METHODS OF 3D PRINTING ARTICLES WITH PARTICLES
The present invention generally relates to methods of printing articles using three-dimensional printing and other printing techniques, and to articles formed from such techniques, including the printing of articles containing particles. Certain embodiments are generally directed to composites comprising particles (e.g., reinforcing particles), for example, rubber particles. The particles may be used, for example, to increase slip or abrasion resistance. The composites may also contain polyurethanes or other compounds, e.g., to facilitate fabrication, e.g., using three-dimensional printing and other printing techniques. Other embodiments are directed to methods of making or using such articles. For example, in some embodiments, a composite may be prepared by mixing particles (e.g., reinforcing particles) with at least a first fluid and a second fluid within a nozzle, such as a microfluidic printing nozzle, which may be used to direct the resulting product onto a substrate.
1 . A method of printing of an article for use in footwear, comprising:
receiving object information associated with the article;
identifying a target material to be printed using the object information;
identifying two or more input materials to create the target material, at least one of the two or more input materials comprising particles;
identifying a set of printer settings for printing the target material;
generating print instructions using the set of printer parameters; and
printing the article using the print instructions.
2 . The method of claim 1 , wherein the target material comprises a composite.
3 . The method of claim 1 , wherein the set of printer settings comprises at least one setting selected from the group consisting of: a ratio of the two or more input materials to a mixing chamber, a spin speed of an impeller in the mixing chamber, a sequence of materials into a mixing chamber, a position of one or more valves to control material inputs into the mixing chamber, total cumulative flowrate of all inputs to a mixing chamber, vertical position of a print head relative to the substrate, speed of movement of the print head, amount of reverse pumping following a movement command, temperature of the print head, temperature of a substrate onto which the article is printed, and the calibration setting for a material inlet pump.
4 . The method of claim 1 , wherein the article comprises a gradient structure.
5 . The method of claim 1 , wherein printing the article comprises mixing at least two fluids with particles.
6 . The method of claim 1 , wherein printing the article comprises mixing at least three fluids with particles.
7 . The method of claim 1 , wherein identifying the target material to be printed using the object information comprises identifying a gradient structure using the object information.
8 . A method of printing of an article, comprising:
flowing a first fluid through a first inlet into a nozzle;
flowing a second fluid through a second inlet into the nozzle;
flowing particles into the nozzle;
mixing the first fluid, the second fluid, and the particles to form a first mixture within the nozzle; and
printing the first mixture onto a substrate from the nozzle.
9 . The method of claim 8 , comprising printing the first mixture onto the substrate in at least a first portion.
10 . The method of claim 8 , wherein the particles comprise a blowing agent.
11 . The method of claim 8 , wherein the mixture of the first fluid and the second fluid cures to form a matrix on the substrate containing the particles.
12 . The method of claim 8 , wherein the minimum activation temperature of the blowing agent is greater than the maximum temperature in the curing profile of the matrix by at least 10 degrees Celsius.
13 . The method of claim 8 , wherein the average activation temperature of the blowing agent is less than the curing temperature of the matrix by at least 10 degrees Celsius.
14 . The method of claim 8 , further comprising:
flowing the first fluid through the first inlet into the nozzle;
flowing the second fluid through the second inlet into the nozzle;
mixing the first fluid and the second fluid to form a second mixture within the nozzle; and
printing the second mixture onto a substrate from the nozzle in at least a second portion.
15 - 88 . (canceled)
89 . A method of printing an article, comprising:
flowing at least two inputs into a mixing nozzle to form a first mixture comprising a blowing agent;
flowing at least two inputs into a mixing nozzle to form a second mixture;
depositing a first region comprising the first mixture to form a first elastomer;
depositing a second region adjacent to the first region, comprising the second mixture to form a second elastomer; and
heating at least the first region of the article to a temperature greater than or equal to the activation temperature of the blowing agent;
wherein heating at least the first region of the article causes differential expansion between the first region and the second region of the article and physical deformation of the article.
90 . The method of claim 89 , wherein the second mixture comprises a blowing agent.
91 . The method of claim 89 , wherein one of the at least two inputs to form the first mixture comprises an isocyanate and another of the at least two inputs to form the first mixture comprises a polyol system containing the blowing agent.
92 . The method of claim 91 , further comprising flowing at least a third input comprising a polyol system into the mixing nozzle to form the first mixture.
93 . The method of claim 89 , wherein one of the at least two inputs to form the second mixture comprises an isocyanate and another of the at least two inputs to form the second mixture comprises a polyol system.
94 . The method of claim 93 , further comprising flowing at least a third input comprising a polyol system containing a blowing agent into the mixing nozzle to form the second mixture.
95 - 102 . (canceled)