Patent Description:
Three-dimensional printing systems and methods may be associated with various technologies including fused deposition modeling (FDM), electron beam freeform fabrication (EBF), and selective laser sintering (SLS), as well as other kinds of three-dimensional printing technologies.

<CIT> describes a method of forming a golf ball, wherein the method includes forming a core using a 3D printer, and molding a cover in a surrounding position over the core through at least one of compression molding and injection molding. The core may be formed by printing a first core portion, printing a second core portion, and fusing the first core portion with the second core portion to form the core. Each of the first and second core portions may respectively include a plurality of concentric shells that are sequentially constructed.

<CIT> describes a method for the production of a fabric for industrial use comprising extruding polymer material onto a carrier structure to produce a patterned design on the carrier structure, wherein a cross-sectional profile of the extruded polymer material is substantially convex. An apparatus for carrying out the method comprising a polymer extrusion apparatus structured and arranged to move in three mutually perpendicular directions. A fabric comprising a carrier structure and a patterned design comprising extruded polymer material arranged on the carrier structure, wherein the extruded polymer material is arranged to form a substantially convex cross section on the carrier structure.

<CIT> relates to portions of an article of footwear formed from an extruded member. A sole or portion of a sole can be formed from one or more extruded members. The extruded member can be a single, continuous piece of solid material. A sole for an article of footwear can be fashioned from an extruded member formed in a controlled geometric pattern. The sole can include one or more layers.

The claimed invention is defined by an apparatus according to appended claim <NUM>, and by a method according to appended claim <NUM>.

<FIG> is a schematic view of an embodiment of a three-dimensional printing system <NUM>, also referred to simply as printing system <NUM> hereafter. <FIG> also illustrates several exemplary articles <NUM> that may be used with printing system <NUM>. Referring to <FIG>, printing system <NUM> may further comprise a printing device <NUM>, a computing system <NUM>, and a network <NUM>.

Embodiments may use various kinds of three-dimensional printing (or additive manufacturing) techniques. Three-dimensional printing, or "3D printing," comprises various technologies that are used to form three-dimensional objects by depositing successive layers of material on top of one another. Exemplary 3D printing technologies that could be used include, but are not limited to: fused filament fabrication (FFF), electron beam freeform fabrication (EBF), direct metal laser sintering (DMLS), electron beam melting (EMB), selective laser melting (SLM), selective heat sintering (SHS), selective laser sintering (SLS), plaster-based 3D printing (PP), laminated object manufacturing (LOM), stereolithography (SLA), and digital light processing (DLP), as well as various other kinds of 3D printing or additive manufacturing technologies known in the art.

For consistency and convenience, directional adjectives are employed throughout this detailed description corresponding to the illustrated embodiments. The term "longitudinal axis," as used throughout this detailed description and in the claims, refers to an axis extending a length of a component. Thus, a "longitudinal direction," as used throughout this detailed description and in the claims, refers to a direction aligned with a longitudinal axis.

The term "lateral axis," as used throughout this detailed description and in the claims, refers to a side-to-side axis extending a width of a component. For example, the lateral axis may extend between a medial side and a lateral side of an article of footwear, with the lateral side of the article of footwear being the surface that faces away from the other foot, and the medial side being the surface that faces toward the other foot. Thus, a "lateral direction," as used throughout this detailed description and in the claims, refers to a direction aligned with a lateral axis.

The term "horizontal," as used throughout this detailed description and in the claims, refers to any direction or axis that is substantially parallel with the longitudinal axis, the lateral axis, and all directions in between. In cases where a component is placed on the ground, a horizontal axis may be parallel with the ground.

The term "vertical," as used throughout this detailed description and in the claims, refers to an axis that is generally perpendicular to both the lateral and longitudinal axes, along a substantially vertically (upward and downward) oriented axis. For example, in cases where a component is flat on a ground surface, the vertical axis may extend from the ground surface upward.

It will be understood that each of these directional adjectives may be applied to individual components of a sole. Furthermore, the term "outer surface" as used throughout this detailed description and in the claims, refers to the surface of a component that is exposed or facing the external environment.

For purposes of this disclosure, the foregoing directional terms, when used in reference to a printing system or an article of footwear or other article of apparel, shall refer to the articles when disposed on a substantially flat surface. With respect to an article of footwear, the directional terms refer to the article when sitting in an upright position, with the sole facing groundward, that is, as it would be positioned when worn by a wearer standing on a substantially level surface.

In the embodiments shown in the figures, printing system <NUM> may be associated with fused filament fabrication (FFF), also referred to as fused deposition modeling. In the embodiment shown in <FIG>, printing device <NUM> of printing system <NUM> may use fused filament fabrication to produce three-dimensional parts. An example of a printing device using fused filament fabrication (FFF) is disclosed in <CIT>, and titled "Apparatus and Method for Creating Three-Dimensional Objects," which application is referred to hereafter as the "3D Objects application. " Embodiments of the present disclosure can make use of any of the systems, components, devices, and methods disclosed in the 3D Objects application.

