Methods and apparatuses to facilitate strain measurement in textiles

A system for producing a textile component of an article includes an additive manufacturing device in selective communication with a processor and memory. The processor and memory are configured to determine a strain value in a region of the textile component of the article based on images of the article from a camera in selective communication with the processor and memory and to generate a strain map based on the strain value. The additive manufacturing device is configured to apply a reinforcement to a textile substrate to variably reinforce the textile substrate according to the strain map and to form the textile component of the article.

FIELD OF THE DISCLOSURE

Embodiments of the present disclosure generally relate to producing apparel and, more particularly, to methods and apparatuses to facilitate strain measurement in textiles.

BACKGROUND

In recent years, apparel has been developed to support athletes' bodies and to improve athletes' performance. For example, athletic shoes now often include elastomers. The elastomers work to cover, compress, and cushion athletes' feet.

Certain known elastomers are in textile form. When an athlete wears a shoe constructed of these elastomeric textiles, the elastomeric textiles conform to the athlete's foot. The elastomeric textiles further gently squeeze the athlete's foot to provide support to the foot. When the foot flexes, the elastomeric textiles flex with the foot.

However, these known elastomeric textiles are produced in a single, uniform layer. Thus, these known elastomeric textiles have a uniform spring rate and provide undifferentiated compression across the athlete's foot.

Therefore, a need exists for an elastomer that has varying spring rates to provide customized varying levels of compression and resiliency to athletes.

SUMMARY

In one aspect, a system to produce a textile component of an article is disclosed that includes an additive manufacturing device in selective communication with a processor and memory. The processor and the memory are configured to determine a strain value in a region of the textile component of the article based on images of the article from a camera in selective communication with the processor and memory, and to generate a strain map based on the strain value. The additive manufacturing device is configured to apply a reinforcement to a textile substrate to variably reinforce the textile substrate according to the strain map and to form the textile component of the article.

In one embodiment, the article can be a shoe and the textile component can be an upper of the shoe. In another embodiment, the textile substrate can be a pre-made structure having a shape of the upper of the shoe. In yet another embodiment, the textile substrate is formed of an elastomeric textile. In a different embodiment, the reinforcement is comprised of an elastomer.

In still another embodiment, the article can include first and second textile components. In yet another embodiment, the article can be a shoe, the first textile component can be an upper of the shoe, and the second textile component can be a tongue of the shoe. In such embodiments, the tongue can be connected to the upper and the upper can be connected to a sole of the shoe. In a different embodiment, the textile substrate can include first and second textile substrates of the first and second textile components, respectively. In such embodiments, the additive manufacturing device can be further configured to apply, according to the strain map, a first plurality of reinforcements to the first textile substrate to form the first textile component, and to apply, according to the strain map, a second plurality of reinforcements to the second substrate to form the second textile component. In such embodiments, the first textile substrate can be a first pre-made structure having a shape of an upper of a shoe and the second textile substrate can be a second pre-made structure having a shape of a tongue of the shoe. In such embodiments, the first textile substrate can include a plurality of lace holes. In one embodiment, the first textile substrate can include a seam flange. In another embodiment, the second textile substrate can include a lace holder.

In another aspect, a system to produce an article is disclosed that includes an additive manufacturing device in selective communication with a processor and memory. The processor and memory are configured to determine a strain value in a region of the article based on images of the article from a camera in selective communication with the processor and memory. The additive manufacturing device is configured to apply a reinforcement to an article substrate to variably reinforce at least the region of the article according to the strain values and to form the article.

In one embodiment, the article can be an article of clothing. In a different embodiment, the reinforcement can be comprised of an elastomer.

In another embodiment, the reinforcement can include a plurality of reinforcements applied to the article substrate. In such embodiments, at least two of the plurality of reinforcements can have a varying thickness relative to each other. In some embodiments, the thickness of each of the plurality of reinforcements can be in a range of about 0.5 millimeters to about 3.0 millimeters. In yet another embodiment, the plurality of reinforcements can be shaped as linear lines. In such embodiments, at least two of the plurality of reinforcements can have a varying length relative to each other. In still another embodiment, the plurality of reinforcements can be shaped as curved lines. In such embodiments, two or more of the plurality of reinforcements can intersect each other. In another embodiment, the plurality of reinforcements can be shaped as dots. In such embodiments, the plurality of reinforcements can each have a non-polygonal shape or a polygonal shape. In such embodiments, two or more of the plurality of reinforcements can have varying shapes and sizes relative to each other.

