GRADIENT PRINTING A THREE-DIMENSIONAL STRUCTURAL COMPONENT

• US 20170341294A1
• Filed: 05/31/2017
• Published: 11/30/2017
• Est. Priority Date: 05/31/2016
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Miller, Todd W.
• Granted Patent: US 10,596,753 B2
• Time in Patent Office: Days
• 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 and a second thickness, the first thickness being less than the second thickness;

instructing a printing device to print a single layer for the three-dimensional structural component using the set of predetermined thicknesses;

printing a first portion of the single layer onto the base so that the first portion has the first thickness; and

printing a second portion of the single layer onto the base so that the second portion has the second thickness.

2. The method of claim 1, wherein the printing device comprises a printhead assembly, the method further comprising:

moving the printhead assembly in a single pass between the first portion of the single layer and the second portion of the single layer; and

wherein the first portion is printed during the single pass and wherein the second portion is printed during the single pass.

3. The method of claim 2, wherein the step of printing the first portion of the single layer comprises dispensing a print material in a liquid state from the printhead assembly onto the base during the single pass;

and

wherein the step of printing the second portion of the single layer comprises dispensing the print material in the liquid state onto the base from the printhead assembly during the single pass.

4. The method of claim 3, wherein the step of printing the first portion of the single layer comprises curing the first portion during the single pass;

and

wherein the step of printing the second portion of the single layer comprises curing the second portion during the single pass.

5. The method of claim 3, wherein a separation distance between an upper surface of the base and the printhead assembly remains constant during the step of moving the printhead assembly in a single pass between the first portion of the single layer and the second portion of the single layer.

6. The method of claim 1, wherein the set of predetermined thicknesses includes a third thickness, the method further comprising:

wherein the third thickness is greater than the second thickness;

printing a third portion of the single layer onto the base so that the third portion has the third thickness; and

wherein the second portion is disposed between the first portion and the third portion.

7. The method of claim 6, wherein the first portion of the single layer, the second portion of the single layer, and the third portion of the single layer collectively form an upper surface having a smoothly sloped geometry.

8. 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; and

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.

9. The method of claim 8, wherein printing the second layer is initiated after printing the first layer.

10. The method of claim 9, 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.

11. The method of claim 8, 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;

and

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.

12. The method of claim 11, 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.

13. The method of claim 8, 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.

14. The method of claim 8, 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.

15. 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;

instructing a printing device to print a set of layers of the three-dimensional structural component onto the base;

printing the three-dimensional structural component onto the base using the set of predetermined thicknesses to form a printed set of layers;

wherein printing the three-dimensional structural component comprises printing a first layer of the set of layers directly onto the base and 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 of the set of layers directly onto the base;

wherein the printed set of layers includes an exposed surface of the three-dimensional structural component, the exposed surface comprising a tall region, an intermediate region, and a short region;

wherein the intermediate region abuts the tall region and wherein the intermediate region abuts the short region;

wherein a difference in height between the tall region of the exposed surface and the short region of the exposed surface is greater than the separation distance; and

wherein the intermediate region of the exposed surface has a smoothly sloped geometry.

16. The method of claim 15, wherein printing the three-dimensional structural component comprises forming each layer of the set of layers by dispensing a print material in a liquid state onto the base and curing the print material to transition the print material from the liquid state to a solid state.

17. The method of claim 16, wherein dispensing the print material in the liquid state onto the base comprises dispensing an amount of the print material based on the set of predetermined thicknesses.

18. The method of claim 15, wherein an angle formed between a plane parallel with the intermediate region of the exposed surface and a plane parallel with the base is between 15 degrees and 75 degrees.

19. The method of claim 15, wherein the intermediate region is planar.

20. The method of claim 15, wherein the intermediate region is contoured.

21. The method of claim 15, wherein the short region has a thickness of less than the separation distance.

22. 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 having printed regions, wherein each thickness corresponds to a different percentage of a selected spot color, and wherein a target thickness for any printed region is determined according to the percentage of a selected spot color used for printing the printed region;

wherein the set of predetermined thicknesses has a first thickness and a second thickness, the first thickness being less than the second thickness;

instructing a printing device to print a single layer for the three-dimensional structural component using the set of predetermined thicknesses;

printing a first portion of the single layer onto the base so that the first portion has the first thickness; and

printing a second portion of the single layer onto the base so that the second portion has the second thickness.