Printing device <NUM> may include a housing <NUM> that supports various systems, devices, components, or other provisions that facilitate the three-dimensional printing of objects (e.g., parts, components, or structures). Although the exemplary embodiment depicts a particular rectangular box-like geometry for housing <NUM>, other embodiments could use any housing having any geometry and/or design. The shape and size of housing <NUM> could be varied according to factors including a desired footprint for the device, the size and shape of parts that may be formed within printing device <NUM>, as well as possibly other factors. It will be understood that housing <NUM> could be open (e.g., provide a frame with large openings) or closed (e.g., with glass or panels of solid material and a door).

In some embodiments, printing device <NUM> may include provisions to retain or hold a printed object (or a component supporting the printed object). In some embodiments, printing device <NUM> may include a table, base, platform, tray, or similar component to support, retain, and/or hold a printed object or an object onto which printed material is applied. In the embodiment of <FIG>, printing device <NUM> includes a surface that will be referred to as a base <NUM>. In some embodiments, base <NUM> may be fixed in place and act as a stable base. In other embodiments, however, base <NUM> could move. For example, in some cases, base <NUM> may be configured to translate within housing <NUM> in various horizontal directions (e.g., front-back and/or left right with respect to housing <NUM>) as well as vertical directions (e.g., up-down within housing <NUM>). Moreover, in some cases, base <NUM> may be configured to rotate and/or tilt about one or more axes associated with base <NUM>. Thus, it is contemplated that in at least some embodiments, base <NUM> may be moved into any desired relative configuration with a nozzle or print head of printing device <NUM>. In some embodiments, base <NUM> may be curved, irregularly shaped, or shaped to provide a customized platform upon which an article or object may be placed or secured. However, in other embodiments, base <NUM> may comprise a substantially flat surface. In some embodiments, printing device <NUM> may include an open space or cavity formed within base <NUM>.

In some embodiments, printing device <NUM> may include one or more systems, devices, assemblies, or components for delivering a printed material (or printed substance) to a target location. Target locations could include the surface of base <NUM>, a surface or portion of a partially printed structure, and/or a surface or portion of a non-printed structure or component. Provisions for delivering printed materials may include, for example, print heads and nozzles. In the embodiment of <FIG>, printing device <NUM> includes a nozzle assembly <NUM>.

Nozzle assembly <NUM> may comprise one or more nozzles that deliver a printed material to a target location. For purposes of clarity, the exemplary embodiment of <FIG> depicts a single nozzle <NUM> of nozzle assembly <NUM>. However, in other embodiments, nozzle assembly <NUM> could be configured with any number of nozzles, which could be arranged in an array or any particular configuration. In embodiments comprising two or more nozzles, the nozzles could be configured to move together and/or independently.

Nozzle <NUM> may be configured with a nozzle aperture <NUM> that can be opened and/or closed to control the flow of material exiting from nozzle <NUM>. Specifically, nozzle aperture <NUM> may be in fluid communication with a nozzle channel <NUM> that receives a supply of material from a material source (not shown) within printing device <NUM>. Some examples of materials that may be received or used are disclosed in U. Patent Publication Number ___ to Sterman et al. , filed ___ (now Attorney Docket No. <NUM>-<NUM>), and titled "Tack and Drag Printing Method," which application is hereinafter referred to as the "Tack and Drag case.

In some embodiments, a worm-drive may be used to push the filament into nozzle <NUM> at a specific rate (which may be varied to achieve a desired volumetric flow rate of material from nozzle <NUM>). In other embodiments, a worm-drive is omitted. For example, the material may be pulled from nozzle <NUM> using an actuating system. It will be understood that in some cases, the supply of material could be provided at a location near nozzle <NUM> (e.g., in a portion of nozzle assembly <NUM>), while in other embodiments the supply of material could be located at some other location of printing device <NUM> and fed via tubes, conduits, or other provisions, to nozzle assembly <NUM>.

As will be described below, printing system <NUM> can include provisions for facilitating the alignment of a printed design or graphic onto an article. In some embodiments, it may be useful to provide a user with a way of aligning an article with printing system <NUM> so as to ensure a graphic is printed in the desired portion of the article. In particular, printing system <NUM> may include provisions for programming the orientation of an article with print device <NUM> in such a way as to accommodate articles of various types, shapes, curves, and sizes.

In some embodiments, nozzle assembly <NUM> is associated with a first actuating system <NUM>. First actuating system <NUM> may include various components, devices, and systems that facilitate the motion of nozzle assembly <NUM> within housing <NUM>. In particular, first actuating system <NUM> may include provisions to move nozzle assembly <NUM> in any horizontal direction (including but not limited to directions aligned with a longitudinal axis <NUM> and directions aligned with a lateral axis <NUM>) and/or directions aligned with a vertical axis <NUM> to facilitate depositing a material so as to form a three-dimensional object or to print along a three-dimensional or curved surface. To this end, embodiments of first actuating system <NUM> may include one or more tracks, rails, and/or similar provisions to hold nozzle assembly <NUM> at various positions and/or orientations within housing <NUM>. Embodiments may also include any kinds of motors, such as a stepper motor or a servo motor, to move nozzle assembly <NUM> along a track or rail, and/or to move one or more tracks or rails relative to one another.

