D-printed article may be less than or equal to 200, less than or
equal to 100, less than or equal to 50, less than or equal to 20,
less than or equal to 10, less than or equal to 5, less than or
equal to 2, less than or equal to 1.5, less than or equal to 1.3,
less than or equal to 1.2, or less than or equal to 1.1.
Combinations of the above-referenced ranges are also possible
(e.g., greater than or equal to 1.05 and less than or equal to 200,
or greater than or equal to 1.05 and less than or equal to 10).
Other ranges are also possible. In some embodiments, the average
reflectivity may vary smoothly from the average reflectivity of the
first portion to the average reflectivity of the second
portion.
[0205] In certain embodiments, a 3D-printed article that comprises
at least two portions (e.g., a 3D-printed article that is a
closed-cell foams which comprises at least a first portion and a
second portion, a 3D-printed article that is not a foam and
comprises at least a first portion and a second portion, a
3D-printed article that comprises an elastomer and at least a first
portion and a second portion) may have a ratio of the average
strength of the second portion to the first portion of greater than
or equal to 1.05, greater than or equal to 1.1, greater than or
equal to 1.2, greater than or equal to 1.3, greater than or equal
to 1.5, greater than or equal to 2, greater than or equal to 5,
greater than or equal to 10, greater than or equal to 20, greater
than or equal to 50, or greater than or equal to 100. In some
embodiments, a ratio of the average strength of the second portion
of the 3D-printed article to the first portion of the 3D-printed
article may be less than or equal to 200, less than or equal to
100, less than or equal to 50, less than or equal to 20, less than
or equal to 10, less than or equal to 5, less than or equal to 2,
less than or equal to 1.5, less than or equal to 1.3, less than or
equal to 1.2, or less than or equal to 1.1. Combinations of the
above-referenced ranges are also possible (e.g., greater than or
equal to 1.05 and less than or equal to 200, or greater than or
equal to 1.05 and less than or equal to 10). Other ranges are also
possible. In some embodiments, the average strength may vary
smoothly from the average strength of the first portion to the
average strength of the second portion.
[0206] In certain embodiments, a 3D-printed article that comprises
at least two portions (e.g., a 3D-printed article that is a
closed-cell foams which comprises at least a first portion and a
second portion, a 3D-printed article that is not a foam and
comprises at least a first portion and a second portion, a
3D-printed article that comprises an elastomer and at least a first
portion and a second portion) may have a ratio of the average
dimensional change upon heat activation of the second portion to
the first portion of greater than or equal to 1.05, greater than or
equal to 1.1, greater than or equal to 1.2, greater than or equal
to 1.3, greater than or equal to 1.5, greater than or equal to 2,
greater than or equal to 5, greater than or equal to 10, greater
than or equal to 20, greater than or equal to 50, greater than or
equal to 100, greater than or equal to 200, greater than or equal
to 500, or greater than or equal to 1,000. In some embodiments, a
ratio of the average dimensional change upon heat activation of the
second portion of the 3D-printed article to the first portion of
the 3D-printed article may be less than or equal to 2,000, less
than or equal to 1,000, less than or equal to 500, less than or
equal to 200, less than or equal to 100, less than or equal to 50,
less than or equal to 20, less than or equal to 10, less than or
equal to 5, less than or equal to 2, less than or equal to 1.5,
less than or equal to 1.3, less than or equal to 1.2, or less than
or equal to 1.1. Combinations of the above-referenced ranges are
also possible (e.g., greater than or equal to 1.05 and less than or
equal to 2,000, or greater than or equal to 1.05 and less than or
equal to 10). Other ranges are also possible. In some embodiments,
the average dimensional change upon heat activation may vary
smoothly from the average dimensional change upon heat activation
of the first portion to the average dimensional change upon heat
activation of the second portion.
[0207] In some embodiments, a 3D-printed article (e.g., a
3D-printed articles that is a foam such as a closed-cell foam, a
3D-printed article that is not a foam, a 3D-printed article that
comprises an elastomer) may comprise one or more macrovoids with an
average cross-sectional diameter of greater than or equal to 0.5
mm, greater than or equal to 1 mm, greater than or equal to 2 mm,
greater than or equal to 5 mm, greater than or equal to 1 cm,
greater than or equal to 2 cm, greater than or equal to 5 cm, or
greater than or equal to 10 cm. In some embodiments, the 3D-printed
article may comprise one or more macrovoids with an average
cross-sectional diameter of less than or equal to 20 cm, less than
or equal to 10 cm, less than or equal to 5 cm, less than or equal
to 2 cm, less than or equal to 1 cm, less than or equal to 5 mm,
less than or equal to 2 mm, or less than or equal to 1 mm.
Combinations of the above-referenced ranges are also possible
(e.g., greater than or equal to 0.5 mm and less than or equal to 5
cm). Other ranges are also possible. In some embodiments, one or
more macrovoids may span the entire length of the shoe. The average
cross-sectional diameter of the macrovoids may be measured by
microscopy or other suitable techniques. In some embodiments, one
or more of the macrovoids may not have an intersecting interface.