In yet another aspect, a method to produce an article is disclosed that includes applying, with an additive manufacturing device, a reinforcement to an article substrate to variably reinforce at least a region of the article according to one or more strain values, which can be determined based on images of the article, and to form the article.

In one embodiment, the reinforcement can have a varying thickness. In another embodiment, the reinforcement can include a plurality of reinforcements applied to the article substrate. In such embodiments, two or more of the plurality of reinforcements can have a varying thickness and a varying shape relative to each other.

In still another embodiment, the article can be a shoe and the article substrate can be an upper of the shoe. In yet another embodiment, the article can be an article of clothing and the article substrate can be a surface of the article of clothing.

In still yet another aspect, a non-transitory computer-readable medium is disclosed that stores instructions for an additive manufacturing device that, when executed by the additive manufacturing device, causes the additive manufacturing device to apply a reinforcement to a substrate of an article to variably reinforce at least a region of the article according to one or more strain values, which is determined based on images of the article, and to form the article.

In one embodiment, the article can be a shoe and the substrate can be an upper of the shoe. In another embodiment, the article can be an article of clothing and the substrate can be a surface of the article of clothing. In still another embodiment, the reinforcement is comprised of an elastomer.

DETAILED DESCRIPTION

Embodiments of the present disclosure provide an example system that has features to facilitate producing an elastomer that has varying spring rates to provide customized varying levels of compression and resiliency. The example system includes cameras and a controller to measure deformation of an athlete's shoes when the athlete's feet exert forces on the shoes through movement (e.g., running, jumping, kicking, etc.). The controller generates a map of the deformation measurements. The map is provided to a three-dimensional (3D) printer of the system, which selectively applies an elastomer to shoe components according to the map. Thus, the shoe components are reinforced by the elastomer in a pattern that is customized to the athlete's feet. It should be understood that the system may be used in any type of application to measure deformation in a test article, generate a map, and reinforce components according to the map to produce a stiffened and/or customized article (e.g., clothing, structures, tools, machinery, etc.).

A system100, according to an embodiment of the present disclosure is depicted inFIGS.1and2. The system100includes a track106, one or more cameras110, a controller114, and a 3D printer118. In some embodiments, the track106and the cameras110are located at a testing facility120(e.g., a track, a gymnasium, a stadium, a retail location, etc.). In some embodiments, the controller114and/or the 3D printer118are also located at the testing facility120. In some embodiments, the controller114and/or the 3D printer118are located remotely from the track106and the cameras110. As an athlete122wearing reference shoes124moves along the track106, the cameras110capture image data of the reference shoes124, which is transmitted to the controller114. The controller114analyzes the image data and instructs the 3D printer118to produce shoe components with varying levels of compression and resiliency that are customized to the athlete122.

Still referring toFIGS.1and2, in some instances, the athlete122may arrive at the testing facility120and be asked to move along the track106while wearing the reference shoes124. More specifically, as the athlete122moves along the track106, the athlete's122feet move within and relative to the reference shoes124(e.g., sliding, rolling, pronating, laterally, axially, etc.). Thus, the athlete's122feet exert forces on the reference shoes124to at least momentarily stretch and/or compress parts and/or regions of the reference shoes124. This stretching and/or compression exerted on the reference shoes124may be measured as strain e, i.e., a change in length of an article as compared to an original length of the article, as will be explained in greater detail below. By capturing image data of the reference shoes124with the cameras110from multiple angles, the strain e values experienced across the various regions of the reference shoes124may be determined. Using these determined strain e values, a custom pair of shoes with regions having varying levels of reinforcement and/or elasticity may be produced for the athlete122, as will be explained in greater detail below.

