具体实施方式：
[0033]In one aspect, a method of printing onto a base includes receiving the base and dispensing a yarn from a nozzle of a printing system. The base has an upper surface spaced from a lower surface by a base thickness. The upper surface includes a plurality of attachment regions for bonding a yarn to the base. The plurality of attachment regions includes a first attachment region. The yarn includes a heat moldable material and a melt-resistant material. The step of dispensing the yarn includes dispensing the heat moldable material in a liquid state. The step of dispensing the yarn includes dispensing the melt-resistant material in a solid state. The upper surface includes a plurality of attachment regions for bonding the yarn to the base. The method includes selectively attaching the yarn to an attachment region of the plurality of attachment regions by moving the nozzle along a first axis into the attachment region. The first axis is approximately normal to the upper surface. The step of moving the nozzle along the first axis into the first attachment region reduces the base thickness by a prodding distance. The heat moldable material bonds to the first attachment region during a transition of the heat moldable material from the liquid state to a solid state.
[0034]In another aspect, a method of printing onto a base includes positioning a nozzle of a printing system above an upper surface of the base and dispensing a yarn from the nozzle. The upper surface includes at least a first attachment region and a second attachment region for bonding the yarn to the base. The yarn includes a heat-moldable material and a melt-resistant material. The step of dispensing the yarn includes dispensing the heat-moldable material of the yarn in a liquid state. The step of dispensing the yarn includes dispensing the melt-resistant material of the yarn in a solid state. The method further includes selectively attaching the yarn to a first attachment region of the plurality of attachment regions by lowering the nozzle into direct contact with the first attachment region, thereby placing the yarn into direct contact with the first attachment region. The step of lowering the nozzle into direct contact with the first attachment region includes a transition of a first portion of the heat-moldable material of the yarn from the liquid state to a solid state. The first portion of the heat-moldable material bonds to the first attachment region during the transition of the first portion of the heat-moldable material. The method further includes selectively attaching the yarn to the second attachment region by moving the nozzle toward the second attachment region and by moving the nozzle into direct contact with the second attachment region, thereby placing the yarn into direct contact with the second attachment region. The step of moving the nozzle into direct contact with the second attachment region includes a transition of a second portion of the heat-moldable material of the yarn from the liquid state to a solid state. The second portion of the heat-moldable material bonds to the second attachment region during the transition of the second portion of the heat-moldable material.
[0035]In another aspect, a system for printing onto a base includes yarn, a heating system, nozzle assembly, and an actuating system. The yarn includes a heat-moldable material and a melt-resistant material. The heating system is configured to heat the yarn. The heating system heats the yarn such that the heat-moldable material is in a liquid state, and the melt-resistant material is in a solid state. The nozzle assembly is configured to dispense the yarn onto the base. The base has an upper surface and a lower surface. The nozzle assembly dispenses the heat-moldable material of the yarn in the liquid state and the melt-resistant material of the yarn in the solid state. The actuating system is configured to lower the nozzle assembly into direct contact with a first attachment region of the upper surface. The actuating system is also configured to raise the nozzle assembly away from the first attachment region of the upper surface. The actuating system is further configured to move the nozzle assembly along the upper surface of the base. A first portion of the heat-moldable material of the yarn is configured to transition from the liquid state to a solid state while in direct contact with the first attachment region. The first portion of the heat-moldable material bonds to the first attachment region during the transition of the first portion of the heat-moldable material. The melt-resistant material of the yarn is configured to remain as a continuous segment extending from the nozzle assembly to the first attachment region during the transition of the first portion of the heat-moldable material from the liquid state to the solid state.
[0036]Other systems, methods, features, and advantages of the embodiments will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description and this summary, be within the scope of the embodiments, and be protected by the following claims.
[0037]FIG. 1 is a schematic view of an embodiment of three-dimensional printing system 100, also referred to simply as printing system 100 hereafter. FIG. 1 also illustrates several exemplary articles 130 that may be used with printing system 100. Referring to FIG. 1, printing system 100 may further include printing device 102, computing system 104, and network 106.