As would be known to one of ordinary skill in the art, an
intersecting interface is a junction between a first material
formed by a first molding process and a second material formed by a
second molding process onto the first material. Intersecting
interfaces typically comprise at least one of the following
features: a lack of chemical bonds across the interface (e.g., a
lack of covalent bonds across the interface), one or more defects,
one or more characteristic markings indicating lamination (e.g.,
one or more hemispherical indentations), non-uniform density across
the interface, and/or conformations of the polymer chains at the
interface which are different than the polymer chain conformations
in the bulk material on either side of the interface. In some
cases, intersecting interfaces show a step change in one or more of
the following properties across the interface: average pore size,
density, stiffness, Shore A hardness, degree of cross-linking,
chemical composition, color, abrasion resistance, thermal
conductivity, electrical conductivity, stiffness anisotropy,
elastic modulus, flexural modulus, filler content, opacity,
conductivity, and breathability.
[0208] In some embodiments, a 3D-printed article may comprise one
or more portions that are open cell foams and of which air makes up
a significant wt %. For instance, a 3D-printed article may comprise
one or more portions that are open-cell foams and for which air
makes up greater than 5 wt % of the open-cell foam, greater than or
equal to 10 wt % of the open-cell foam, greater than or equal to 15
wt % of the open-cell foam, greater than or equal to 20 wt % of the
open-cell foam, greater than or equal to 25 wt % of the open-cell
foam, greater than or equal to 30 wt % of the open-cell foam,
greater than or equal to 35 wt % of the open-cell foam, greater
than or equal to 40 wt % of the open-cell foam, or greater than or
equal to 45 wt % of the open-cell foam. In some embodiments, a
3D-printed article may comprise one or more portions that are
open-cell foams and for which air makes up less than or equal to 50
wt % of the open-cell foam, less than or equal to 45 wt % of the
open-cell foam, less than or equal to 40 wt % of the open-cell
foam, less than or equal to 35 wt % of the open-cell foam, less
than or equal to 30 wt % of the open-cell foam, less than or equal
to 25 wt % of the open-cell foam, less than or equal to 20 wt % of
the open-cell foam, less than or equal to 15 wt % of the open-cell
foam, or less than or equal to 10 wt % of the open-cell foam.
Combinations of the above-referenced ranges are also possible
(e.g., greater than or equal to 30 wt % and less than or equal to
50 wt %). Other ranges are also possible. The wt % of air within an
open-cell foam may be determined by optical microscopy of sections
of the open cell foam followed by image analysis of the sections to
determine the volume fraction of the open-cell foam that is air.
Then, knowledge of the density of air and the density of the
non-air components of the foam may be used to determine the wt % of
the open-cell foam that is air.
[0209] In some embodiments, a 3D-printed article may comprise one
or more portions that are open-cell foams and for which air makes
up greater than 5 vol % of the open-cell foam, greater than or
equal to 10 vol % of the open-cell foam, greater than or equal to
15 vol % of the open-cell foam, greater than or equal to 20 vol %
of the open-cell foam, greater than or equal to 25 vol % of the
open-cell foam, greater than or equal to 30 vol % of the open-cell
foam, greater than or equal to 35 vol % of the open-cell foam,
greater than or equal to 40 vol % of the open-cell foam, or greater
than or equal to 45 vol % of the open-cell foam. In some
embodiments, a 3D-printed article may comprise one or more portions
that are open-cell foams and for which air makes up less than or
equal to 50 vol % of the open-cell foam, less than or equal to 45
vol % of the open-cell foam, less than or equal to 40 vol % of the
open-cell foam, less than or equal to 35 vol % of the open-cell
foam, less than or equal to 30 vol % of the open-cell foam, less
than or equal to 25 vol % of the open-cell foam, less than or equal
to 20 vol % of the open-cell foam, less than or equal to 15 vol %
of the open-cell foam, or less than or equal to 10 vol % of the
open-cell foam. Combinations of the above-referenced ranges are
also possible (e.g., greater than or equal to 30 vol % and less
than or equal to 50 vol %). Other ranges are also possible. The vol
% of air within an open-cell foam may be determined by optical
microscopy of sections of the open cell foam followed by image
analysis of the sections to determine the volume fraction of the
open-cell foam that is air.
[0210] In various aspects, a variety of 3D-printed articles such as
foams and/or elastomers as well as other products may be produced.
For example, in some embodiments, a foam may be created from a foam
precursor comprising a polymer and a cross-linking agent. The
polymer can comprise polyol with a low or high average molecular
weight such as a low number average molecular weight diol, high
number-average molecular weight diol, a low number-average
molecular weight triol, a high number-average molecular weight
triol, or a high number-average molecular weight monol. For
instance, a high molecular weight monol, diol, or triol may have a
number-average molecular weight of greater than 300, 400, or 500,
while a low molecular weight monol, diol, or triol may have a
number-average molecular weight less than 300, 400, or 500. For
instance, the monol, diol, or triol may have a number-average
molecular weight less than 500 or greater than 6000. In some
embodiments, a polyol may comprise more than three alcohol groups.
