Digital molding and associated articles and methods
The present disclosure relates generally to three-dimensionally printed molds, and associated methods, for use in manufacturing articles such as footwear. In some embodiments, for example, a three-dimensionally printed mold may be a master mold that is used to manufacture a secondary mold. The secondary mold may be used, in certain embodiments, to provide a cured material that can be transferred to a substrate, such as a textile, thereby providing the manufactured article. 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 curing a liquid, comprising:
dispensing a curable liquid into a mold through a printing nozzle disposed on a robotic gantry, wherein a composition of the curable liquid is varied between at least a first portion of the composition and a second portion of the composition; and
at least partially curing the curable liquid to provide an at least partially cured material.
2. The method of claim 1 , wherein the robotic gantry is configured to move the printing nozzle relative to the mold.
3. The method of claim 1 , further comprising depositing a pigment-containing component into the mold prior to dispensing the curable liquid.
4. The method of claim 1 , further comprising transferring the at least partially cured material from the mold to a substrate such that the at least partially cured material is adhered to the substrate, thereby providing an article.
5. The method of claim 4 , wherein at least partially curing and transferring occur simultaneously.
6. The method of claim 4 , wherein the at least partially cured material is fully cured after transferring.
7. The method of claim 4 , wherein the substrate comprises a textile, leather, or polymer.
8. The method of claim 1 , wherein a tensile elastic modulus of the at least partially cured material is varied by at least 10% between at least a first portion of the at least partially cured material and a second portion of the at least partially cured material.
9. The method of claim 1 , wherein the mold comprises an elastomer.
10. The method of claim 1 , wherein the mold comprises silicone.
11. The method of claim 1 , wherein the curable liquid comprises polyurethane.
12. The method of claim 1 , wherein the curable liquid comprises polyurea.
13. The method of claim 1 , wherein the curable liquid comprises a catalyst.
14. The method of claim 13 , wherein a concentration of the catalyst is varied between the first portion of the composition and the second portion of the composition.
15. A method of manufacturing an article, comprising:
casting an elastomer into a first mold to provide a second mold;
dispensing a curable liquid into the second mold;
at least partially curing the curable liquid to provide an at least partially cured material; and
transferring the at least partially cured material from the second mold to a substrate such that the at least partially cured material is adhered to the substrate, thereby providing the article.
16. The method of claim 15 , further comprising coating at least a portion of the curable liquid with a thermoplastic powder after dispensing the curable liquid into the second mold and before fully curing the curable liquid.
17. The method of claim 15 , wherein transferring the at least partially cured material to the substrate occurs while the at least partially cured material is in the second mold.
18. The method of claim 17 , further comprising peeling the at least partially cured material adhered to the substrate out of the second mold.
19. The method of claim 15 , further comprising depositing a pigment-containing component into the second mold prior to dispensing the curable liquid.
20. A method of manufacturing a colored article, comprising:
depositing one or more pigment-containing components into a mold;
dispensing a curable liquid onto the one or more pigment-containing components;
at least partially curing the curable liquid to provide an at least partially cured material associated with the one or more pigment-containing components; and
transferring the at least partially cured material associated with the one or more pigment-containing components from the mold to a substrate such that the at least partially cured material associated with the one or more pigment-containing components is adhered to the substrate, thereby providing the colored article.