[0038]Embodiments may use various kinds of three-dimensional printing (or additive manufacturing) techniques. Three-dimensional printing, or “3D printing,” includes various technologies that are used to form three-dimensional objects by depositing successive layers of material on top of one another. Exemplary 3D printing technologies that could be used include, but are not limited to, fused filament fabrication (FFF), electron beam freeform fabrication (EBF), direct metal laser sintering (DMLS), electron beam melting (EMB), selective laser melting (SLM), selective heat sintering (SHS), selective laser sintering (SLS), plaster-based 3D printing (PP), laminated object manufacturing (LOM), stereolithography (SLA), digital light processing (DLP) as well as various other kinds of 3D printing or additive manufacturing technologies known in the art.
[0039]In the embodiments shown in the figures, printing system 100 may be associated with fused filament fabrication (FFF), also referred to as fused deposition modeling. In the embodiment shown in FIG. 1, printing device 102 of printing system 100 uses fused filament fabrication to produce three-dimensional parts. An example of a printing device using fused filament fabrication (FFF) is disclosed in Crump, U.S. Pat. No. 5,121,329, filed Oct. 30, 1989 and titled “Apparatus and Method for Creating Three-Dimensional Objects,” which application is hereby incorporated by reference and referred to hereafter as the “3D Objects” application. Embodiments of the present disclosure can make use of any of the systems, components, devices, and methods disclosed in the 3D Objects application.
[0040]Printing device 102 may include housing 110 that supports various systems, devices, components, or other provisions that facilitate the three-dimensional printing of objects. Although the exemplary embodiment depicts a particular rectangular box-like geometry for housing 110, other embodiments could use any housing having any geometry and/or design. The shape and size of the housing of a printing device could be varied according to factors including a desired footprint for the device, the size and shape of parts that may be formed within the printing device as well as possibly other factors. It will be understood that the housing of a printing device could be open or closed. For example, a printing device could be open to provide a frame with large openings. In another example, a printing device could be closed with glass or panels of solid material and a door.
[0041]In some embodiments, printing device 102 may include provisions to retain or hold a printed object (or a component supporting the printed object). In some embodiments, printing device 102 may include a table, platform, tray, or similar component to support, retain, and/or hold a printed object or an object onto which printed material is being applied. In the embodiment of FIG. 1, printing device 102 includes tray 112. In some embodiments, tray 112 may be fixed in place. In other embodiments, however, tray 112 could move. For example, in some cases, tray 112 may be configured to translate within housing 110 in one or more horizontal directions (e.g., directions along a horizontal axis), as well as in one or more vertical directions (e.g., directions along a vertical axis). As used herein, a horizontal axis may refer to an axis extending front to back and/or left to right with respect to housing 110. As used herein, a vertical axis may refer to an axis extending up and down within housing 110. Moreover, in some cases, tray 112 may be configured to rotate and/or tilt about one or more axes associated with tray 112. Thus, it is contemplated that in at least some embodiments, tray 112 may be moved into any desired relative configuration with a nozzle or print head of printing device 102.
[0042]In some embodiments, printing device 102 may include one or more systems, devices, assemblies, or components for delivering a printed material (or printed substance) to a target location. Target locations could include the surface of tray 112, a surface or portion of a partially printed structure, and/or a surface or portion of a non-printed structure or component. Provisions for delivering printed materials include, for example, print heads and nozzles. In the embodiment of FIG. 1, printing device 102 includes nozzle assembly 116.
[0043]Nozzle assembly 116 may include one or more nozzles that deliver a printed material to a target location. For purposes of clarity, the exemplary embodiment of FIG. 1 depicts a single nozzle 118 of nozzle assembly 116. However, in other embodiments, nozzle assembly 116 could be configured with any number of nozzles, which could be arranged in an array or any particular configuration. In embodiments including two or more nozzles, the nozzles could be configured to move together and/or independently. For example, in an embodiment of a printing system discussed below, a printing device could be configured with at least two nozzles that can move in an independent manner from one another.