For instance, it may comprise four, five, six, seven, or more
alcohol groups. Other examples of polymers include, but are not
limited to, polyureas, polyurethane/polyurea hybrid formulations,
epoxies, acrylates, cyanate esters, silicones, polyesters,
phenolics, hydrogels, or the like.
[0211] In one set of embodiments, the polymer includes a
polyurethane, e.g., formed by reacting the polyol with an
isocyanate. The polyol may be any suitable polyhydroxy compound.
For example, the polyol may be a hydroxy-terminated ester, ether or
carbonate diol. Non-limiting examples of polyalkylene ether glycols
include polyethylene ether glycols, poly-1,2-propylene ether
glycols, polytetramethylene ether glycols,
poly-1,2-dimethylethylene ether glycols, poly-1,2-butylene ether
glycol, and polydecamethylene ether glycols. Examples of polyester
polyols include polybutylene adipate and polyethylene
terephthalate. Examples of polycarbonate diols include
polytetramethylene carbonate diol, polypentamethylene carbonate
diol, polyhexamethylene carbonate diol, polyhexane-1,6-carbonate
diol and poly(1,6-hexyl-1,2-ethyl carbonate)diol. However, many
other suitable polyhydroxy compounds can also be used depending
upon the desired application. Any suitable polyol, polythiol or
polyamine or mixture thereof that is suitable for this purpose may
be used, such as, for example, mixed diols comprising a
2,4-dialkyl-1,5-pentanediol and a 2,2-dialkyl-1,3-propanediol.
Specific examples of 2,4-dialkyl-1,5-pentanediols include
2,4-dimethyl-1,5-pentanediol, 2-ethyl-4-methyl-1,5-pentanediol,
2-methyl-4-propyl-1,5-pentanediol, 2,4-diethyl-1,5-pentanediol,
2-ethyl-4-propyl-1,5-pentanediol, 2,4-dipropyl-1,5-pentanediol,
2-isoptopyl-4-methyl-1,5-pentanediol,
2-ethyl-4-isoptopyl-1,5-pentanediol,
2,4-diisopropyl-1,5-pentanediol,
2-isopropyl-4-propyl-1,5-pentanediol, 2,4-dibutyl-1,5-pentanediol,
2,4-dipentyl-1,5-pentanediol, 2,4-dihexyl-1,5-pentanediol, and the
like. Specific examples of 2,2-dialkyl-1,3-propanediols include
2,2-dipentyl-1,3-propanediol, 2,2-dihexyl-1,3-propanediol and the
like.
[0212] In some cases, longer-chain or higher molecular weight
polyols may be used to produce relatively softer materials because
they have more polyol relative to isocyanate. In some cases, the
isocyanate can also be underindexed compared to the number of
reactive sites on the polyol to make a softer foam that behaves
less elastically.
[0213] The cross-linking agent, if present, can comprise an
isocyanate in some cases, and/or an isocyanate prepolymer. An
isocyanate may have more than one functional isocyanate group per
molecule and may be any suitable aromatic, aliphatic or
cycloaliphatic polyisocyanate. In some cases, the isocyanate is a
diisocyanate. One non-limiting example is an organic diisocyanate.
Additional examples of organic diisocyanates include
4,4'-diisocyanatodiphenylmethane, 2,4'-diisocyanatodiphenylmethane,
isophorone diisocyanate, p-phenylene diisocyanate, 2,6-toluene
diisocyanate, polyphenyl polymethylene polyisocyanate,
1,3-bis(isocyanatomethyl)cyclohexane, 1,4-diisocyanatocyclohexane,
1,6-hexamethylene diisocyanate, 1,5-naphthalene diisocyanate,
3,3'-dimethyl-4,4'-biphenyl diisocyanate,
4,4'-diisocyanatodicyclohexylmethane,
2,4'-diisocyanatodicyclohexylmethane, and 2,4-toluene diisocyanate,
or combinations thereof.
[0214] In some embodiments, the foam precursor comprises a
polyurethane, a polyurea, a polyurethane/polyurea hybrid
formulation, an epoxy, a silicone, a cyanoacrylate, an adhesive, a
cyanate ester, a polyester, a polyimide, a phenolic, or another
suitable material.
In some cases, an isocyanate prepolymer may be used, e.g., in
addition to and/or instead of an isocyanate. For instance, where
two isocyanates are added to the ends of a polyol, so it still has
functionality of two, but with a higher molecular weight.
[0215] In addition, it should be understood that a cross-linking
agent is not required. For example, in some embodiments a polymer
(such as a thermoplastic polyurethane) can be mixed with fillers
and frothed in a nozzle or a mixing chamber, then cooled upon
exiting to form a foam.
[0216] In some embodiments, no foam is produced and a crosslinked
product results. As a non-limiting example, a high number-average
molecular weight diol may be mixed with an isocyanate (e.g., a
diisocyanate, or other isocyanates described herein) and deposited
onto a substrate, e.g., to produce a thermoplastic elastomer. In
another embodiment, a low number-average molecular weight diol can
be mixed with an isocyanate and deposited onto a substrate, e.g.,
to produce a rigid thermoplastic. In yet another embodiment, a high
number-average molecular weight diol and a high number-average
molecular weight triol can be mixed, and then the polyol mixture
mixed with an isocyanate and deposited onto a substrate, e.g., to
produce a flexible thermosetting elastomer with high
resiliency.