With continued reference toFIGS.1and2, the athlete122is shown at a first time t1(in phantom) and at a second time t2. The second time t2is after the first time t1. It should be understood that the time period between t1and t2is relatively short (e.g., in a range between 0.4 millisecond and 5.0 milliseconds). Thus, the athlete122moves a relatively small distance along the track106during the time period between t1and t2.

Still referring toFIGS.1and2, in some embodiments, the track106is a substrate (e.g., a mat, a carpet, an artificial turf section, etc.) placed on the ground. In some embodiments, the track106is a predetermined area outlined on the ground (e.g., with paint, chalk, tape, etc.). In some embodiments, the track106is an elongated area between the cameras110for the athlete122to move and/or run along. In some embodiments, the track106is curvilinear. In some embodiments, the track106includes one or more corners (not shown).

Referring specifically toFIG.1, each camera110includes one or more lenses126, a processor128, and a memory130. Thus, in some embodiments, one or more of the cameras110is a stereoscopic camera. Further, in some embodiments, two single-lensed cameras110may be coupled together and/or arranged directly next to one another to produce a stereoscopic (e.g., three dimensional) image. The cameras110are arranged about the track106to collect image data from multiple views of the reference shoes124and the athlete122. More specifically, the cameras110are located at opposing ends and alongside opposing sides of the track106. Thus, the cameras110are located in front of, behind, and to the sides of the athlete122. With reference specifically toFIG.2, the cameras110are disposed low to the ground along the track106to capture image data of the reference shoes124. It should be understood that the cameras110may be alternatively arranged to capture image data of any part and/or side of the athlete122.

With continued reference toFIG.1, the controller114is in communication with the cameras110and with the 3D printer118. It should be understood that arrows indicating communication are omitted fromFIG.2for clarity. The controller114includes a processor132and a memory134. More specifically, the controller114may be in communication with the cameras110and with the 3D printer118via direct wired connections, a wired network, wirelessly, a wireless network, etc. Further, the controller114may be in selective communication with the cameras110and with the 3D printer118. In other words, the controller114may be communicatively connected to the cameras110to receive image data and to the 3D printer118to transmit 3D printing instructions. Thus, in some embodiments, the controller114is remote from the cameras110and/or the 3D printer118.

Still referring toFIG.1, in some embodiments, the controller114is a programmable logic controller (PLC). Additionally, the processors128,132may be any suitable processing device or set of processing devices such as, but not limited to, a microprocessor, a microcontroller-based platform, an integrated circuit, one or more field programmable gate arrays (FPGAs), and/or one or more application-specific integrated circuits (ASICs). The memories130,134may be volatile memory (e.g., RAM including non-volatile RAM, magnetic RAM, ferroelectric RAM, etc.), non-volatile memory (e.g., disk memory, FLASH memory, EPROMs, EEPROMs, memristor-based non-volatile solid-state memory, etc.), unalterable memory (e.g., EPROMs), read-only memory, and/or high-capacity storage devices (e.g., hard drives, solid state drives, etc.). In some examples, the memories130,134includes multiple kinds of memory, particularly volatile memory and non-volatile memory.

The memories130,134are computer readable media on which one or more sets of instructions, such as the software for operating the methods of the present disclosure, can be embedded. The instructions may embody one or more of the methods or logic as described herein. For example, the instructions reside completely, or at least partially, within any one or more of the memories130,134, the computer readable medium, and/or within the processors128,132during execution of the instructions.

Referring again toFIGS.1and2, the 3D printer118is an additive manufacturing device. Additive manufacturing is also often referred to as 3D-printing. Products made via additive manufacturing are often referred to as additively manufactured and/or 3D-printed. As used herein, the terms “additive manufacturing,” “3D-printing,” “3D printing,” and the like are equivalent to one another. The 3D printer118is configured to extrude and/or deposit subsequent layers of polymers and/or elastomers (e.g., plastic, silicone, artificial rubber, etc.) to produce a predetermined shape. The predetermined shape is provided by the controller114.

Referring now toFIG.3, the processor132is structured to include an image receiver140, a reference detector142, a distance determiner144, a distance comparator146, a strain determiner148, and a map compiler150. The memory134stores reinforcement data152.