[0044]Nozzle 118 may be configured with nozzle aperture 119 that can be opened and/or closed to control the flow of material exiting from nozzle 118. Specifically, nozzle aperture 119 may be in fluid communication with nozzle channel 121 that receives a supply of material from a material source (not shown) within printing device 102. For example, the supply of material may be a yarn structure composition. In other examples, the supply of material is a heat-moldable material. In at least some embodiments, a filament of material is provided as a coil, which may then be unwound and fed through nozzle 118 to be deposited at a target location. In some embodiments, a worm-drive may be used to push the filament into nozzle 118 at a specific rate (which may be varied to achieve a desired volumetric flow rate of material from nozzle 118). In other embodiments, a worm-drive is omitted. For example, in another embodiment, the material is pulled from the nozzle using an actuating system. It will be understood that in some cases, the supply of material could be provided at a location near nozzle 118, while in other embodiments the supply of material could be located at some other location of printing device 102 and fed via tubes, conduits, or other provisions, to nozzle assembly 116. For example, the supply of material could be in a portion of nozzle assembly 116.
[0045]In some embodiments, nozzle assembly 116 is associated with actuating system 114. Actuating system 114 may include various components, devices, and systems that facilitate the motion of nozzle assembly 116 within housing 110. In particular, actuating system 114 may include provisions to move nozzle assembly 116 in any horizontal direction and/or vertical direction to facilitate depositing a material so as to form a three-dimensional object. To this end, embodiments of actuating system 114 may include one or more tracks, rails, and/or similar provisions to hold nozzle assembly 116 at various positions and/or orientations within housing 110. Embodiments may also include any kinds of motors, such as a stepper motor or a servo motor, to move nozzle assembly 116 along a track or rail, and/or to move one or more tracks or rails relative to one another.
[0046]The printing system may move the nozzle in various directions and/or along one or more axes. In at least some embodiments, actuating system 114 may provide movement for nozzle assembly 116 in any of an x-axis, a y-axis, and a z-axis defined with respect to printing device 102. For example, the x-axis, the y-axis, and the z-axis defined with respect to printing device 102 may be a Cartesian coordinate system. In one embodiment, the printing system may be configured to move nozzle 118 in one or two directions along a first axis. For example, printing system 100 may include actuating system 114 configured to move nozzle 118 in one or two directions along first axis 160. In certain embodiments, the first axis is approximately normal to the upper surface and/or normal to the base. As used herein, an axis is approximately normal to a surface when it is within 10 degrees from perpendicular to the surface. For example, as shown, first axis 160 is normal to upper surface 148 and base 144. In some embodiments, the printing system may be configured to move the nozzle in one or two directions along a second axis. For example, printing system 100 may include actuating system 114 configured to move nozzle 118 in one or two directions along second axis 162. In certain embodiments, the second axis is approximately parallel to the upper surface and/or approximately parallel to the base. As used herein, an axis is approximately parallel to a surface when it is within 10 degrees from parallel to the surface. For example, as shown, second axis 162 is parallel to upper surface 148 and base 144. In some embodiments, the second axis is approximately perpendicular to the first axis. For example, as shown, second axis 162 is approximately perpendicular to first axis 160. Similarly, in various embodiments, the printing system may be configured to move the nozzle in one or two directions along a third axis. For example, printing system 100 may include actuating system 114 configured to move nozzle 118 in one or two directions along third axis 164. In certain embodiments, the third axis is parallel to the upper surface and/or parallel to the base. For example, third axis 164 may be parallel to upper surface 148 and base 144. In some embodiments, the third axis is perpendicular to the first axis and/or the third axis is perpendicular to the second axis. For example, third axis 164 may be perpendicular to first axis 160. In another example, third axis 164 may be perpendicular to second axis 162.
[0047]In certain embodiments, the printing system selectively moves the nozzle. In one embodiment, the printing system simultaneously moves the nozzle along three axes. For example, the printing system may move nozzle 118 along first axis 160 away from base 144 while simultaneously moving nozzle 118 along second axis 162 and/or along third axis 164. In other embodiments, a position along an axis is maintained while the printing system selectively moves the nozzle along another axis. In certain embodiments, the printing system may move the nozzle along the first axis toward or away from a base while simultaneously maintaining a base position of the nozzle along the second axis and along the third axis. For example, printing system 100 may move nozzle 118 along first axis 160 away from base 144 while simultaneously maintaining a base position of nozzle 118 along second axis 162 and along third axis 164 (see FIGS. 8-10 and 14-16). In some embodiments, the printing system may maintain a predetermined distance from the nozzle to the upper surface while simultaneously moving the nozzle parallel to the upper surface. For example, printing system 100 may maintain a predetermined distance between nozzle 118 and upper surface 148 along first axis 160 while simultaneously moving nozzle 118 along second axis 162 and/or along third axis 164.