[0217] In some embodiments, the foam precursor comprises a
polyurethane, a polyurea, a polyurethane/polyurea hybrid
formulation, an epoxy, a silicone, a cyanoacrylate, an adhesive, a
cyanate ester, a polyester, a polyimide, a phenolic, or another
suitable material. In another embodiment, the foam precursor could
comprise a decomposeable binder and particles which stabilize the
bubble interface. In some cases, the particles may be sintered at
the bubble interface to form a non-polymeric foam, e.g., a metal
foam or a ceramic foam.
[0218] As a non-limiting example of a foam, in one embodiment, a
high number-average molecular weight diol and a high number-average
molecular weight triol are mixed with a surfactant, and then the
polyol-surfactant mixture is mixed with an isocyanate. The foam
precursor that results may be mixed with nitrogen, or another gas,
and deposited onto a substrate. Mixing techniques such as those
discussed herein, e.g., involving more than one stage of mixing or
combining fluids, may be used.
[0219] As yet another non-limiting example, a high number-average
molecular weight diol and a high number-average molecular weight
monol are mixed with a surfactant, and then the polyol-surfactant
mixture is mixed with an isocyanate. Mixing techniques such as
those discussed herein, e.g., involving more than one stage of
mixing or combining fluids, may be used. The foam precursor that
results is then mixed with nitrogen, or another gas, and deposited
onto a substrate. This may be used to produce memory foam, or other
types of foam.
[0220] As still additional non-limiting examples of foams, a high
number-average molecular weight diol may be mixed with an
isocyanate and deposited onto a substrate, e.g., to produce a
thermoplastic elastomer. In another embodiment, a low
number-average molecular weight diol can be mixed with an
isocyanate and deposited onto a substrate, e.g., to produce a rigid
thermoplastic. In yet another embodiment, a high number-average
molecular weight diol and a high number-average molecular weight
triol can be mixed, and then the polyol mixture mixed with an
isocyanate and deposited onto a substrate, e.g., to produce a
flexible thermosetting elastomer with high resiliency.
[0221] As mentioned, in some embodiments, a surfactant may be used
to produce a foam or 3D-printed article as discussed herein. For
example, a surfactant may be used to facilitate the introduction of
gas into a fluid, the subsequent stability of the bubbles that are
formed, and/or the rheology of the foam can be altered or tuned
using various surfactants, or altering their concentration, etc.
For instance, in one embodiment, a surfactant may be used that
comprises a first moiety with affinity for an air-liquid interface,
e.g., to facilitate the introduction of gas into a fluid.
Non-limiting examples of such surfactants include sodium stearate,
sodium dodecyl sulfate, or silicone-based surfactants such as
silicone polyethers. Many such surfactants are widely available
commercially.
[0222] In some cases, a surfactant molecule may be used that allows
production of a high yield stress foam, e.g., a foam able to
maintain its shape after deposition on a substrate. For example, in
some embodiments, a high-yield stress inducing surfactant is one
where the end of the surfactant is more soluble in the continuous
phase of the foam precursor. The surfactant may have a relatively
high molecular weight, and may be non-ionic. Non-limiting examples
of such surfactants include surfactants with a molecular weight of
greater than or equal to 1500 Daltons. In addition, in some cases,
a surfactant molecule may be used that allows production of a low
yield stress foam, e.g., a foam unable to maintain its shape after
deposition on a substrate, and the foam may conform to the material
around it after deposition. In some embodiments, a low-yield stress
inducing surfactant is one where the soluble end may be either
charged or have a relatively low molecular weight, e.g., such that
no entanglement between the surfactants is able to occur.
Non-limiting examples of such surfactants include surfactants with
a low molecular weight (e.g., silicone surfactants with a low
molecular weight). In addition, in some embodiments, different
types of surfactants may be used, e.g., a high yield and a low
yield surfactant. By varying the relative concentration of the
first surfactant and the second surfactant in the mixture, the
resultant foam may vary from high yield stress to low or no yield
stress, depending upon the application.
[0223] In certain embodiments, the first surfactant molecule may
comprise a first moiety having an affinity for an air-liquid
interface, and a second moiety that comprises a long chain that is
soluble in the foam precursor and prone to entanglement. The second
surfactant molecule may, in some instances, comprise the same first
moiety with affinity for the air-liquid interface, and a second
moiety that comprises a short chain with an electrostatic charge.
The electrostatic charge may in some cases be such that the cells
of the closed-cell foam repel one another and can move freely past
one another.
