Gradient printing a three-dimensional structural component

• US 10,596,753 B2
• Filed: 05/31/2017
• Issued: 03/24/2020
• 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:
  US15/609,205
• Publication Number:
  US 20170341294A1
• Time in Patent Office: 1,028 Days
• Field of Search: 264308
• CPC Class Codes: A43B 23/0235 Different layers of different material
• CPC Class Codes: A43B 23/024 Different layers of the same material
• CPC Class Codes: A43B 23/026 Laminated layers
• CPC Class Codes: B29C 64/10 Processes of additive manufacturing
• 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: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: H04N 1/4092 Edge or detail enhancement

Abstract

Methods are provided for printing a three-dimensional structural component onto a base. For example, a method of printing is provided, including receiving a set of predetermined thicknesses for the three-dimensional structural component. The set of predetermined thicknesses has a first thickness and a second thickness. The first thickness is greater than the second thickness. The method further includes instructing a printing device to print a single layer for the three-dimensional structural component using the set of predetermined thicknesses. The method further includes printing a first portion of the single layer onto the base so that the first portion has the first thickness. The method further includes printing a second portion of the single layer onto the base so that the second portion has the second thickness.

Claims

1. A method of printing a three-dimensional structural component onto a base, the method comprising:

receiving a set of predetermined thicknesses for the three-dimensional structural component;

wherein the set of predetermined thicknesses has a first thickness corresponding to a first position of the base and a second thickness corresponding to a second position of the base, the first thickness being greater than the second thickness;

instructing a printing device to print a set of layers of the three-dimensional structural component using the set of predetermined thicknesses, the set of layers comprising at least a first layer and a second layer;

printing the first layer of the three-dimensional structural component directly onto the base using the set of predetermined thicknesses;

wherein printing the first layer includes printing the first layer to have the first thickness at the first position of the base and wherein printing the first layer includes printing the first layer to have the second thickness at the second position of the base;

printing the second layer of the three-dimensional structural component directly onto the first layer using the set of predetermined thicknesses;

wherein printing the second layer includes printing the second layer to have the first thickness at the first position of the base and wherein printing the second layer includes printing the second layer to have the second thickness at the second position of the base;

wherein a separation distance between the base and a printhead assembly of the printing device remains constant during the step of printing the first layer;

wherein the set of layers of the three-dimensional structural component has a combined thickness at the second position of the base that is less than the separation distance; and

wherein the set of layers of the three-dimensional structural component has a combined thickness at the first position of the base that is greater than the separation distance.

2. The method of claim 1, wherein printing the second layer is initiated after printing the first layer.

3. The method of claim 2, wherein printing the first layer comprises dispensing a print material in a liquid state onto the base and curing the print material such that the first layer has the first thickness at the first position of the base and the first layer has the second thickness at the second position of the base;

and

wherein printing the second layer is initiated after curing the print material.

4. The method of claim 1, wherein the first layer at the first position of the base extends away from the base further than the second layer at the second position of the base.

5. The method of claim 1, wherein the second layer is printed directly onto a first upper surface of the first layer;

and

wherein the second layer covers at least a portion of the first upper surface.