For purposes of this description, an object or article with a curved surface refers to articles with one or more portions that include curves, bumps, and varying regions of thickness, such as articles <NUM> of <FIG>. For example, an article may have regions that are flat, smooth, level, or even, with relatively little thickness. However, the same article may also include curved regions with surfaces that deviate from being straight for some or all of its length or area. In some embodiments, a curved surface or curved area identifies a portion of an article that increases and/or decreases in height or thickness associated with the vertical axis of the article. In some embodiments, curved surfaces can comprise regular, geometric curves such as those associated with circles, triangles, squares, and other geometric shapes, and/or they may also be irregular, for example in articles shaped to accommodate or include a particular uneven configuration.

An actuating system can be configured to move a nozzle in one or more directions. In some embodiments, an actuating system could move a nozzle in a single linear direction. In other embodiments, an actuating system could move a nozzle in at least two perpendicular directions. In still other embodiments, an actuating system could move a nozzle in three perpendicular directions. For example, in the exemplary embodiment shown in <FIG>, first actuating system <NUM> may be configured to move nozzle <NUM> in a first direction <NUM> (here, similar to an upward direction), a second direction <NUM> (here, similar to a downward direction), a third direction <NUM>, a fourth direction <NUM>, a fifth direction <NUM>, and a sixth direction <NUM>. As seen in <FIG>, in some embodiments, first direction <NUM> and second direction <NUM> may be aligned with vertical axis <NUM>, and may generally represent opposing directions. Furthermore, third direction <NUM> and fourth direction <NUM> may be aligned with longitudinal axis <NUM> in some embodiments, and may generally represent opposing directions. In addition, fifth direction <NUM> and sixth direction <NUM> can be aligned with lateral axis <NUM> in some embodiments, and may generally represent opposing directions. Thus, third direction <NUM>, fourth direction <NUM>, fifth direction <NUM>, and sixth direction <NUM> can represent generally horizontally oriented directions (e.g., length and width directions), while first direction <NUM> and second direction <NUM> can represent vertically oriented directions (e.g., height directions). Of course, while the exemplary embodiment depicts an actuating system capable of moving a nozzle through three independent x-y-z or Cartesian directions, other embodiments may be configured to move a nozzle in six independent directions associated with a non-Cartesian coordinate system (e.g., a spherical coordinate system or a cylindrical coordinate system). Still further, in other cases an actuating system could move a nozzle through six or more different directions that may not be orthogonal (e.g., directions of an oblique coordinate system).

In some embodiments, first direction <NUM> and/or second direction <NUM> may be at a non-zero angle relative to a surface, such as base <NUM> or print surface <NUM>. For example, in <FIG>, first direction <NUM> and second direction <NUM> are approximately normal to base <NUM>. As used herein, a direction is approximately normal to a surface when it is within <NUM> degrees from perpendicular to the surface. Thus, in different embodiments, first direction <NUM>, second direction <NUM>, and/or nozzle <NUM> may be at a non-zero angle relative to print surface <NUM> and/or base <NUM>.

For purposes of this discussion, a print surface may be associated with the surface where a nozzle is printing. For purposes of this disclosure, print surface <NUM> refers to the surface of an article that receives or is attached to a printing material such as a composite yarn or other material extruded or otherwise discharged or emitted from nozzle <NUM> during printing. For example, in cases where nozzle <NUM> prints directly onto base <NUM>, the print surface is associated with or comprises a surface of base <NUM>. In the embodiment of <FIG>, print surface <NUM> is illustrated as the side of base <NUM> that faces upward toward nozzle assembly <NUM>. However, it should be noted that in other embodiments, print surface <NUM> may comprise the surface or side of an article or object that is printed upon by nozzle <NUM>. Print surface <NUM> may be generally flat, or it may be substantially curved and include contours. In one embodiment, print surface <NUM> may be the side or surface of an object or article that is generally normal relative to vertical axis <NUM>. However, in other embodiments, for example in cases where the article is non-flat, print surface <NUM> may not be normal relative to vertical axis <NUM>.

In certain embodiments, printing system <NUM> can selectively move nozzle <NUM>. In one embodiment, printing system <NUM> simultaneously moves nozzle <NUM> in directions aligned with three different axes, as noted above. In one example, printing system <NUM> may move nozzle <NUM> in first direction <NUM> away from base <NUM>, while simultaneously moving nozzle <NUM> in third direction <NUM> and/or in fifth direction <NUM> over print surface <NUM>. In another example, a position along a direction is maintained while printing system <NUM> selectively moves nozzle <NUM> in another direction. Printing system <NUM> may move nozzle <NUM> in second direction <NUM> toward print surface <NUM> while simultaneously maintaining a base position of nozzle <NUM> along longitudinal axis <NUM> and lateral axis <NUM> over print surface <NUM>. For example, printing system <NUM> may move nozzle <NUM> in first direction <NUM> away from base <NUM> while simultaneously maintaining a base position of nozzle <NUM> in third direction <NUM>, fourth direction <NUM>, fifth direction <NUM>, and sixth direction <NUM> (i.e., remaining stationary with respect to those directions). In another example, printing system <NUM> may maintain a print distance <NUM> (see <FIG>) from nozzle <NUM> with respect to vertical axis <NUM> while simultaneously moving nozzle <NUM> parallel to print surface <NUM> in a horizontal direction (e.g., third direction <NUM>, fourth direction <NUM>, fifth direction <NUM>, and sixth direction <NUM>).