[0224] The cell-forming agent, in some embodiments, forms cells
within a material such as a foam or froth, as discussed herein. For
instance, the cell-forming agent may comprise water, and/or a
gaseous material such as air, carbon dioxide, nitrogen, butane, or
the like. In some embodiments, the cell-forming agent comprises a
blowing agent that is added that can generate a gas, e.g.,
chemically. The microfluidic printing nozzle may disperse the
blowing agent in a material, for example a polymer, to form a
two-phase mixture of blowing agent cells within the polymer. Thus,
the blowing agent can comprise a material that decomposes into a
gas, e.g., at an elevated temperature. In some cases, the blowing
agent can comprise a gaseous material that maintains its liquid
state by cooling or pressurization, and reverts to its native gas
state when the pressure is released or the blowing agent is heated,
which may cause the blowing agent to form a gas, e.g., to cause
cells in the polymer to grow. The resultant gas may become trapped
in cells within the material, e.g., forming a foam.
[0225] As an example of use of a blowing agent, the microfluidic
printing nozzle may mix a blowing agent with a material, for
example a polymer, which may undergo a chemical reaction to cause
the formation of a gas. Chemical blowing agents may include
generally low molecular weight organic compounds that decompose to
release a gas such as nitrogen, carbon dioxide, or carbon monoxide.
Non-limiting examples of chemical blowing agents include azo
compounds such as azodicarbonamide. In some cases the blowing agent
may be activated on the surface (e.g., selectively on the surface)
to produce a rough surface finish, to impart a matte finish, and/or
to provide a soft feel to the exterior of a print.
[0226] Thus, in some cases, the blowing agent can be used to create
foams that form cells by induction by heat, removal of pressure, or
the like. For instance, a foam precursor can be mixed with the
blowing agent and deposited onto a substrate or part without
forming cells until after deposition, or with only partially formed
cells. Thus, in some cases, material may be deposited onto a
substrate, then induced to form cells by heating the material.
After deposition, cells may form within the product, e.g., by
induction by heat, removal of pressure, or the like.
[0227] As a non-limiting example, a foam may comprise an
ethylene-vinyl acetate foam, which may be utilized in footwear or
other applications. A blowing agent may be selected such that the
agent phase-transitions or decomposes into a gas at a temperature
at which the polymer containing it is soft and malleable. In some
cases, the polymer can expand (e.g., expand up to 200%) as the
cells form without rupturing, and the resultant material can be
cooled to form a solid foam.
[0228] As another example, water may be used in another embodiment
as a cell-forming agent. For example, a water-blown foam may be
produced where water and a surfactant are mixed into a polymer
component, which is then mixed with isocyanate or another substance
able to react with water, e.g., to produce a gas. For instance, as
a non-limiting example, isocyanate chemically reacts with both
water and polyol; the reaction of polyols with isocyanate may be
used to increase the molecular weight of the polymer, e.g., to form
a polyurethane, while the reaction of water with the isocyanate
forms carbon dioxide gas. The carbon dioxide gas becomes trapped in
the polymer as it solidifies, and a foam is thus created. In some
cases, the amount of water may be controlled to control the
properties of the resulting foam, such as density or cell size,
e.g., during the reaction process.
[0229] In addition, in some embodiments, a material may be
deposited onto a substrate, e.g., to fill a mold, then the mold may
be sealed and the blowing agent induced to form a foam, which may
then start to fill in the mold as the foam expands.
[0230] In some embodiments, a 3D-printed article described herein
comprises one or more additives. These additives can comprise
particles, hollow glass spheres, polymer spheres, a pigment, a
metal, a filler such as a thermally conductive filler, a filler
having a relative dielectric constant of at least 5, an ultraviolet
stabilizer, a filler concentrate, or another suitable additive.
Additional examples of additives include surfactants (e.g.,
silicone surfactants), catalysts, nucleation promotors, fillers for
better abrasion resistance, chemical foaming agents, etc.
Combinations of these and/or other additives are also possible. As
a non-limiting example, a 3D printed closed-cell foam may be
produced that incorporates particulate additives comprising a
cellular network of cell walls separating empty cells, where the
cell walls comprise a polymer composite including filler particles
dispersed in a polymer matrix.
[0231] As a non-limiting example, hollow glass spheres and/or
polymer spheres may be incorporated into polyurethanes or other
polymers as discussed herein to reduce density, increase stiffness,
reduce dielectric constant, provide more nucleation sites for
bubble formation, or the like. For instance, hollow spheres may be
used to decrease weight. Hollow glass spheres can be varied, e.g.,
spatially, in order to change the properties of the product.
[0232] As described above, in certain embodiments a 3D-printed
article (e.g., a 3D-printed articles that is a foam such as a
closed-cell foam, a 3D-printed article that is not a foam, a
3D-printed article that comprises an elastomer) may comprise at
least a first portion and a second portion that interpenetrate. In
some embodiments, the first portion may form a skeleton-like
structure that spans the second portion. For example, a 3D-printed
article may comprise a first portion with a skeleton-like structure
that is stiffer than a second portion in which it is embedded. This
may be achieved in some cases by varying the stiffness of the
material being extruded from a nozzle during a 3D-printing
process.
[0233] In one aspect, a foam may be printed (e.g., via 3D-printing)
into a structure defining a plurality of cells, i.e., into a
foam-like structure. Thus, a foam may be printed as part of a
larger foam-like structure, e.g., where the walls of the foam-like
structure (e.g., defining cells of the foam-like structure
themselves are foams having cells. The foam-like structure may have
open cells, closed cells, or any combination of open and closed
cells, independently of the structure of the foam itself forming
the foam-like structure.