With reference now toFIG.4, the reference shoe124includes an upper154, a tongue156, a sole158, and laces160. The upper154includes a lateral section162, a front section164, a rear section166, and a medial section168(shown via the left reference shoe124of the athlete122inFIG.2). As shown inFIG.4, the front section164is opposite the rear section166, and the lateral section162is opposite the medial section168(shown inFIG.2). Additionally, the upper154features a plurality of reference marks170. In some embodiments, the plurality of reference marks170are arranged in a decorative pattern. In some embodiments, the plurality of reference marks170are spread randomly across the reference shoe124. In some embodiments, the upper154is a substrate and the plurality of reference marks170are attached to the upper154(e.g., printed, embroidered, adhered, fastened, etc.). In some embodiments, the plurality of reference marks170are a pattern within the upper154(e.g., woven, knitted, crocheted, etc.).

Referring now toFIG.4A, a calibration image172taken by the cameras110shows the reference shoe124under no load and/or constraint. The calibration image172is taken at a calibration time to. In some instances, the calibration time to is before the first time t1. In some instances, the calibration time to is after the first time t1. In some instances, the calibration time to is after the second time t2. In the illustrated example ofFIG.4A, the calibration image172is primarily directed to the lateral section162. In some instances, the calibration image172is a stereoscopic image.

With reference now toFIG.5, a first image174taken by the cameras110shows the reference shoe124at the first time t1. In the illustrated example ofFIG.5, the first image174is primarily directed to the lateral section162. In some instances, the first image174is a stereoscopic image. Similarly, with reference now toFIG.6, a second image176taken by the cameras110shows the reference shoe124at the second time t2. In the illustrated example ofFIG.6, the second image176is also primarily directed to the lateral section162. In some instances, the second image176is a stereoscopic image. As will be explained in greater detail below, the calibration image172, the first image174, and/or the second image176are analyzed to determine strain exerted on the lateral section162by the athlete122.

With reference again toFIGS.4A,5, and6, it should be understood that the cameras110(shown inFIGS.1and2) may take additional images (not shown) of the reference shoe124directed toward the front section164, the rear section166, and/or the medial section168(shown inFIG.2) as the athlete122moves along the track106. The sampling rate at which the cameras110take these images is relatively fast (e.g., in a range between 200 samples per second and 2500 samples per second). In some instances, these additional images may be taken at the first time t1and/or the second time t2. In some instances, these additional images may be taken at times differing from the first time t1and/or the second time t2. It should be further understood that these additional images may be analyzed in the same manner as the calibration image172, the first image174, and/or the second image176to determine strain exerted on the front section164, the rear section166, and/or the medial section168by the athlete122.

With continued reference toFIGS.4A,5, and6, the plurality of reference marks170define a plurality of regions178between neighboring reference marks170. For example, a first reference mark180neighbors a second reference mark182. Thus, the plurality of reference marks170includes a plurality of neighboring reference mark sets184. For example, the first reference mark180and the second reference mark182form one of the plurality of neighboring reference mark sets184. In other words, each region178is defined by one of the plurality of neighboring reference mark sets184. It should be understood that each reference mark170may be part of multiple neighboring reference mark sets184.

With reference again toFIG.4A, at the calibration time to, the first reference mark180is separated from the second reference mark182by a reference distance D0across the region178. With reference again toFIG.5, at the first time t1, the first reference mark180is separated from the second reference mark182by a first distance D1across the region178. With reference again toFIG.6, at the second time t2, the first reference mark180is separated from the second reference mark182by a second distance D2across the region178. In the illustrated examples ofFIGS.4A,5, and6, D1is longer than D0and D2is longer than D1. Thus, in the examples ofFIGS.4A and5, the foot of the athlete122moves laterally outwardly relative to the sole158against the region178to stretch the upper154from the reference distance D0(shown inFIG.4A) to the first distance D1(shown inFIG.5). In other words, the region178stretches by the difference between the reference distance D0and the first distance D1under outward lateral pressure exerted by the foot of the athlete122. It should be understood that, depending on the movements of the athlete122(shown inFIGS.1,2, and4), D1may be shorter than or equal to D0. When D1is shorter than D0, the region178is compressed. When D1is equal to D0, no net forces are acting on the region178.

