Thread structure composition and method of making

1. A system comprising:

a thread structure composition comprising:

a first thread comprising a first material, the first material having a first melting temperature;

a second thread comprising a second material, the second material having a second melting temperature; and

wherein the second thread is twisted around the first thread;

a heat source configured to heat the thread structure composition to a temperature;

wherein the temperature is less than the first melting temperature;

wherein the temperature is greater than the second melting temperature;

an extruder configured to extrude the heated thread structure composition; and

a fabric for receiving the extruded thread structure composition,

wherein the fabric has a length, a width, and a thickness;

wherein a first direction extends along the length;

wherein a second direction extends along the width;

wherein a third direction extends along the thickness; and

wherein the extruder is further configured to move in the first direction, the second direction, and the third direction.

2. The system according to claim 1 , wherein the second material is configured to permeate into the fabric.

3. The system according to claim 1 , wherein the second material is configured to bond directly onto an outer surface of the first thread.

4. The system according to claim 1 , wherein the second material is configured to permeate through an outer surface of the first thread.

5. The system according to claim 1 , wherein the second material is thermoplastic.

6. The system according to claim 1 , wherein the temperature is approximately 250 degrees Celsius.

7. The system according to claim 1 , wherein the first thread has a first diameter substantially equal to a second diameter of the second thread.

8. The system according to claim 1 , wherein the second thread includes a core layer and an outer layer, the outer layer being formed of the second material; and

wherein the core layer is formed of the first material.

9. The system according to claim 1 , wherein the first thread includes a core layer and an outer layer, the outer layer being formed of the second material; and

wherein the core layer is formed of the first material.

10. A method of using a printable thread structure composition, the method comprising:

providing a printable thread structure composition comprising

a first thread comprising a first material, wherein the first material has a first melting temperature;

a second thread comprising a second material, wherein the second material has a second melting temperature;

heating the printable thread structure composition to a temperature, wherein the temperature is less than the first melting temperature and greater than the second melting temperature;

extruding the heated printable thread structure composition onto a fabric with an extruder,

wherein the fabric has a length, a width, and a thickness;

wherein a first direction extends along the length;

wherein a second direction extends along the width;

wherein a third direction extends along the thickness; and

wherein the step of extruding includes moving the extruder in the first direction, the second direction, and the third direction.

11. The method according to claim 10 , wherein the extruder is a component of a freeform printer.

12. The method according to claim 11 , wherein the step of heating the printable thread structure composition includes using a heater, wherein the heater is a second component of the freeform printer.

13. The method according to claim 10 , wherein the step of providing a printable thread composition includes

providing a first thread comprising a first material;

providing a second thread comprising a second material that is different from the first material;

wherein the second material is moldable above the temperature;

wherein the first material is in a solid state above the temperature; and

twisting the second thread around the first thread to form the thread structure composition.

14. The method according claim 13 , wherein the step of twisting the second thread around the first thread helically twists the second thread around the first thread.

15. The method according claim 13 , wherein the twisting the second thread around the first thread twists the first thread around the second thread.

16. The method according to claim 10 , wherein the first thread is provided with a core layer formed of the first material; and

wherein the first thread is provided with an outer layer formed of the second material.

17. The method according to claim 10 , wherein the second thread is provided with a core layer and an outer layer, the outer layer being formed of the second material; and

wherein the core layer is formed of the first material.

18. The method according to claim 10 , wherein the temperature is approximately 250 degrees Celsius.

19. The method according to claim 10 further comprising the step of applying a downward force to the heated printable thread structure composition after the step of extruding to push a portion of the heated printable thread structure composition into the fabric.

20. The method according to claim 10 , wherein the material of the second thread permeates the fabric after the step of extruding.