[0048]It will be understood that for purposes of illustration, the components, devices, and systems of printing device 102 are shown schematically in FIG. 1. It will, therefore, be appreciated that embodiments may include additional provisions not shown, including specific parts, components, and devices that facilitate the operation of actuating system 114 and nozzle assembly 116. For example, actuating system 114 is shown schematically as including several tracks or rails, but the particular configuration and number of parts including actuating system 114 may vary from one embodiment to another.
[0049]In different embodiments, printing device 102 may use a variety of different materials for forming 3D parts, including, but not limited to, thermoplastics, high-density polyethylene, eutectic metals, rubber, clays (including metal clays), Room Temperature Vulcanizing silicone (RTV silicone), porcelain, as well as possibly other kinds of materials known in the art. As used herein, thermoplastics may include polyactic acid and acrylonitrile butadiene styrene. In embodiments where two or more different printed or dispensed materials are used to form a part, any two or more of the materials disclosed above could be used. In some embodiments, printing device 102 may use a yarn composition having one or more features described in Sterman et al., U.S. Patent Publication Number 2016-0053410 published on Feb. 25, 2016, titled “Thread Structure Composition and Method of Making,” (now U.S. patent application Ser. No. 14/466,319, filed on Aug. 22, 2014), which is hereby incorporated by reference.
[0050]As discussed above, printing system 100 can include provisions to control and/or receive information from printing device 102. These provisions can include computing system 104 and network 106. Generally, the term “computing system” refers to the computing resources of a single computer, a portion of the computing resources of a single computer, and/or two or more computers in communication with one another. Any of these resources can be operated by one or more human users. In some embodiments, computing system 104 may include one or more servers. In some cases, a print server may be primarily responsible for controlling and/or communicating with printing device 102, while a separate computer may facilitate interactions with a user. As used herein, separate computer may refer to desktop, laptop, or tablet. Computing system 104 can also include one or more storage devices including, but not limited to, magnetic, optical, magneto-optical, and/or memory, including volatile memory and non-volatile memory.
[0051]In the exemplary embodiment of FIG. 1, computing system 104 may include central processing device 185, viewing interface 186, input devices 187, and software for designing a computer-aided design (“CAD”) representation 189 of a printed structure. As used herein, viewing interface 186 may include a monitor or screen. As used herein, input devices 187 may include a keyboard and mouse. In at least some embodiments, the CAD representation 189 of a printed structure may include not only information about the geometry of the structure but also information related to the materials required to print various portions of the structure.
[0052]In some embodiments, computing system 104 may be in direct contact with printing device 102 via network 106. Network 106 may include any wired or wireless provisions that facilitate the exchange of information between computing system 104 and printing device 102. In some embodiments, network 106 may further include various components such as network interface controllers, repeaters, hubs, bridges, switches, routers, modems, and firewalls. In some cases, network 106 may be a wireless network that facilitates wireless communication between two or more systems, devices, and/or components of printing system 100. Examples of wireless networks include, but are not limited to, wireless personal area networks (including, for example, Bluetooth), wireless local area networks (including networks utilizing the IEEE 802.11 WLAN standards), wireless mesh networks, mobile device networks as well as other kinds of wireless networks. In other cases, network 106 could be a wired network including networks whose signals are facilitated by twister pair wires, coaxial cables, and optical fibers. In still other cases, a combination of wired and wireless networks and/or connections could be used.
[0053]In some embodiments, printed structures may be printed directly to one or more articles. The term “articles” is intended to include both articles of footwear and articles of apparel. As used throughout this disclosure, the terms “article of footwear” and “footwear” include any footwear and any materials associated with footwear, including an upper, and may also be applied to a variety of athletic footwear types, including baseball shoes, basketball shoes, cross-training shoes, cycling shoes, football shoes, tennis shoes, soccer shoes, and hiking boots, for example. As used throughout this disclosure, the terms “article of footwear” and “footwear” also include footwear types that are generally considered to be nonathletic, formal, or decorative, including dress shoes, loafers, sandals, slippers, boat shoes, and work boots.
