System and method for forming three-dimensional structures
First Claim
Patent Images
1. A method of manufacturing a structure onto a base component, comprising:
- providing a nozzle in a first position near the base component, the nozzle being configured to extrude material in a first direction perpendicular to the base component;
extruding a first portion of material in a continuous flow through the nozzle in the first direction onto the base component, wherein the first portion of material spreads radially outwardly in a second direction that is perpendicular to the first direction when the first portion of material contacts the base component;
forming a first portion of the structure including the extruded first portion of material;
moving the nozzle away from the first portion of material in a third direction that is opposite the first direction to a second position;
extruding a second portion of material in a continuous flow through the nozzle in the first direction onto the first portion of the structure, wherein the second portion of material spreads radially outwardly in the second direction when the second portion of material contacts the first portion of the structure;
forming a second portion of the structure including the extruded second portion of material;
wherein the first portion of the structure has a first cross-sectional area perpendicular to the first direction and the second portion of the structure has a second cross-sectional area perpendicular to the first direction; and
wherein the first cross-sectional area is different from the second cross-sectional area;
further comprising varying a rate at which the nozzle is withdrawn from the base component during material extrusion to control a radial outflow rate of extruded material and thereby control the first cross-sectional area and the second cross sectional area, wherein the first cross-sectional area of the first portion of the structure corresponds to a first withdrawal rate of the nozzle and wherein the second cross-sectional area of the second portion of the structure corresponds to a second withdrawal rate of the nozzle that is different from the first withdrawal rate.
1 Assignment
0 Petitions
Accused Products
Abstract
A system and method for forming 3D printed structures on a base component includes extruding material through a nozzle while moving the nozzle vertically. Extruded material flows from the nozzle and spreads outwardly upon contact with an underlying portion of material. The outward spread of material is controlled to form a desired geometry for the 3D printed structure. An optical sensing device may provide feedback for controlling the outward spread of material. Using a molding component, structures with anchored portions extending through openings in the base component can be formed.
-
Citations
13 Claims
-
1. A method of manufacturing a structure onto a base component, comprising:
-
providing a nozzle in a first position near the base component, the nozzle being configured to extrude material in a first direction perpendicular to the base component; extruding a first portion of material in a continuous flow through the nozzle in the first direction onto the base component, wherein the first portion of material spreads radially outwardly in a second direction that is perpendicular to the first direction when the first portion of material contacts the base component; forming a first portion of the structure including the extruded first portion of material; moving the nozzle away from the first portion of material in a third direction that is opposite the first direction to a second position; extruding a second portion of material in a continuous flow through the nozzle in the first direction onto the first portion of the structure, wherein the second portion of material spreads radially outwardly in the second direction when the second portion of material contacts the first portion of the structure; forming a second portion of the structure including the extruded second portion of material; wherein the first portion of the structure has a first cross-sectional area perpendicular to the first direction and the second portion of the structure has a second cross-sectional area perpendicular to the first direction; and
wherein the first cross-sectional area is different from the second cross-sectional area;further comprising varying a rate at which the nozzle is withdrawn from the base component during material extrusion to control a radial outflow rate of extruded material and thereby control the first cross-sectional area and the second cross sectional area, wherein the first cross-sectional area of the first portion of the structure corresponds to a first withdrawal rate of the nozzle and wherein the second cross-sectional area of the second portion of the structure corresponds to a second withdrawal rate of the nozzle that is different from the first withdrawal rate. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
-
-
9. A method of manufacturing a structure attached to a base component for an article of apparel, comprising:
-
providing a nozzle near a first side of the base component, the nozzle being configured to extrude material in a first direction, wherein the base component is for an article of apparel; providing a molding component on a second side of the base component, opposite from the nozzle; with the nozzle near the first side of the base component, extruding a first portion of material through the nozzle in the first direction, such that the first portion of material flows through an opening in the base component and fills a cavity in the molding component adjacent the second side of the base component, thereby forming a first portion of the structure in the cavity on the second side of the base component; moving the nozzle away from the first portion of the structure opposite the first direction; extruding a second portion of material through the nozzle onto the first portion of the structure, wherein the second portion of material spreads outwardly in the second direction when the second portion of material contacts the first portion of the structure; forming a second portion of the structure with the extruded second portion of material, the second portion of the structure being disposed on the first side of the base component wherein the first and second portions of the structure are connected together through the opening in the base component and form the structure; wherein the first portion of the structure has a first cross-sectional area, the second portion of the structure has a second cross-sectional area, and the opening has a third cross-sectional opening; and wherein the first cross-sectional area is greater than the third cross-sectional area and wherein the second cross-sectional area is greater than the third cross-sectional area, such that the structure is anchored to the base component through the opening. - View Dependent Claims (10, 11, 12, 13)
-
Specification