Further, in the example ofFIGS.5and6, during the time period from the first time t1to the second time t2, the foot of the athlete122moves laterally outwardly relative to the sole158against the region178to stretch the upper154from the first distance D1(shown inFIG.5) to the second distance D2(shown inFIG.6). In other words, the region178stretches by the difference between the first distance D1and the second distance D2under outward lateral pressure exerted by the foot of the athlete122. It should be understood that, depending on the movements of the athlete122(shown inFIGS.1,2, and4), D2may be shorter than or equal to D1. When D2is shorter than D1, the region178is compressed during the time period from the first time t1to the second time t2. When D2is equal to D1, no net forces have acted on the region178during the time period from the first time t1to the second time t2.

With reference again toFIGS.1,2, and3, in operation, the controller114receives the calibration image172(shown inFIG.4A), the first image174(shown inFIG.5), and/or the second image176(shown inFIG.6) from the cameras110. In other words, in operation, the controller114receives the calibration image172(shown inFIG.4A) and one or more of the time-separated pair of images directed to the lateral section162(shown inFIGS.4,5, and6) from the cameras110. It should be understood that the controller114additionally receives calibration images and time-separated pairs of images directed to the front section164(shown inFIGS.4,5, and6), the rear section166(shown inFIGS.4,5, and6), and the medial section168(shown inFIG.2) from the cameras110. Further in operation, the controller114analyzes the received calibration images (e.g., the calibration image172) and time-separated pairs of images (e.g., the first image174and the second image176) to generate a strain map186(shown inFIG.7), as will be explained in greater detail below.

Referring now toFIG.7, the strain map186includes a legend188, an upper guide190, a tongue guide192, strain indicators196, and reinforcement thickness values198. The strain indicators196are distributed across the upper guide190and the tongue guide192according to the analysis of the first image174and the second image176. The strain indicators196are graphical representations of mechanical strain e experienced by the upper154(shown inFIG.4) and/or the tongue156while the athlete122(shown inFIGS.1,2, and4) moved along the track106. The legend188correlates the graphical representation of the strain indicators196to the reinforcement thickness values198. More specifically, strain e is described by Equation 1, below:

Thus, in Equation 1, strain e is the ratio of the change in length between the reference distance D0(shown inFIG.4A) and the first distance D1(shown inFIG.5) as compared to the reference distance D0. It should be appreciated that because D0and D1both have units of length (e.g., millimeters and/or inches), strain e is unitless. Strain e is often described in terms of percentage.

In some instances, strain e is described by Equation 2, below:

Thus, in Equation 2, strain e is the ratio of the change in length between the first distance D1(shown inFIG.5) and the second distance D2(shown inFIG.6) as compared to the first distance D1.

With reference now toFIG.8, shoe components200include a first example upper blank204and a tongue blank206. The upper blank204includes a first substrate210, which has a seam flange212and defines lace holes214. The upper blank204is a pre-made structure ready for 3D printing. In some embodiments, the first substrate210is formed of an elastomeric textile. The upper blank204further includes a first plurality of reinforcements216applied to the first substrate210by the 3D printer118(shown inFIGS.1and2) according to the strain map186(shown inFIG.7), as will be explained in greater detail below. The tongue blank206includes a second substrate222, which defines a lace holder224. The tongue blank206is also a pre-made structure ready for 3D printing. The tongue blank206further includes a second plurality of reinforcements226applied to the second substrate222by the 3D printer118according to the strain map186, as will also be explained in greater detail below. In some embodiments, the first plurality of reinforcements216and/or the second plurality of reinforcements226are resilient and/or are composed of an elastomer. In the example ofFIG.8, the first plurality of reinforcements216and the second plurality of reinforcements226are shaped as a plurality of dashes.

Referring now toFIG.9, in some embodiments, the reinforcement data152is organized as a look-up table. The reinforcement data152includes strain value ranges234and the reinforcement thickness values198. The reinforcement data152correlates the strain value ranges234to the reinforcement thickness values198.