For purposes of this description, print distance <NUM> (as shown in <FIG>) refers to the distance or height extending along vertical axis <NUM> between nozzle <NUM> and print surface <NUM>. Thus, in some embodiments, as print surface <NUM> may be curved or otherwise vary in height, print distance <NUM> may increase or decrease without any corresponding vertical motion of nozzle <NUM> when nozzle moves in the horizontal plane. In other words, print distance <NUM> may change even though the distance between nozzle <NUM> and base <NUM> remains constant due to the contoured geometry of an underlying article. In other embodiments, print distance <NUM> may remain constant as nozzle <NUM> moves in the horizontal plane. In one embodiment, due to a vertical motion of nozzle <NUM>, the distance between nozzle <NUM> and base <NUM> may vary while nozzle <NUM> maintains a constant print distance <NUM> relative to print surface <NUM>. Thus, printing system <NUM> can maintain a generally constant distance between nozzle <NUM> and print surface <NUM>, which can facilitate printing directly to objects with some curvature and/or surface texture.

One or more articles <NUM> are associated with a second actuating system <NUM> that is included in printing system <NUM>. Second actuating system <NUM> may include various components, devices, and systems that facilitate the motion of articles <NUM> within housing <NUM>. Although the exemplary embodiment depicts a particular rectangular box-like geometry for second actuating system <NUM>, other embodiments could use any system having any geometry and/or design. The shape and size of the actuating system could vary according to factors including the article being printed on, the size and shape of parts that may be formed within printing device <NUM>, as well as possibly other factors.

The second actuating system <NUM> includes provisions to move articles <NUM> in any horizontal direction and/or vertically oriented direction to facilitate the position of articles <NUM> underneath nozzle <NUM> for printing along a three-dimensional surface. To this end, embodiments of second actuating system <NUM> may include one or more tracks, rails, and/or similar provisions to hold articles <NUM> at various positions and/or orientations within housing <NUM>. Embodiments may also include any kinds of motors, such as a stepper motor or a servo motor, to move articles <NUM> along a track or rail, and/or to move one or more tracks or rails relative to one another. In some embodiments, there may be a securing device <NUM>, such as a clamp, claw, or other adjustable gripping member, in second actuating system <NUM> to provide a means of attachment between second actuating system <NUM> and articles <NUM>. In other embodiments, there may be no securing device <NUM>. It should be noted that portions of second actuating system <NUM> may be positioned in various locations within printing system <NUM> in order to provide the necessary orientation to articles <NUM>.

Thus, second actuating system <NUM> is configured to move an article in one or more directions. In some embodiments, an actuating system could move an article in a single linear direction, or two linear directions. In other embodiments, an actuating system could move an article in at least two perpendicular directions. In still other embodiments, an actuating system could move an article in at least three perpendicular directions. For example, in the exemplary embodiment shown in <FIG>, second actuating system <NUM> may be configured to move articles <NUM> in first direction <NUM>, second direction <NUM>, third direction <NUM>, fourth direction <NUM>, fifth direction <NUM>, and sixth direction <NUM>. As seen in <FIG>, first direction <NUM> and second direction <NUM> may be associated with a vertical axis of housing <NUM>, while third direction <NUM>, fourth direction <NUM>, fifth direction <NUM>, and sixth direction <NUM> may be associated with horizontal directions of housing <NUM> (e.g., length and width directions). Of course, while the exemplary embodiment depicts second actuating system <NUM> capable of moving an article through three independent x-y-z or Cartesian directions, other embodiments may be configured to move an article in six independent directions associated with a non-Cartesian coordinate system (e.g., a spherical coordinate system or a cylindrical coordinate system). Still further, in other cases an actuating system could move an article through six different directions that may not be orthogonal (e.g., directions of an oblique coordinate system).

In certain embodiments, printing system <NUM> may selectively move the article using second actuating system <NUM> or another mechanism. In one embodiment, printing system <NUM> may move an article in three directions simultaneously. For example, printing system <NUM> may move articles <NUM> in first direction <NUM> away from base <NUM> while simultaneously moving articles <NUM> in third direction <NUM> and/or in fifth direction <NUM> in a direction generally parallel to base <NUM>. In other embodiments, a position along one direction is maintained while printing system <NUM> selectively moves articles <NUM> in another direction. In certain embodiments, printing system <NUM> may move articles <NUM> with respect to vertical axis <NUM> away from or toward base <NUM> while simultaneously maintaining a base position of articles <NUM> with respect to lateral axis <NUM> and longitudinal axis <NUM>. For example, printing system <NUM> may move articles <NUM> in first direction <NUM> away from base <NUM> while simultaneously maintaining a base position of articles <NUM> in third direction <NUM>, fourth direction <NUM>, fifth direction <NUM>, and sixth direction <NUM>. In some embodiments, printing system <NUM> may maintain print distance <NUM> from articles <NUM> along vertical axis <NUM> while simultaneously moving articles <NUM> parallel to the base of housing <NUM>. For example, printing system <NUM> may maintain print distance <NUM> from articles <NUM> along vertical axis <NUM> while simultaneously moving articles <NUM> in directions aligned with lateral axis <NUM> and longitudinal axis <NUM>.

