SYSTEMS AND METHODS FOR 3D PRINTING ARTICLES OF FOOTWEAR WITH PROPERTY GRADIENTS
The present disclosure is related to three-dimensionally printed articles for use in footwear and associated systems and methods. In some embodiments, a three-dimensionally printed article may comprise a closed-cell foam. The closed-cell foam may have a gradient in and/or may be a single integrated material. In some embodiments, a three-dimensionally printed article may comprise a sensor. The use of such arrangements can, according to certain embodiments, allow for the production of improved articles of footwear and/or customized articles of footwear.
1 . A method of printing of an article for use in footwear, comprising:
receiving object information associated with the article comprising a gradient structure having a gradient in a property between a first portion and second portion, wherein the property is selected from the group consisting of: average stiffness, average Shore A hardness, average pore size, average density, color, average surface roughness, average reflectivity, average strength, average elongation at break, average tensile elastic modulus, and average 100% modulus;
identifying the gradient structure using the object information;
identifying a set of printer parameters for printing the gradient structure;
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 set of printer parameters comprises at least one setting selected from the group consisting of: a ratio of 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 combined volumetric flow rate of one or more input materials to a mixing chamber, nozzle tip height relative to the substrate, target temperature of the mixing chamber and/or the substrate, target catalyst concentration of the resulting mixed material, target line width of the printed material, target fumed silica concentration of the printed composite, target viscosity of the printed composite at the point of exiting the nozzle, and target concentration of an additive.
3 . The method of claim 1 , wherein identifying a set of printer parameters comprises calculating a set of ratios of two or more material inputs.
4 . The method of claim 1 , wherein generating print instructions comprises outputting machine readable code.
5 . The method of any claim 1 , wherein printing the article using the print instructions comprises:
controlling a flow of a first fluid into a mixing chamber using the print instructions;
controlling a flow of a second fluid into the mixing chamber using the print instructions;
spinning an impeller in the mixing chamber to mix the first and second fluids using the print instructions; and
depositing the mixture onto a substrate from the mixing chamber using the print instructions.
6 . A method for 3D-printing an article for use in footwear, comprising:
3D-printing an article having a gradient in a property between a first portion and a second portion, wherein the 3D-printed article is a single integrated material, and wherein the property is selected from the group consisting of average stiffness, average Shore A hardness, average Shore D hardness, average Asker C hardness, average pore size, average density, color, average surface roughness, average reflectivity, average strength, average elongation at break, average tensile elastic modulus, average modulus at 100% strain, average opacity, and average dimensional change upon heat activation.
7 . A method for 3D-printing an article for use in footwear, comprising:
3D-printing an article having a gradient in a property between a first portion and a second portion, wherein the 3D-printed article is a single integrated material, and wherein the property is a mechanical property.
8 - 9 . (canceled)
10 . A method as in claim 6 , wherein the property is average pore size.
11 . (canceled)
12 . A method as in claim 6 , wherein the property is average stiffness.
13 - 19 . (canceled)
20 . A method as in any claim 6 , wherein the property is average density.
21 - 22 . (canceled)
23 . A method as in claim 6 , wherein the first portion is positioned above the second portion.
24 . A method as in claim 6 , wherein the first portion is positioned beside the second portion.
25 . A method as in claim 6 , wherein the first portion and the second portion are directly adjacent.
26 - 32 . (canceled)
33 . A method as in claim 6 , wherein the 3D-printed article is a component of one or more of a sole, an upper, a midsole, an outsole, an insole, a toe box, an eyestay, a heel counter, a logo, an eyelet, a quarter panel, and a no sew overlay feature.
34 . (canceled)
35 . A method as in claim 6 , wherein the 3D-printed article comprises a foam.
36 - 42 . (canceled)
43 . A method as in claim 6 , wherein the gradient is present over a distance of greater than or equal to 2 mm.
44 . (canceled)
45 . A method as in claim 6 , wherein the 3D-printed article comprises a pathway along which the 3D-printed article lacks an interface over which the property undergoes a step change, and wherein the pathway has a length of greater than or equal to 5 mm.
46 - 48 . (canceled)
49 . A method as in claim 6 , wherein the property varies smoothly throughout the printed article.
50 - 86 . (canceled)
87 . A method as in claim 6 , wherein the 3D-printed article is disposed on a textile.
88 . A method as in claim 87 , wherein the textile is a component of a footwear upper.
89 - 92 . (canceled)