Three-dimensional printing utilizing a captive element
A method of forming a printed structure is disclosed. The method may include printing layers of a printed structure and incorporating an element within the printed structure. The element may be removed in order to form tunnels within the printed structure. In some embodiments the element may be removed and reused in the formation of additional printed structures. The element may also be retained to form a composite printed structure.
1 . An article of apparel or equipment, comprising:
a first structure formed of a printed material, the first structure having a first printed portion bonded to a surface of the article of apparel or equipment;
an element having a first portion adjacent the first printed portion of the first structure, wherein the first portion of the element is in contact with the first structure, the element having a length that is longer than a width of the element;
a second printed portion of the first structure, the second printed portion being printed on the first printed portion such that the second printed portion is spaced apart from the surface of the article or equipment, and the first printed portion and the second printed portion collectively define a first tunnel enclosing the element at least partially within the first structure;
a second structure spaced apart from the first structure along the length of the element and formed of the printed material, the second structure having a third printed portion bonded to the surface of the article of apparel or equipment;
the element having a second portion adjacent the third printed portion of the second structure, wherein the second portion of the element is in contact with the second structure; and
a fourth printed portion of the second structure, the fourth printed portion being printed on the third printed portion such that the fourth printed portion is spaced apart from the surface of the article or equipment, and the third printed portion and the fourth printed portion collectively define a second tunnel enclosing the element at least partially within the second structure,
wherein the first structure is formed on a first surface area of the surface of the article of apparel or equipment, the second structure is formed on a second surface area of the surface of the article of apparel or equipment, and a gap between the first structure and the second structure along the length of the element defines an intermediate surface area of the surface of the article of apparel or equipment, and
wherein the element extends across the intermediate surface area between the first structure and the second structure.
2 . The article of claim 1 , wherein the element is a cord.
3 . The article of claim 1 , wherein the element is a wire.
4 . The article of claim 1 , wherein the element is a cylinder.
5 . The article of claim 1 , wherein the element is a tube.
6 . The article of claim 1 , wherein the element is a reusable shaft.
7 . The article of claim 6 , wherein the reusable shaft includes at least one vane.
8 . The article of claim 1 , wherein the element comprises a material that has a friction coefficient of 0.01 to 0.30 relative to the printed material.
9 . The article of claim 1 , wherein the element is movable within the first structure.
10 . The article of claim 1 , wherein the first structure comprises a recess, the first portion of the element being received in the recess.
11 . The article of claim 1 , wherein the first portion of the element is configured to be removable from the first structure to form the first tunnel.
12 . The article of claim 11 , wherein the first tunnel is a through-hole.
13 . The article of claim 11 , wherein the first tunnel is a blind-hole.
14 . The article of claim 1 , wherein the first portion of the element is fully enclosed by the first and second printed portions of the first structure.
15 . The article of claim 1 , wherein the article of apparel or equipment is an article of footwear.
16 . The article of claim 15 , wherein the element is a lace.
17 . The article of claim 1 , wherein the article of apparel or equipment is an article of footwear and the element is a lace for the article of footwear, and wherein the lace extends continuously between the first structure and the second structure.
18 . The article of claim 1 , wherein the printed material includes a thermoplastic material.
19 . An article of apparel or equipment, comprising:
a plurality of spaced-apart structures formed of a printed material, each of the plurality of spaced-apart structures comprising:
a first printed portion bonded to a surface of the article of apparel or equipment;
an element having a plurality of portions adjacent respective ones of the first printed portion of the plurality of structures; and
a second printed portion printed on the first printed portion such that the second printed portion is spaced apart from the surface of the article or equipment, and the first printed portion and the second printed portion collectively define a tunnel that encloses the element,
wherein the element has a length that is longer than a width of the element, and the plurality of spaced-apart structures are spaced apart along the length of the element to define a plurality of intermediate surface areas of the surface of the article of apparel or equipment that are between adjacent ones of the plurality of spaced-apart structures, and
wherein the element extends across the intermediate surface areas.
20 . The article of claim 19 , wherein the article of apparel or equipment is an article of footwear and the element is a lace for the article of footwear.