With reference again toFIG.3, in operation, the image receiver140receives the calibration image172(shown inFIG.4A), the first image174(shown inFIG.5), and the second image176(shown inFIG.6) from the cameras110. In some embodiments, the cameras110send image data to the controller114as the image data is produced. Thus, in some embodiments, the controller114receives the second image176after the first image174. Further, in some embodiments, the controller114receives the first image174after the calibration image172. In some embodiments, the controller114receives the calibration image172, the first image174, and the second image176generally simultaneously.

With continued reference toFIG.3, in operation, the reference detector142detects the plurality of reference marks170(shown inFIGS.4A,5, and6) in the calibration image172, the first image174, and/or in the second image176. More specifically, the reference detector142detects neighboring reference mark sets184visible in the calibration image172, the first image174, and/or in the second image176. For example, the reference detector142detects the first reference mark180and the second reference mark182. The reference detector142detects the plurality of reference marks170(e.g., the first reference mark180and the second reference mark182) via one or more of edge detection, contrast differentiation, pattern recognition, etc.

Still referring toFIG.3, in operation, the distance determiner144determines distances between reference marks170in neighboring reference mark sets184in the first image174(shown inFIG.5) and in the second image176(shown inFIG.6). In other words, the distance determiner144determines distances across the regions178in the first image174and in the second image176. For example, the distance determiner144determines the reference distance D0(shown inFIG.4A) between the first reference mark180and the second reference mark182in the calibration image172. Additionally, the distance determiner144determines the first distance D1(shown inFIG.5) between the first reference mark180and the second reference mark182in the first image174. Further, for example, the distance determiner144determines the second distance D2(shown inFIG.6) between the first reference mark180and the second reference mark182in the second image176.

With continued reference toFIG.3, in operation, the distance comparator146compares the distances between reference marks170in neighboring reference mark sets184determined from the first image174(shown inFIG.5) and the second image176(shown inFIG.6). In other words, the distance comparator146compares the distances across the regions178found from the calibration image172(shown inFIG.4A), the first image174, and/or the second image176. For example, the distance comparator146compares the reference distance D0(shown inFIG.4A) to the first distance D1(shown inFIG.5). As another example, the distance comparator146compares the reference distance D0to the second distance Dz (shown inFIG.6). In a further example, the distance comparator146compares the first distance D1to the second distance Dz. Further, the distance comparator146determines differences between the distances determined from the calibration image172, the first image174, and/or the second image176. In other words, the distance comparator146determines distance differences corresponding to each neighboring reference mark set184. For example, the distance comparator146determines a difference between the reference distance D0and the first distance D1. As another example, the distance comparator146determines a difference between the reference distance D0and the second distance Dz. In a further example, the distance comparator146determines a difference between the first distance D1and the second distance Dz.

With reference still toFIG.3, in operation, the strain determiner148determines strain values e corresponding to each region178based on the determined distance differences and the distances found in the first image174(shown inFIG.5) according to Equation 1 and/or Equation 2, above. For example, the strain determiner148determines a strain value e from the difference between the reference distance D0(shown inFIG.4A) and the first distance D1(shown inFIG.5) as compared to the reference distance D0according to Equation 1. In another example, the strain determiner148determines a strain value e from the difference between the first distance D1and the second distance D2(shown inFIG.6) as compared to the first distance D1according to Equation 2.

With continued reference toFIG.3, it should be understood that the image receiver140, the reference detector142, the distance determiner144, the distance comparator146, and the strain determiner148receive, process, and analyze the time-separated pairs of images directed to the front section164(shown inFIGS.4,5, and6), the rear section166(shown inFIGS.4,5, and6), and/or the medial section168(shown inFIG.2) in the same manner as the calibration image172, the first image174, and the second image176. Thus, the controller114generates strain values e for the lateral section162, the front section164, the rear section166, and/or the medial section168. In other words, the controller114generates strain values e for some or all portions of the reference shoe124using image data from the cameras110(shown inFIG.1).