[0054]While the disclosed embodiments are described in the context of footwear, the disclosed embodiments may further be equally applied to any article of clothing, apparel, or equipment that includes 3D printing. For example, the disclosed embodiments may be applied to hats, caps, shirts, jerseys, jackets, socks, shorts, pants, undergarments, athletic support garments, gloves, wrist/arm bands, sleeves, headbands, any knit material, any woven material, any nonwoven material, sports equipment, and the like. Thus, as used throughout this disclosure, the term “article of apparel” may refer to any apparel or clothing, including any article of footwear, as well as hats, caps, shirts, jerseys, jackets, socks, shorts, pants, undergarments, athletic support garments, gloves, wrist/arm bands, sleeves, headbands, any knit material, any woven material, any nonwoven material, and the like.
[0055]In an exemplary embodiment, printing device 102 may be configured to print one or more structures directly onto a portion of one of exemplary articles 130. Exemplary articles 130 include exemplary articles that may receive a printed structure directly from printing device 102, including article of footwear 132, which has a three-dimensional configuration, as well as upper 134, which has a flattened configuration. Exemplary articles 130 also include t-shirt 136. Thus, it will be understood that printing device 102 may be used to apply printed material to articles in three-dimensional configurations and/or flattened configurations.
[0056]In order to apply printed materials directly to one or more articles, printing device 102 may be capable of printing onto the surfaces of various kinds of materials. Specifically, in some cases, printing device 102 may be capable of printing onto the surfaces of various materials such as textile, natural fabric, synthetic fabric, knit, woven material, nonwoven material, mesh, leather, synthetic leather, polymer, rubber, and foam, or any combination of them, without the need for a release layer interposed between a substrate and the bottom of the printed material, and without the need for a perfectly or near-perfectly flat substrate surface on which to print. For example, the disclosed methods may include printing a resin, acrylic, thermoplastic material, or ink material onto a fabric, for example a knit material, where the material is adhered/bonded to the fabric and where the material does not generally delaminate when flexed, rolled, worked, or subject to additional assembly processes/steps. As used throughout this disclosure, the term “fabric” may be used to refer generally to materials chosen from any textile, natural fabric, synthetic fabric, knit, woven material, nonwoven material, mesh, leather, synthetic leather, polymers, rubbers, and foam.
[0057]Although some embodiments may use printing device 102 to print structures directly onto the surface of a material, other embodiments may include steps of printing a structure onto a tray or release paper, and then joining the printed structure to an article in a separate step. In other words, in at least some embodiments, printed structures need not be printed directly to the surface of an article.
[0058]Printing system 100 may be operated as follows to provide one or more structures that have been formed using a 3D printing, or additive, process. Computing system 104 may be used to design a structure. This may be accomplished using some type of CAD software, or other kind of software. The design may then be transformed into information that can be interpreted by printing device 102 (or a related print server in communication with printing device 102). In some cases, the design may be converted to a 3D printable file, such as a stereolithography file (STL file).
[0059]Before printing, an article may be placed onto tray 112. Once the printing process is initiated (by a user, for example), printing device 102 may begin depositing material onto the article. This may be accomplished by moving nozzle 118 (using actuating system 114) to build up layers of a structure using deposited material. In embodiments where fused filament fabrication is used, material dispensed from nozzle 118 may be heated so as to increase the pliability of the heat-moldable material as it is deposited.
[0060]Although some of the embodiments shown in the figures depict a system using filament fused fabrication printing technologies, it will be understood that still other embodiments could incorporate one or more different 3D printing technologies. For example, printing system 100 may use a tack and drag printing method. Moreover, still other embodiments could incorporate a combination of filament fused fabrication and another type of 3D printing technique to achieve desired results for a particular printed structure or part.
[0061]As previously noted, printing device 102 may be configured to print directly onto various articles. Similarly, printing device 102 may be configured to print on various surface geometries (e.g., flat, curved, and/or irregular surfaces). For example, as shown in FIG. 2, tray 112 supports base 144 that is substantially planar. In other embodiments, base 144 may include one or more protrusions and/or one or more cavities. Moreover, printing device 102 may print on surfaces having various shapes. For example, as shown, tray 112 supports base 144 that is rectangular. In other embodiments, tray 112 may support a base that is circular, triangular, shaped like an upper for an article of footwear, and the like. As shown, base 144 includes upper surface 148 and lower surface 150.
