Method and apparatus for printing three-dimensional structures with image information

• US 10,518,474 B2
• Filed: 05/31/2017
• Issued: 12/31/2019
• Est. Priority Date: 05/31/2016
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Miller, Todd W.
• Primary Examiner(s): Goff, II, John L
• Application Number:
  US15/609,220
• Publication Number:
  US 20170341304A1
• Time in Patent Office: 944 Days
• Field of Search: 264308
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B29C 64/386 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29K 2995/002 Coloured
• CPC Class Codes: B29L 2031/50 Footwear, e.g. shoes or parts thereof
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: H04N 1/4078 using gradational references, e.g. grey-scale test pattern analysis

Abstract

A method and system for printing 3D structures using 2D monochromatic images (for example, greyscale images) is provided. The method can include instructing a printing device to print a 2D monochromatic image using print material in a reservoir known to contain a structural print material. Greater amounts of print material are printed in locations corresponding to relatively darker regions of the 2D monochromatic image.

Claims

1. A method of printing with a printing system, comprising:

receiving reservoir identification information corresponding to a reservoir of a printing device filled with a structural print material;

receiving an image file including information corresponding to a monochromatic image;

wherein the image file includes a shade level for each pixel of the monochromatic image;

instructing the printing device to print the image file using the reservoir corresponding to the reservoir identification information;

wherein a three-dimensional structure is formed as the printing device prints the image file;

wherein each location on an upper surface of the three-dimensional structure has a corresponding pixel in the monochromatic image;

wherein a height of the three-dimensional structure at each location is determined by the shade level for the corresponding pixel;

wherein the printing device dispenses more structural print material at a first location corresponding with a first pixel having a first shade level than at a second location corresponding with a second pixel having a second shade level that is lighter than the first shade level;

wherein the printing device forms the three-dimensional structure by printing multiple layers of the structural print material;

wherein the printing device prints an equal number of layers in the first location and in the second location; and

wherein each layer printed at the second location has less thickness than each layer printed at the first location.

2. The method of claim 1, wherein the shade levels in the image file take on values in a range between white and black, including a plurality of grey shade levels between white and black.

3. The method of claim 2, wherein the method further includes:

receiving a predetermined maximum height for the three-dimensional structure;

wherein locations of the upper surface of the three-dimensional structure having the predetermined maximum height correspond to pixels in the monochromatic image with black shade levels.

4. The method of claim 3, wherein locations of the upper surface of the three-dimensional structure having a height less than the predetermined maximum height correspond to pixels in the monochromatic image with grey shade levels.

5. The method of claim 3, wherein a relationship between the height of the three-dimensional structure at each location and the shade level of each pixel in the monochromatic image corresponding to each location is a linear relationship.

6. The method of claim 1, wherein the printing device calculates the amount of structural print material to dispense at each location according to the shade level of the corresponding pixel in the monochromatic image.

7. The method of claim 1, wherein the reservoir identification information is received from user input provided by an operator of the printing system.

8. The method of claim 1, wherein the image file is loaded into the printing system by an operator of the printing system.

9. A method of printing with a printing system, comprising:

receiving reservoir identification information corresponding to a first reservoir of a printing device filled with a structural print material;

receiving reservoir identification information corresponding to a second reservoir of the printing device filled with a color print material;

receiving monochromatic image information corresponding to a monochromatic image, wherein the monochromatic image information includes a shade level for each pixel of the monochromatic image;

receiving color image information corresponding to a color image;

instructing the printing device to print the monochromatic image information using the first reservoir; and

instructing the printing device to print the color image information using the second reservoir;

wherein a three-dimensional structure is formed as the printing device prints the monochromatic image information using the structural print material from the first reservoir;

wherein a two-dimensional color layer is formed as the printing device prints the color image information using the color print material from the second reservoir;

wherein the printing device dispenses more structural print material at a first location of the three-dimensional structure than at a second location of the three-dimensional structure, the first location corresponding to a darker portion of the monochromatic image information relative to the second location;

wherein the printing device forms the three-dimensional structure by printing multiple layers of the structural print material;

wherein the printing device prints an equal number of layers in the first location and in the second location; and

wherein each layer printed at the second location has less thickness than each layer printed at the first location.

10. The method of claim 9, wherein each location on an upper surface of the three-dimensional structure has a corresponding pixel in the monochromatic image information;

and

wherein a height of the three-dimensional structure at each location is determined by the shade level for the corresponding pixel.

11. The method of claim 9, wherein the printing system prints the color image information after printing the monochromatic image information to create an outer color layer of the three-dimensional structure.

12. The method of claim 9, wherein the printing system prints the color image information before printing the monochromatic image information to create an inner color layer of the three-dimensional structure.

13. The method of claim 12, wherein the printing system receives color image information for another color image;

and

wherein the printing system prints the color image information corresponding to the another color image after printing the monochromatic image information to create an outer color layer of the three-dimensional structure.

14. The method of claim 13, wherein the three-dimensional structure and outer color layer are printed onto an article.

15. The method of claim 14, wherein the article is part of an article of footwear.