In some embodiments, components of printing system <NUM> associated with second actuating system <NUM> may be specifically adapted to secure articles <NUM> in a fixed position or orientation. For example, some embodiments may include various kinds of mounting devices, harnesses, temporary adhesives, or other provisions that may temporarily fix or hold the position of an article relative to housing <NUM>. Such provisions may help precisely orient a specific portion of an article towards nozzle <NUM> (and correspondingly towards other components of printing device <NUM>). For example, some embodiments could utilize a harness that fixes the orientation and position of an article over base <NUM> so that a three-dimensional design can be printed onto any desired portion of an article, such as an article of footwear. These provisions may also reduce the tendency of an article to move or jostle as the position of base <NUM> is adjusted, or nozzle <NUM> extrudes a print material onto articles <NUM>.

Furthermore, in some embodiments, second actuating system <NUM> or another mechanism of printing system <NUM> may rotate or reposition articles <NUM> in a horizontal plane about a horizontal axis oriented with respect to vertical axis <NUM>, or in a vertical plane about a vertical axis oriented with respect to longitudinal axis <NUM> and/or lateral axis <NUM>. For example, in some embodiments, there may be a mechanism allowing between about a <NUM> and about a <NUM> degree rotation of articles <NUM>. In other embodiments, there may be a mechanism allowing at least about a <NUM> degree rotation of articles <NUM>. In one embodiment, there may be a mechanism that allows about a <NUM> degree rotation. In other embodiments, there may be between about a <NUM> and about a <NUM> degree rotation of articles <NUM> in printing system <NUM>. For example, in one embodiment, printing system <NUM> may include provisions for rotation of articles <NUM> in the horizontal plane about a horizontal axis oriented with respect to vertical axis <NUM>. In another embodiment, printing system <NUM> may include provisions for rotation of articles <NUM> in the vertical plane about a vertical axis oriented with respect to longitudinal axis <NUM> and/or lateral axis <NUM>. In some embodiments, printing system <NUM> may include provision for rotation of articles <NUM> in both the horizontal and vertical planes. In one embodiment, repositioning movement of articles <NUM> may not be circular (i.e., rotational), and instead may involve a non-circular, linear, or otherwise irregular repositioning of articles <NUM>.

Thus, in some embodiments, articles <NUM> may be oriented in multiple positions in housing <NUM> during printing. It should be noted that first actuating system <NUM> and second actuating system <NUM> may be operated simultaneously or independently during use of printing system <NUM>. In addition, first actuating system <NUM> and second actuating system <NUM> may be connected in such a way so as to allow both to operate in conjunction with one another during printing. Furthermore, in some embodiments, printing device <NUM> may include base <NUM> that can move independently of second actuating system <NUM>. In other embodiments, second actuating system <NUM> may be fixed to base <NUM> such that the components move or operate in concert. In one embodiment, there may be no base, such that second actuating system <NUM> operates to move an article that is independent of a platform or tray surface.

In some embodiments, repositioning may be initiated or performed by a user. For example, in some embodiments, first actuating system <NUM> and/or second actuating system <NUM> can be operated manually by a user. In other embodiments, repositioning of articles <NUM> may occur in an automated manner by printing system <NUM>. For example, there may be provisions for automating the operation of first actuating system <NUM> and second actuating system <NUM>. In one example, some embodiments could include motors and/or other provisions for automatically driving nozzle <NUM> to various positions along one or more tracks. In embodiments according to the claimed invention, the position or speed of nozzle <NUM> and articles <NUM> is adjusted using computing system <NUM>, which is discussed in further detail below.

It will be understood that for purposes of illustration, the components, devices and systems of printing device <NUM> are shown schematically in <FIG>. It will therefore be appreciated that embodiments may include additional provisions not shown, including specific parts, components, and devices that facilitate the operation of first actuating system <NUM>, second actuating system <NUM>, and nozzle assembly <NUM>. For example, first actuating system <NUM> is shown schematically as including several tracks or rails, but the particular configuration and number of parts comprising first actuating system <NUM> may vary from one embodiment to another.

As discussed above, printing system <NUM> can include provisions to control and/or receive information from printing device <NUM>. These provisions can include a computing system <NUM> and a network <NUM>. Generally, the term "computing system" refers to the computing resources of a single computer, a portion of the computing resources of a single computer, and/or two or more computers in communication with one another. Any of these resources can be operated by one or more human users. In some embodiments, computing system <NUM> may include one or more servers. In some cases, a print server may be primarily responsible for controlling and/or communicating with printing device <NUM>, while a separate computer (e.g., desktop, laptop, or tablet) may facilitate interactions with a user. Computing system <NUM> can also include one or more storage devices including but not limited to magnetic, optical, magneto-optical, and/or memory, including volatile memory and non-volatile memory.

In the exemplary embodiment of <FIG>, computing system <NUM> may comprise a central processing device <NUM>, a viewing interface <NUM> (e.g., a monitor or screen), input devices <NUM> (e.g., keyboard and mouse), and software for designing a computer-aided design ("CAD") representation <NUM> of a printed structure. In at least some embodiments, the CAD representation <NUM> of a printed structure may include not only information about the geometry of the structure, but also information related to the materials required to print various portions of the structure.

In some embodiments, computing system <NUM> may be in direct contact with printing device <NUM> via network <NUM>. Network <NUM> may include any wired or wireless provisions that facilitate the exchange of information between computing system <NUM> and printing device <NUM>. In some embodiments, network <NUM> may further include various components such as network interface controllers, repeaters, hubs, bridges, switches, routers, modems and firewalls. In some cases, network <NUM> may be a wireless network that facilitates wireless communication between two or more systems, devices, and/or components of printing system <NUM>. Examples of wireless networks include, but are not limited to:.