Still referring toFIG.3, in operation, the map compiler150compiles and graphically represents the strain values e to generate the strain map186(shown inFIG.7). More specifically, the map compiler150positions the strain indicators196on the strain map186corresponding to the regions178(shown inFIGS.5and6). Additionally, the map compiler150accesses the reinforcement data152(shown inFIGS.3and9) and assigns one of reinforcement thickness values198to each strain indicator196according to the corresponding strain values e for each region178. Further, the map compiler150codes the strain indicators196according to the corresponding strain values e and/or reinforcement thickness values198(e.g., by color, numeral tags, vector arrows, thickness, pattern, etc.). Thus, referring again toFIG.7, the strain indicators196are mapped onto the upper guide190and the tongue guide192according to the strain values e for each region178. Continuing in operation, the map compiler150sends the generated strain map186to the 3D printer118.

With reference again toFIG.8, the 3D printer118(shown inFIGS.1and2) produces the shoe components200. More specifically, the 3D printer118extrudes and/or deposits the first plurality of reinforcements216directly onto the first substrate210according to the positions and reinforcement thickness values198indicated by the strain map186(shown inFIG.7) to produce a customized upper238. Additionally, the 3D printer118extrudes and/or deposits the second plurality of reinforcements226directly onto the second substrate222according to the positions and reinforcement thickness values198indicated by the strain map186to produce a customized tongue240. In some embodiments, the first plurality of reinforcements216and/or the second plurality of reinforcements226are composed of an elastomer. Thus, the first substrate210is variably reinforced and/or stiffened by the first plurality of reinforcements216. Similarly, the second substrate222is variably reinforced and/or stiffened by the second plurality of reinforcements226. Thus, the shoe components200are customized to the athlete122.

Referring now toFIG.11, once the first plurality of reinforcements216and the second plurality of reinforcements226are cured (e.g., by the 3D printer118), the shoe components200may be utilized with a sole242and laces244to construct a customized shoe248specifically for the athlete122. More specifically, the customized upper238may be connected to the customized tongue240(e.g., stitched, adhered, welded, etc.) and further connected to the sole242.

With reference now toFIG.12, a second example upper blank304includes the first substrate210and is a pre-made structure ready for 3D printing. The upper blank304further includes a plurality of reinforcements316applied to the first substrate210by the 3D printer118(shown inFIGS.1and2) according to the strain map186(shown inFIG.7), in the same manner as with the first example upper blank204and the example tongue206(shown inFIG.8). In some embodiments, the plurality of reinforcements316are resilient and/or are composed of an elastomer. In the example ofFIG.12, the plurality of reinforcements316are shaped as a plurality of lines.

Referring now toFIG.13, a third example upper blank404includes the first substrate210and is a pre-made structure ready for 3D printing. The upper blank404further includes a plurality of reinforcements416applied to the first substrate210by the 3D printer118(shown inFIGS.1and2) according to the strain map186(shown inFIG.7), in the same manner as with the first example upper blank204and the example tongue206(shown inFIG.8). In some embodiments, the plurality of reinforcements416are resilient and/or are composed of an elastomer. In the example ofFIG.13, the plurality of reinforcements416are shaped as a plurality of lines along which pointed dots are disposed.

With reference now toFIG.14, a fourth example upper blank504includes the first substrate210and is a pre-made structure ready for 3D printing. The upper blank504further includes a plurality of reinforcements516applied to the first substrate210by the 3D printer118(shown inFIGS.1and2) according to the strain map186(shown inFIG.7), in the same manner as with the first example upper blank204and the example tongue206(shown inFIG.8). In some embodiments, the plurality of reinforcements516are resilient and/or are composed of an elastomer. In the example ofFIG.14, the plurality of reinforcements516are shaped as a plurality of pointed dots.

Referring now toFIG.15, a fifth example upper blank604includes the first substrate210and is a pre-made structure ready for 3D printing. The upper blank604further includes a plurality of reinforcements616applied to the first substrate210by the 3D printer118(shown inFIGS.1and2) according to the strain map186(shown inFIG.7), in the same manner as with the first example upper blank204and the example tongue206(shown inFIG.8). In some embodiments, the plurality of reinforcements616are resilient and/or are composed of an elastomer. In the example ofFIG.15, the plurality of reinforcements616are shaped as a plurality of lines along which hexagons are disposed.