[0062]In some instances, it is desirable to dampen an impact when the nozzle descends toward a tray. In one embodiment, printing system 100 may include an elastic layer to prevent tray 112 from impacting nozzle 118. In other embodiments, an elastic layer is omitted.
[0063]In those instances where an elastic layer is used, any suitable position may be used to dampen an impact when the nozzle descends toward a tray. In one embodiment, an elastic layer may be placed between a tray and a base. Referring to FIGS. 1-2, elastic layer 146 may be placed on tray 112 to separate tray 112 from base 144. In other embodiments, the elastic layer may be positioned in other locations.
[0064]In those instances where an elastic layer is used, any suitable number of layers may be used to dampen an impact when the nozzle descends toward a tray. In some embodiments, the lower surface directly contacts the elastic layer. For example, lower surface 150 directly contacts elastic layer 146. In some embodiments, another layer separates the lower surface and the elastic layer (not shown). In other embodiments, other layers may be used.
[0065]In those instances where an elastic layer is used, the elastic layer may have any suitable shape to facilitate a dampening of an impact when the nozzle descends toward a tray. Referring to FIG. 2, elastic layer 146 may have a rectangular shape. In some embodiments, the elastic layer may be circular (not shown). In some embodiments, the elastic layer may be triangular (not shown). In other embodiments, the elastic layer may have other shapes.
[0066]Some embodiments may be provisioned to permit the elastic layer to have a shape corresponding with another component of the printing system. In one embodiment, the elastic layer may have a shape corresponding to a base. Referring to FIG. 2, elastic layer 146 may have a shape corresponding with base 144. In some embodiments, the elastic layer may have a shape corresponding to a tray. Referring to FIG. 2, elastic layer 146 may have a shape corresponding with tray 112. In other embodiments, the elastic layer may have a shape corresponding to other components.
[0067]In those instances where an elastic layer is used, the elastic layer may have any suitable material to facilitate a dampening of an impact when the nozzle descends toward a tray. In some embodiments, the elastic layer is formed of an elastic material. As used herein, elastic material may include natural and/or synthetic rubber, nylon, polystyrene, Teflon, polyethylene, and the like. In other embodiments, the elastic layer may be formed of other materials.
[0068]In those instances where a nozzle is used to dispense a print material, any suitable material may be used. In one embodiment, the nozzle dispenses yarn. Referring to FIG. 2, nozzle 118 may dispense yarn 151. In other embodiments, the nozzle dispenses other material.
[0069]In those instances where the nozzle dispenses yarn, the yarn may be formed of any suitable material. Such yarn may include a yarn structure composition having one or more features described in Sterman et al., U.S. Patent Publication Number 2016-0053410, published on Feb. 25, 2016, titled “Thread Structure Composition and Method of Making,” (now U.S. patent application Ser. No. 14/466,319, filed on Aug. 22, 2014), which is hereby incorporated by reference. For example, in some embodiments, yarn 151 may include a melt-resistant material and/or a heat-moldable material. As used herein, a heat-moldable material may be any material that is substantially moldable (or pliable) above a predetermined temperature, such as a glass transition temperature and/or a melting temperature. As used herein, the term “melt-resistant material” may refer to any material without a melting temperature (or any material with a melting temperature well above a predetermined threshold temperature). A melt-resistant material may include a material that combusts above a predetermined temperature such as paper. Another melt-resistant material may include metals that have a melting temperature significantly above a threshold temperature of about 500° C. In other embodiments, the yarn may be formed of other materials.
[0070]In those instances where the yarn is formed of heat-moldable material, the heat-moldable material may have any suitable property. In one embodiment, a heat moldable material has one or more thermal properties such as a glass-liquid transition (“glass transition”) temperature and/or a melting temperature. For example, the heat-moldable material may be a thermoplastic material having a glass transition temperature and a melting temperature. In other embodiments, a heat-moldable material may have other properties.
[0071]In those instances where the yarn is formed of heat-moldable material, any suitable material may be used to form the heat-moldable material. As used herein, ther