[0234] In some embodiments, one or more portions of a 3D-printed
article as described herein (e.g., a 3D-printed articles that is a
foam such as a closed-cell foam, a 3D-printed article that is not a
foam, a 3D-printed article that comprises an elastomer) may be
responsive to one or more stimuli. For example, the 3D-printed
article may comprise a portion that changes shape after printing,
such as a portion that is flat directly after printing but curves
upwards upon removal from the substrate (e.g., a mold). As another
example, the 3D-printed article may comprise a portion that can
respond to temperature, such as a portion that can decrease
ventilation of the article upon exposure to cold temperatures.
[0235] In some embodiments, one or more portions of a 3D-printed
article as described herein (e.g., a 3D-printed articles that is a
foam such as a closed-cell foam, a 3D-printed article that is not a
foam, a 3D-printed article that comprises an elastomer) may
comprise one or more cooling channels and/or may comprise one or
more ventilation channels.
[0236] As described above, certain embodiments relate to methods
for 3D printing a mixture onto a substrate. The substrate may be
any suitable target for a material exiting a nozzle. In some cases,
the substrate is planar, although in other cases, the substrate is
non-planar (e.g., curved). For instance, the substrate may be a
mold (e.g., the mold of a shoe), to which a material may be
introduced. In some cases, the material may be relatively fluid and
able to conform to contours within the substrate (e.g., if the
substrate is a mold). In some such embodiments, the substrate may
have one or more morphological features that are desirable for an
external surface of the 3D-printed article (e.g., a desirable
surface texture, a desirable curvature). However, in other cases,
the material may be relatively solid, e.g., having a defined shape,
upon deposition onto the substrate, such as is discussed
herein.
[0237] In some cases, the substrate may also be heated or cooled,
e.g., to promote or inhibit a reaction, to cause solidification to
occur, or the like. In some cases, the temperature may be altered
by at least 5.degree. C., at least 10.degree. C., or by other
ranges such as those discussed herein. Any method may be used to
heat or cool the substrate. For example, heat or cooling sources
may be used to apply heat or cooling to the substrate, the
substrate may be contained within a heated or cooled environment,
or a source of a heated or cooled fluid may be used to heat or cool
the substrate, e.g., via a heat exchanger). In one embodiment,
radiant light or infrared radiation may be applied to the substrate
for heating.
[0238] In some embodiments, heat may be applied to a substrate
(e.g., a mold) after printing in order to cause expansion of the
printed material. Expansion may include either or both of thermal
expansion and expansion due to foam formation. In some embodiments,
heating the substrate may cause expansion of printed material into
previously unfilled portions of the substrate.
[0239] In one set of embodiments, the nozzle and/or the mixing
chamber may be heated or cooled. In some cases, the temperature of
mixing may be controlled, for instance, to allow for uniform
mixing, to facilitate reaction of fluids therein (e.g., to an
optimum or desired temperature), to remove excess heat (e.g.,
contributed by a chemical reaction, the spinning of an impeller,
etc.), or the like. Various methods can be used to add heat or
remove heat from the nozzle or the mixing chamber. For example, a
heat source may be positioned to deliver heat to the nozzle or
mixing chamber, or to one or more fluids entering therein. Examples
of heat sources include electrically resistive heaters, infrared
light sources, or heating fluids (e.g., which can transmit heat
using a heat exchanger or the like). In some cases, more than one
heat source may be used. Similarly, a variety of cooling sources
can be used in some embodiments to remove heat from the nozzle or
mixing chamber. Non-limiting examples include Peltier coolers or
cooling fluids (e.g., which can remove heat using a heat exchanger
or the like).
[0240] Heating and/or cooling may, for example, be used to control
mixing and/or reaction within the material, to keep the temperature
at substantially the temperature of the surrounding environment
(e.g., at room temperature), to prevent the surrounding
environmental conditions and/or the heat generated by friction of
the impeller and exotherm of the material curing from affecting the
reaction or the printing parameters, or the like. In some cases,
the temperature may be altered by at least 5.degree. C., at least
10.degree. C., at least 15.degree. C., at least 20.degree. C., at
least 30.degree. C., at least 40.degree. C., at least 50.degree.
C., at least 60.degree. C., or by other ranges such as those
discussed herein. In other embodiments, however, the temperature
may be controlled or altered by no more than 20.degree. C., no more
than 15.degree. C., no more than 10.degree. C., no more than
5.degree. C., etc. relative to the incoming fluids or the
surrounding environmental conditions.
[0241] In addition, in some embodiments, one or more sensors may be
present, e.g., within the nozzle or mixing chamber, within an
outlet, within the substrate, or within sensing communication of
the nozzle, mixing chamber, outlet, and/or substrate. Such sensors
may be used to determine a property of the incoming fluids, the
mixing process, and/or the exiting material, e.g., qualitatively
and/or quantitatively. In some cases, such information may be used
to control the process, e.g., by controlling the flow of fluid into
the nozzle or mixing chamber, the mixing speed (e.g., of an
impeller), the flow exiting an outlet, the opening and closing of a
valve at the outlet, or the like. Non-limiting examples include
temperature sensors (e.g., thermocouples, infrared cameras, or the
like), pressure transducers, photodiodes, colorimetric sensors,
flow meters, etc. In addition, more than one sensor can be used in
some cases.