With reference now toFIG.16, a sixth example upper blank704includes the first substrate210and is a pre-made structure ready for 3D printing. The upper blank704further includes a plurality of reinforcements716applied to the first substrate210by the 3D printer118(shown inFIGS.1and2) according to the strain map186(shown inFIG.7), in the same manner as with the first example upper blank204and the example tongue206(shown inFIG.8). In some embodiments, the plurality of reinforcements716are resilient and/or are composed of an elastomer. In the example ofFIG.16, the plurality of reinforcements716are shaped as a plurality of tear drops.

Referring now toFIG.17, a seventh example upper blank804includes the first substrate210and is a pre-made structure ready for 3D printing. The upper blank804further includes a plurality of reinforcements816applied to the first substrate210by the 3D printer118(shown inFIGS.1and2) according to the strain map186(shown inFIG.7), in the same manner as with the first example upper blank204and the example tongue206(shown inFIG.8). In some embodiments, the plurality of reinforcements816are resilient and/or are composed of an elastomer. In the example ofFIG.17, the plurality of reinforcements316are shaped as a plurality of rectangles.

A flowchart representative of a first example method1000that may be performed to produce variably resilient elastomers is depicted inFIG.10. The flowchart ofFIG.10is representative of machine readable instructions that are stored in memory (such as the memory134ofFIGS.1-3) and include one or more programs which, when executed by a processor (such as the processor132ofFIGS.1-3), cause the controller114to operate the example system100ofFIGS.1and2. While the example program is described with reference to the flowchart illustrated inFIG.10, many other methods of operating the example system100may alternatively be used. For example, the order of execution of the blocks may be rearranged, changed, eliminated, and/or combined to perform the method1000. Further, because the method1000is disclosed in connection with the components ofFIGS.1and2, some functions of those components will not be described in detail below.

Initially, at block1002, the controller114receives images from the cameras110(shown inFIGS.1and2). More specifically, the image receiver140receives the calibration image172(shown inFIG.4A) taken at the calibration time to and the first image174(shown inFIG.5) taken at the first time t1. In some embodiments, the image receiver140receives the first image174and the second image176(shown inFIG.6) subsequently taken at the second time t2. In some embodiments, image receiver140receives the calibration image172taken at the calibration time to and the second image176.

At block1004, the controller114detects reference marks170(shown inFIGS.4A,5, and6) in the images (e.g., the calibration image172, the first image174, the second image176, etc.). More specifically, the reference detector142finds neighboring reference mark sets184and their corresponding regions178.

At block1006, the controller114determines distances across the regions178. More specifically, the distance determiner144finds lengths between reference marks170(shown inFIGS.4a,5, and6) of neighboring reference mark sets184in the images.

At block1008, the controller114compares distances across the regions178between the images. More specifically, the distance comparator146determines length differences between the distances from the respective images corresponding to each region178.

At block1010, the controller114determines strain values e for each region178. More specifically, the strain determiner148computes strain values e corresponding to each region178based on the determined length differences and the distances from the images.

At block1012, the controller114compiles the strain map186(shown inFIG.7). More specifically, the map compiler150positions strain indicators196on the upper guide190and the tongue guide192corresponding to each of the regions178. The map compiler150assigns reinforcement thickness values198to each of the strain indicators196according to the reinforcement data152and the determined strain values e corresponding to the regions178.

At block1014, the 3D printer118(shown inFIGS.1and2) additively manufactures the shoe components200(shown inFIG.8). More specifically, the 3D printer118deposits and/or extrudes the first plurality of reinforcements216onto the first substrate210and the second plurality of reinforcements226onto the second substrate222according to the strain map186(shown inFIG.7). The method1000then returns to block1002.

From the foregoing, it will be appreciated that the above example system100includes cameras and a controller to measure strain in an athlete's shoes and generate a strain map of the shoes. The system100also includes a 3D printer to produce reinforced shoe components according to the strain map. Thus, the reinforced shoe components are customized to the athlete's feet. Because the shoe components are reinforced, the shoe components may be more durable as to existing athletic shoe components. Thus, the above-disclosed example system100conserves resources as compared to existing athletic shoe production systems.

Variations and modifications of the foregoing are within the scope of the present disclosure. It is understood that the embodiments disclosed and defined herein extend to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present disclosure. The claims are to be construed to include alternative embodiments to the extent permitted by the prior art.