Printing system <NUM> may be operated as follows to form one or more structures using a 3D printing, or additive, process. Computing system <NUM> may be used to design a structure. This may be accomplished using some type of CAD software, or other kind of software. The design may then be transformed into information that can be interpreted by printing device <NUM> (or a related print server in communication with printing device <NUM>). In some cases, the design may be converted to a 3D printable file, such as a stereolithography file (STL file).

Before printing, an article may be placed onto base <NUM> or may be secured using second actuating system <NUM>. Once the printing process is initiated (by a user, for example), printing device <NUM> may begin depositing material onto the article. This may be accomplished by moving nozzle <NUM> (using first actuating system <NUM>) to build up layers of a structure using deposited material. In embodiments where fused filament fabrication is used, material extruded from nozzle <NUM> may be heated so as to increase the pliability of the heat moldable material as it is deposited.

Although some of the embodiments shown in the figures depict a system using filament fused fabrication printing technologies, it will be understood that still other embodiments could incorporate one or more different 3D printing technologies. For example, printing system <NUM> may use a tack and drag print method, as described in the Tag and Drag case. Moreover, still other embodiments could incorporate a combination of filament fused fabrication and another type of 3D printing technique to achieve desired results for a particular printed structure or part.

In different embodiments, printing device <NUM> may use a variety of different materials for forming 3D parts, including, but not limited to: thermoplastics (e.g., polyactic acid and acrylonitrile butadiene styrene), high density polyethylene, eutectic metals, rubber, clays (including metal clays), Room Temperature Vulcanizing silicone (RTV silicone), and porcelain, as well as possibly other kinds of materials known in the art. In embodiments where two or more different printed or extruded materials are used to form a part, any two or more of the materials disclosed above could be used. In some embodiments, printing device <NUM> may extrude, discharge or use a material or thread and/or yarn composition as described in U. Patent Publication Number to<CIT>) and titled "Thread Structure Composition and Method of Making," the disclosure of which is hereinafter referred to as the "Thread Structure Composition" case.

As discussed above, in some embodiments, printed structures may be printed directly to one or more articles <NUM>. The term "articles" is intended to include a sole structure. As used throughout this disclosure, the terms "article of footwear" and "footwear" include any footwear and any materials associated with footwear, including an upper, and may also be applied to a variety of athletic footwear types, including baseball shoes, basketball shoes, cross-training shoes, cycling shoes, football shoes, tennis shoes, soccer shoes, and hiking boots, for example. As used throughout this disclosure, the terms "article of footwear" and "footwear" also include footwear types that are generally considered to be nonathletic, formal, or decorative, including dress shoes, loafers, sandals, slippers, boat shoes, and work boots.

In an exemplary embodiment, printing device <NUM> may be configured to print one or more structures directly onto a portion of one of articles <NUM>. Articles <NUM> comprise exemplary articles that may receive a printed structure directly from printing device <NUM>. It will be understood that printing device <NUM> may be used to apply printed material to articles <NUM> in three-dimensional configurations and/or flattened configurations.

In order to apply printed materials directly to one or more articles, printing device <NUM> may be capable of printing onto the surfaces of various kinds of materials. Specifically, in some cases, printing device <NUM> may be capable of printing onto the surfaces of various materials such as a textile, a natural fabric, a synthetic fabric, a knit, a woven material, a nonwoven material, a mesh, a leather, a synthetic leather, a polymer, a rubber, and a foam, or any combination thereof, without the need for a release layer interposed between a substrate and the bottom of the printed material, and without the need for a perfectly or near-perfectly flat substrate surface on which to print. For example, the disclosed methods may include printing a resin, acrylic, thermoplastic material, or ink material onto a fabric, for example, a knit material, where the material is adhered or bonded to the fabric and where the material does not generally delaminate when flexed, rolled, worked, or subjected to additional assembly processes or steps. As used throughout this disclosure, the term "fabric" may be used to refer generally to materials chosen from any textile, natural fabric, synthetic fabric, knit, woven material, nonwoven material, mesh, leather, synthetic leather, polymers, rubbers, foam, and combinations thereof.

As previously noted, printing device <NUM> may be configured to print directly onto various articles <NUM>. Similarly, printing device <NUM> may be configured to print on various surface topographies. For example, as shown in <FIG>, a three-dimensional (non-flat) first article <NUM> is depicted. In <FIG>, first article <NUM> includes a forefoot region <NUM>, a midfoot region <NUM>, and a heel region <NUM>, as described above. Furthermore, first article <NUM> includes a medial side <NUM> and a lateral side <NUM>.

In other embodiments, first article <NUM> can include one or more protrusions and/or cavities, curves, contours, and other non-flat surfaces. Moreover, printing device <NUM> may print on surfaces having various shapes. For example, as shown, first article <NUM> is a generally oblong, irregularly shaped object, comprising a partially assembled upper for an article of footwear. In other embodiments, first article <NUM> may include a variety of three-dimensional contours, geometries, or shapes, including, for example, circular geometries, triangular geometries, rectangular geometries, sock-like geometries, sandal-like geometries, irregularly shaped geometries, or geometries corresponding to other components for an article of footwear. As shown in <FIG>, first article <NUM> includes print surface <NUM> that faces toward nozzle <NUM>, as well as a lower surface (not shown) that is in contact with base <NUM>.

