Direct Printing to Fabric

• US 20140020191A1
• Filed: 07/19/2012
• Published: 01/23/2014
• Est. Priority Date: 07/19/2012
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Jones, David P., Larson, Ryan R.
• Granted Patent: US 8,993,061 B2
• Time in Patent Office: Days
• US Class Current: 12/142.R
• CPC Class Codes: A43B 1/04 braided, knotted, knitted or crocheted
• CPC Class Codes: A43B 23/0235 Different layers of different material
• CPC Class Codes: A43B 23/026 Laminated layers
• CPC Class Codes: A43B 3/0084 Arrangement of flocked decoration on shoes
• CPC Class Codes: A43D 11/00 Machines for preliminary treatment or assembling of upper-parts, counters, or insoles on their lasts preparatory to the pulling-over or lasting operations; Applying or removing protective coverings
• CPC Class Codes: A43D 2200/00 Machines or methods characterised by special features
• CPC Class Codes: A43D 2200/60 Computer aided manufacture of footwear, e.g. CAD or CAM
• CPC Class Codes: A43D 8/00 Machines for cutting, ornamenting, marking or otherwise working up shoe part blanks pulling-over or lasting A43D9/00 - A43D23/00; making or fastening soles, heels or welts A43D25/00 - A43D83/00
• CPC Class Codes: B29C 64/106 using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
• CPC Class Codes: B29C 70/78 Moulding material on one side only of the preformed part
• CPC Class Codes: B29K 2713/00 Use of textile products or fabrics for preformed parts, e.g. for inserts B29K2105/06 takes precedence
• 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 50/00 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing

Abstract

Methods and systems are disclosed for three-dimensional printing directly onto an article of apparel. Disclosed is a method and system for direct three-dimensional printing onto an article of apparel, including designing a three-dimensional pattern for printing onto the article, positioning at least a portion of the article on a tray in a three-dimensional printing system, the portion being positioned substantially flat on the tray, printing a three-dimensional material directly onto the article using the designed pattern, curing the printed material, and removing the article from the three-dimensional printing system.

Claims

1. A method of direct three-dimensional printing onto an article of apparel, comprising:

designing a three-dimensional pattern for printing onto the article;

positioning at least a portion of the article on a tray in a three-dimensional printing system, the portion being positioned substantially flat on the tray;

printing a three-dimensional material directly onto the article using the designed pattern;

curing the printed material; and

removing the article from the three-dimensional printing system.

2. The method according to claim 1, wherein the printing onto the article further comprises printing at least one layer of the material.

3. The method according to claim 1, wherein the printing onto the article further comprises allowing the printed material to at least partially absorb into a surface of the article prior to the curing.

4. The method according to claim 1, wherein the printing onto the article further comprises:

printing a first layer of the material;

allowing the first layer of printed material to at least partially absorb into a surface of the article;

curing the first layer of printed material;

printing at least one additional layer of the material on the cured first layer; and

curing the at least one additional layer.

5. The method according to claim 4, wherein the printed first layer has a first modulus of elasticity and the at least one additional layer has a second modulus of elasticity different than the first modulus.

6. The method according to claim 4, wherein the printed first layer has a first color and the at least one additional layer has a second color.

7. The method according to claim 1, wherein the article of apparel is chosen from a textile, a natural fabric, a synthetic fabric, a knit, a woven material, a nonwoven material, a mesh, a leather, a synthetic leather, a polymer, a rubber, a foam, clothing, footwear, hats, caps, shirts, jerseys, jackets, socks, shorts, pants, undergarments, athletic support garments, gloves, wrist/arm bands, sleeves, and headbands.

8. The method according to claim 1, wherein the portion of the article has at least one nonflat surface.

9. The method according to claim 8, wherein the at least one nonflat surface is a substrate on which the printing occurs.

10. The method according to claim 1, wherein the removing the article does not require a release layer disposed between the printed material and the tray.

11. The method according to claim 1, wherein the printed material is chosen from an ink, a resin, an acrylic, a polymer, a thermoplastic material, a thermosetting material, and a light-curable material.

12. The method according to claim 1, wherein the printed material further comprises a filler material.

13. The method according to claim 1, wherein the printed material is adhered or bonded to the article.

14. A method of fabricating an article of footwear, comprising:

designing a three-dimensional pattern for printing onto an upper;

providing the pattern to a print server;

positioning at least a portion of the upper on a tray in a three-dimensional printing system, the portion being positioned substantially flat on the tray;

aligning the portion of the upper on the tray with the pattern;

printing a three-dimensional material directly onto the upper using the designed pattern on the print server and the three-dimensional printing system;

curing the printed material;

removing the upper from the three-dimensional printing system; and

assembling the article of footwear using the printed upper and at least one footwear component chosen from a sock liner, a midsole, and an outsole.

15. The method according to claim 14, wherein the printing onto the upper further comprises printing at least one layer of the material.

16. The method according to claim 14, wherein the printing onto the upper further comprises allowing the printed material to at least partially absorb into a surface of the upper prior to the curing.

40. The method according to claim 14, wherein the printing onto the upper further comprises:

printing a first layer of the material;

allowing the first layer of printed material to at least partially absorb into a surface of the upper;

curing the first layer of printed material;

printing at least one additional layer of the material on the cured first layer; and

curing the at least one additional layer.