[0242] 3D-printed articles for use in footwear may be suitable for
use in any type of footwear. Non-limiting examples of footwear
include athletic footwear, shoes, sneakers, tennis shoes,
basketball shoes, sandals, shoes appropriate for work, boots,
booties, footwear comprising a heel of at least one inch, footwear
lacking a heel or comprising a heel of less than one inch, boots,
booties, basketball shoes, hiking boots, dress shoes, orthotics,
bunion orthotics, ski boots and ski boots. Footwear comprising a
3D-printed article as described herein may be appropriate for men,
women, and/or children.
[0243] The following examples are intended to illustrate certain
embodiments of the present invention, but do not exemplify the full
scope of the invention.
Example 1
[0244] Various 3D-printed articles were fabricated, and are shown
in FIGS. 18-21. FIG. 18 shows a partially enclosed open cell foam,
which is surrounded by a layer of continuous material on each of
its sides except for its top. FIG. 19 shows a shoe insole printed
with 50% infill density on the inside. The articles shown in FIGS.
18-19 were formed from two part polyurethane elastomers. FIGS. 20
and 21 show a 3D-printed article comprising a midsole and an
outsole printed in one continuous process from the same mixing
nozzle. The outsole comprises a rigid two part polyurethane, and
the midsole comprises a two part waterblown polyurethane foam.
Example 2
[0245] A prophetic non-limiting example for printing a shoe into a
mold is described below. It should be understood that certain steps
listed below may be optional even if not listed as such, and that
certain inventive methods may further comprise additional steps
that are not listed.
The following steps may be followed to print a shoe into a mold: 1.
Choose an external shoe sole shape based on shoe size and style 2.
Select a mold (e.g., a premade mold) made of, e.g., metal or
plastic. The mold may have shape and/or alignment features that to
aid positioning of a gantry system relative to it. 3. Place the
mold on a printer attached to a kinematic coupling or fixture. 4.
Prepare machine commands to make the shoe (e.g., machine commands
in Gcode) 5. Upload the machine commands to a machine. The code may
cause translation of a nozzle in the x-, y-, and/or z-direction. In
some cases, the code may cause the nozzle to conformally trace the
shape of the mold. 6. Optionally print a color image onto the
inside of the mould using an inkjet process, a transfer film
process, or a different process. This image may then be picked up
by and cured into the materials printed into the mold above the
color image. The ink may be pigment coupled to a polyurethane
and/or a latent curing agent such as a blocked isocyanate. 7.
Conformally print an outsole material into the bottom and sides of
the mold. This will be the most exterior portion of the shoe, and
will be in direct contact with the ground. The material set used
for this may be a polyester polyurethane elastomer with no
porosity, a high density polyester polyurethane foam. Non-limiting
examples of other options include thermoplastic polyurethanes, or
vulcanized natural rubbers. 8. Print a material with high
resilience that is stiff yet flexible conformally onto the mold to
create one or more features that will be externally visible to the
shoe sole. These features may be printed into an arch area of the
mold. 9. Print a polyurethane foam into the mold in one or more
locations. The foam density, foam rheology, foam expansion after
deposition, and foam mechanical properties can be tuned spatially
by varying the inputs and impeller parameters of the mixing nozzle
as the foam is deposited. The printed structure could be a solid
foam, or could have a lattice like architecture where the foam
filaments have a macroscopic porous structure, but each filament
also has a microscopic porous structure. 10. Print additional rigid
and/or flexible materials onto the foam structure to give advanced
customized structure and bending properties to the shoe. 11.
Optionally, print more foam. 12. After all of the foam has been
deposited, cap the mold, raise the temperature of the mold, and
drive the foam to expand more. This process may push material
firmly against the sides of the mold, may enhance the surface
quality of the article, and/or may enhance the resolution of mold
features. 13. Remove the top from mold and allow the mold to cool.
14. Print additional materials on top of the piece of the shoe sole
that has conformed to the shape of the top of the mold. This
process may enable customization of the contour of the sole that
comes into direct contact with the foot. Printing the additional
materials may comprise printing through a mixing nozzle. In some
embodiments, the additional materials may rapidly solidify after
extrusion. 15. Optionally, inkjet print a lower viscosity material.
The lower viscosity material may bond well to the top of the sole
and/or may enhance the smoothness of the sole. 16. Deposit an
adhesive onto the printed surface 17. Translate a shoe upper
attached to shoe last, and stamp it into the shoe sole and mold.
Continue to apply pressure until the adhesive is fully bonded. 18.
Use the upper on shoe last to demold the shoe. 19. Transfer the
shoe to a 4th rotational axis, or have a stamping mechanism and
last already be attached to 4th axis. 20. Scan the shoe using a
3D-scanning system. 21. Print specified patterns conformally on the
upper and/or on parts of the shoe sole. 22. Print or fabricate shoe
insole insert separately, and place it into the shoe.