In some embodiments, the horizontal or vertical position of articles <NUM> may be adjusted using a sensor <NUM>. Sensor <NUM> may be adjacent to nozzle <NUM> in some embodiments. Sensor <NUM> may help to align the position of articles <NUM> with print nozzle <NUM>. In other words, sensor <NUM> may provide printing system <NUM> with a mechanism for determining the movement of articles <NUM> relative to nozzle <NUM>, for example, during repositioning of articles <NUM> in any of the usual x, y, and z spatial directions as described above with reference to the actuating systems. Moreover, some cases may include steps of adjusting nozzle <NUM> to better align nozzle <NUM> with the selected surface of articles <NUM> that will be printed on. Thus, in some embodiments, printing system <NUM> may include sensor <NUM> that provides printing system <NUM> with information regarding the position of articles <NUM> and/or nozzle <NUM>. Sensor <NUM> may operate in conjunction with computing system <NUM> to provide greater automation to printing system <NUM>.

It should be noted that in some embodiments, base <NUM> may be removed and articles <NUM> may be secured by other means in printing device <NUM>. For example, article of footwear <NUM> may be attached to a device or component that holds article of footwear <NUM> in position within printing device <NUM>, such as securing device <NUM>. Securing device <NUM> may be part of second actuating system <NUM>, or may be a separate device. In one embodiment, securing device <NUM> can be moved or rotated such that first article <NUM> changes orientation or position, permitting nozzle <NUM> to print along substantially all areas and surfaces of first article <NUM>. As shown in <FIG>, securing device <NUM> may be used to hold, grip, or reposition first article <NUM>.

As previously mentioned, nozzle <NUM> is configured to extrude various materials. According to the invention, as shown, nozzle <NUM> extrudes a substantially elongated continuous composite yarn <NUM>, or nozzle <NUM> may extrude multiple elongated continuous composite yarn segments. A composite yarn may include a composition as described in the Thread Structure Composition case. For example, in some embodiments, composite yarn <NUM> may include a melt resistant material and/or a heat moldable material. As used herein, heat moldable material includes thermoplastic. In some embodiments, a composite yarn is at least partially formed of thermoplastic.

In different embodiments, a continuous segment of composite yarn <NUM> extends over base <NUM> of printing device <NUM> including first article <NUM>. For example, composite yarn <NUM> extends over a curved surface <NUM> in <FIG>. A composite yarn <NUM> or other printing material may be attached to curved surface <NUM> using various techniques and various materials. In some embodiments, a heat moldable material bonds directly to the attaching surface. Additionally, in certain embodiments, the heat moldable material bonds to a melt resistant material.

In some embodiments, a heating system is configured to heat a portion of composite yarn <NUM> into a liquid state. Accordingly, in various embodiments, printing system <NUM> may be configured to force a portion of composite yarn <NUM> onto curved surface <NUM> by moving nozzle <NUM> along various directions (see <FIG>). Composite yarn <NUM> may then transition from the liquid state to a solid state to bond with an attaching surface. As discussed below, nozzle <NUM> may maintain print distance <NUM> between nozzle <NUM> and a curved surface <NUM> to allow composite yarn <NUM> to bond with curved surface <NUM> (see <FIG>).

In <FIG>, a portion of printing system <NUM> is depicted. For purposes of convenience some components of printing system <NUM> are not shown. It should be understood that <FIG> are for purposes of illustration only, and the components described above with respect to <FIG> and <FIG> may be included or referred to in the following description while not illustrated in the figures. As shown in the figures, in different embodiments, securing device <NUM> may be used to hold, grip, or reposition the article or print surface <NUM>. In other embodiments, a different component or system may be used to hold, rotate, or reposition the articles.

In some instances it is desirable to print directly along the surface of an object or articles <NUM> that includes contours, or is three-dimensionally configured. Selectively attaching composite yarn <NUM> along a curved surface <NUM> can allow formation of designs, structures, and other features directly onto a preassembled or pre-made object. <FIG> illustrate embodiments of methods of printing a material along a series of curved surfaces of a second article <NUM>. The methods illustrated may be implemented on various devices, may utilize various materials, and use different types of bases. Accordingly, the exemplary methods illustrated in <FIG> are for illustrative purposes only. In some embodiments, the printing can occur over articles <NUM> that have been previously manufactured or fabricated, or partially manufactured, and printing can occur post-manufacture. This can allow customization of articles <NUM> to be processed more quickly, as well as more cost-efficiently. Furthermore, printing system <NUM> can allow formation of designs that encompass multiple surfaces and curves of article <NUM>, including surfaces comprising varying materials, and can provide more seamless design appearance.

In <FIG>, second article <NUM> is disposed in a first position <NUM> within housing <NUM> (not shown) such that a portion of medial side <NUM> is presented as print surface <NUM> to nozzle <NUM>. Nozzle <NUM> has begun to deposit composite yarn <NUM> in a direction generally aligned with longitudinal axis <NUM> of second article <NUM>. Specifically, nozzle <NUM> deposits composite yarn <NUM> along heel region <NUM> of medial side <NUM> of second article <NUM>. In <FIG>, nozzle <NUM> is continuing to move in a direction generally aligned with longitudinal axis <NUM> and has moved toward midfoot region <NUM>.