41. The method according to claim 40, wherein the printed first layer has a first modulus of elasticity and the at least one additional layer has a second modulus of elasticity different than the first modulus.

42. The method according to claim 40, wherein the printed first layer has a first color and the at least one additional layer has a second color.

43. The method according to claim 14, wherein the upper is chosen from a textile, a natural fabric, a synthetic fabric, a knit, a woven material, a nonwoven material, a mesh, a leather, a synthetic leather, a polymer, a rubber, and a foam.

44. The method according to claim 14, wherein the portion of the upper has at least one nonflat surface.

45. The method according to claim 44, wherein the at least one nonflat surface is a substrate on which the printing occurs.

46. The method according to claim 14, wherein the removing the upper does not require a release layer disposed between the printed material and the tray.

47. The method according to claim 14, wherein the printed material is chosen from an ink, a resin, an acrylic, a polymer, a thermoplastic material, a thermosetting material, and a light-curable material.

48. The method according to claim 14, wherein the printed material further comprises a filler material.

49. The method according to claim 14, wherein the printed material is adhered or bonded to the upper.

17-39. -39. (canceled)

50. A method of fabricating an article of footwear, comprising:

designing a three-dimensional pattern for printing onto an upper;

providing the pattern to a print server;

positioning at least a portion of the upper on a tray in a three-dimensional printing system, the portion being positioned substantially flat on the tray;

aligning the portion of the upper on the tray with the pattern;

printing a first layer of three-dimensional material directly onto the upper using the designed pattern on the print server and the three-dimensional printing system;

allowing the first layer of printed material to at least partially absorb into a surface of the upper;

curing the first layer,

wherein the cured first layer has a first modulus of elasticity;

printing at least one additional layer of the material on the cured first layer;

curing the at least one additional layer,

wherein the cured at least one additional layer has a different modulus of elasticity than the first modulus;

removing the upper from the three-dimensional printing system; and

assembling the article of footwear using the printed upper and at least one footwear component chosen from a sock liner, a midsole, and an outsole.

51. The method according to claim 50, wherein the printing the first layer further comprises printing the material having a gradient in modulus of elasticity within at least a region of the printed material.

52. The method according to claim 51, wherein the printing the at least one additional layer further comprises printing multiple layers having varied moduli of elasticity as a function of depth or length of the printed material.

53. The method according to claim 50, wherein the upper is chosen from a textile, a natural fabric, a synthetic fabric, a knit, a woven material, a nonwoven material, a mesh, a leather, a synthetic leather, a polymer, a rubber, and a foam.

54. The method according to claim 50, wherein the portion of the upper has at least one nonflat surface.

55. The method according to claim 54, wherein the at least one nonflat surface is a substrate on which the printing occurs.

56. The method according to claim 50, wherein the removing the upper does not require a release layer disposed between the printed material and the tray.

57. The method according to claim 50, wherein the printed material is chosen from an ink, a resin, an acrylic, a polymer, a thermoplastic material, a thermosetting material, and a light-curable material.

58. The method according to claim 50, wherein the printed material further comprises a filler material.

59. The method according to claim 50, wherein the printed material is adhered or bonded to the upper.

60. A method of fabricating an article of footwear, comprising:

designing at least a first three-dimensional pattern and a second three-dimensional pattern for printing onto an upper;

providing the at least first and second three-dimensional patterns to a print server;

positioning at least a first portion of the upper on a tray in a three-dimensional printing system, the first portion being positioned substantially flat on the tray;

aligning the first portion of the upper with the first pattern;

printing at least one layer of a first three-dimensional material having a first material property directly onto the first portion of the upper using the designed first pattern;

allowing the at least one layer of printed first three-dimensional material to at least partially absorb into a first portion of a surface of the upper;

curing the at least one layer of printed first three-dimensional material;

positioning at least a second portion of the upper on the tray, the second portion being positioned substantially flat on the tray;

aligning the second portion of the upper with the second pattern;

printing at least one layer of a second three-dimensional material having a second material property directly onto the second portion of the upper using the designed second pattern;

allowing the at least one layer of printed second three-dimensional material to at least partially absorb into a second portion of the surface of the upper;

curing the at least one layer of printed second three-dimensional material;

removing the upper from the three-dimensional printing system; and

assembling the article of footwear using the printed upper and at least one footwear component chosen from a sock liner, a midsole, and an outsole.

61. A system for three-dimensional printing directly onto a fabric upper, comprising:

a first nontransitory computer-readable medium encoded with a first computer program product loadable into a first memory of a first computer and including first software code portions for storing a three-dimensional pattern for printing directly onto the upper;

a print server;

a switching device; and

a three-dimensional printer device,

wherein the print server is in direct communication with the three-dimensional printer device and the switching device,

wherein the switching device is in direct communication with the three-dimensional printer device and the print server,

wherein the first nontransitory computer readable medium is in direct communication with the switch,

wherein the print server comprises a second nontransitory computer-readable medium encoded with a second computer program product loadable into a second memory of a second computer and including second software code portions for instructing the three-dimensional printing device to print directly onto the upper through a sequence of printing steps;

wherein the three-dimensional printer device comprises a tray receiving the fabric upper, at least one printing head for printing onto the upper in the sequence, and at least one ultraviolet light for curing material printed onto the upper, and

wherein the three-dimensional printing system does not require a substantially flat surface for printing.