[0246] While several embodiments of the present invention have been
described and illustrated herein, those of ordinary skill in the
art will readily envision a variety of other means and/or
structures for performing the functions and/or obtaining the
results and/or one or more of the advantages described herein, and
each of such variations and/or modifications is deemed to be within
the scope of the present invention. More generally, those skilled
in the art will readily appreciate that all parameters, dimensions,
materials, and configurations described herein are meant to be
exemplary and that the actual parameters, dimensions, materials,
and/or configurations will depend upon the specific application or
applications for which the teachings of the present invention
is/are used. Those skilled in the art will recognize, or be able to
ascertain using no more than routine experimentation, many
equivalents to the specific embodiments of the invention described
herein. It is, therefore, to be understood that the foregoing
embodiments are presented by way of example only and that, within
the scope of the appended claims and equivalents thereto, the
invention may be practiced otherwise than as specifically described
and claimed. The present invention is directed to each individual
feature, system, article, material, kit, and/or method described
herein. In addition, any combination of two or more such features,
systems, articles, materials, kits, and/or methods, if such
features, systems, articles, materials, kits, and/or methods are
not mutually inconsistent, is included within the scope of the
present invention.
[0247] In cases where the present specification and a document
incorporated by reference include conflicting and/or inconsistent
disclosure, the present specification shall control. If two or more
documents incorporated by reference include conflicting and/or
inconsistent disclosure with respect to each other, then the
document having the later effective date shall control.
[0248] All definitions, as defined and used herein, should be
understood to control over dictionary definitions, definitions in
documents incorporated by reference, and/or ordinary meanings of
the defined terms.
[0249] The indefinite articles "a" and "an," as used herein in the
specification and in the claims, unless clearly indicated to the
contrary, should be understood to mean "at least one."
[0250] The phrase "and/or," as used herein in the specification and
in the claims, should be understood to mean "either or both" of the
elements so conjoined, i.e., elements that are conjunctively
present in some cases and disjunctively present in other cases.
Multiple elements listed with "and/or" should be construed in the
same fashion, i.e., "one or more" of the elements so conjoined.
Other elements may optionally be present other than the elements
specifically identified by the "and/or" clause, whether related or
unrelated to those elements specifically identified. Thus, as a
non-limiting example, a reference to "A and/or B", when used in
conjunction with open-ended language such as "comprising" can
refer, in one embodiment, to A only (optionally including elements
other than B); in another embodiment, to B only (optionally
including elements other than A); in yet another embodiment, to
both A and B (optionally including other elements); etc.
[0251] As used herein in the specification and in the claims, "or"
should be understood to have the same meaning as "and/or" as
defined above. For example, when separating items in a list, "or"
or "and/or" shall be interpreted as being inclusive, i.e., the
inclusion of at least one, but also including more than one, of a
number or list of elements, and, optionally, additional unlisted
items. Only terms clearly indicated to the contrary, such as "only
one of" or "exactly one of," or, when used in the claims,
"consisting of," will refer to the inclusion of exactly one element
of a number or list of elements. In general, the term "or" as used
herein shall only be interpreted as indicating exclusive
alternatives (i.e. "one or the other but not both") when preceded
by terms of exclusivity, such as "either," "one of," "only one of,"
or "exactly one of."
[0252] As used herein in the specification and in the claims, the
phrase "at least one," in reference to a list of one or more
elements, should be understood to mean at least one element
selected from any one or more of the elements in the list of
elements, but not necessarily including at least one of each and
every element specifically listed within the list of elements and
not excluding any combinations of elements in the list of elements.
This definition also allows that elements may optionally be present
other than the elements specifically identified within the list of
elements to which the phrase "at least one" refers, whether related
or unrelated to those elements specifically identified. Thus, as a
non-limiting example, "at least one of A and B" (or, equivalently,
"at least one of A or B," or, equivalently "at least one of A
and/or B") can refer, in one embodiment, to at least one,
optionally including more than one, A, with no B present (and
optionally including elements other than B); in another embodiment,
to at least one, optionally including more than one, B, with no A
present (and optionally including elements other than A); in yet
another embodiment, to at least one, optionally including more than
one, A, and at least one, optionally including more than one, B
(and optionally including other elements); etc.
[0253] When the word "about" is used herein in reference to a
number, it should be understood that still another embodiment of
the invention includes that number not modified by the presence of
the word "about."
[0254] It should also be understood that, unless clearly indicated
to the contrary, in any methods claimed herein that include more
than one step or act, the order of the steps or acts of the method
is not necessarily limited to the order in which the steps or acts
of the method are recited.
[0255] In the claims, as well as in the specification above, all
transitional phrases such as "comprising," "including," "carrying,"
"having," "containing," "involving," "holding," "composed of," and
the like are to be understood to be open-ended, i.e., to mean
including but not limited to. Only the transitional phrases
"consisting of" and "consisting essentially of" shall be closed or
semi-closed transitional phrases, respectively, as set forth in the
United States Patent Office Manual of Patent Examining Procedures,
Section 2111.03.
* * * * *