As described with reference to <FIG>, in some embodiments, printing system <NUM> maintains print distance <NUM> between nozzle <NUM> and print surface <NUM> to allow attachment of composite yarn <NUM> along curved surface <NUM>. First actuating system <NUM> (shown in <FIG>) may allow movement of nozzle <NUM> in multiple directions. Some embodiments may use one or more features of U. Publication Number ___ to Sterman et al. , published ___ (Attorney Docket No. <NUM>-<NUM>), titled "Selective Attachment of a Thread Structure".

For example, nozzle <NUM> may be moved in first direction <NUM> or second direction <NUM> (i.e., nozzle <NUM> may move up and down relative to base <NUM>). As shown in a magnified area <NUM> in <FIG>, in one embodiment, printing system <NUM> can maintain a constant print distance <NUM> between nozzle <NUM> and print surface <NUM>. In other embodiments, composite yarn <NUM> may be pushed into print surface <NUM>, and composite yarn <NUM> may bond with print surface <NUM> as composite yarn <NUM> is prodded or tacked onto print surface <NUM>. In such embodiments, print distance <NUM> may decrease as nozzle <NUM> is prodded into print surface <NUM>, while print distance <NUM> may increase as nozzle <NUM> recedes from print surface <NUM> following prodding.

It should be noted that in some embodiments, composite yarn <NUM> is not pushed into print surface <NUM>, and so print distance <NUM> may remain relatively constant during printing. For example, composite yarn <NUM> may bond with print surface <NUM> once composite yarn <NUM> has been deposited on print surface <NUM> from a constant print distance <NUM>. Bonding may occur in some embodiments as a result of the composition of composite yarn <NUM> or other features of printing system <NUM>.

In different embodiments, print distance <NUM> may comprise varying distances. In some embodiments, print distance <NUM> may be selected by a user through central processing device <NUM>, as illustrated in <FIG>. In one embodiment, print distance <NUM> is greater than a thickness of composite yarn <NUM>. In some embodiments, print distance <NUM> may be less than the thickness of composite yarn <NUM> in cases where composite yarn <NUM> is being pushed or prodded onto print surface <NUM>.

In certain instances it may be desirable to move nozzle <NUM> along print surface <NUM> of second article <NUM> while maintaining a generally constant print distance <NUM> between nozzle <NUM> and print surface <NUM>. For example, to allow the flow of composite yarn <NUM> along a three-dimensional curved surface <NUM> in a generally smooth and consistent manner, print distance <NUM> may remain generally constant as nozzle <NUM> moves along print surface <NUM>. In some embodiments, as shown in <FIG>, printing system <NUM> moves nozzle <NUM> along print surface <NUM> in a direction generally aligned with longitudinal axis <NUM> while maintaining a constant print distance <NUM> between nozzle <NUM> and print surface <NUM>.

In different embodiments, composite yarn <NUM> may be disposed, attached, printed, or otherwise joined to any non-flat areas and/or flat areas of print surface <NUM> as composite yarn <NUM> is released or extruded. Composite yarn <NUM> may bond with print surface <NUM>, thereby allowing for printing along one or more curved surfaces <NUM> (e.g., as shown in magnified area <NUM>). In other embodiments, the printing method applied to curved surface <NUM> may feature one or more of the methods described in the Tack and Drag case.

Thus, in different embodiments, printing system <NUM> may be configured to position or attach a thread or composite yarn onto any portions of an article that include various curved surfaces <NUM>. In some embodiments, printing system <NUM> moves nozzle <NUM> toward and/or over second article <NUM>. For example, as shown in <FIG>, printing system <NUM> moves nozzle <NUM> along third direction <NUM>, fourth direction <NUM>, fifth direction <NUM>, and/or sixth direction <NUM> as it deposits composite yarn <NUM> along print surface <NUM>. As shown in <FIG>, in certain instances it may be desirable to move nozzle <NUM> along print surface <NUM> while maintaining a constant print distance <NUM> between nozzle <NUM> and print surface <NUM> to allow attachment of composite yarn <NUM> to second article <NUM>.

For example, as shown in <FIG>, printing system <NUM> maintains a constant print distance <NUM> between nozzle <NUM> and print surface <NUM> by moving nozzle <NUM> in first direction <NUM> or second direction <NUM> as nozzle moves in the horizontal plane. As such, composite yarn <NUM> is deposited along print surface <NUM> and composite yarn <NUM> can bond with print surface <NUM>, thereby allowing for three-dimensional surface printing. For example, as seen in magnified area <NUM> of <FIG>, composite yarn <NUM> is being laid along a first curved area <NUM>. By adjusting height of nozzle <NUM> along vertical axis <NUM>, nozzle <NUM> maintains a constant print distance <NUM> and composite yarn <NUM> can be laid or deposited along first curved area <NUM> in a stable, smooth, continuous manner. It should be noted that in other embodiments, print distance <NUM> may be increased or decreased over different portions of second article <NUM> while maintaining print quality.

In <FIG>, nozzle <NUM> has moved farther toward forefoot region <NUM> along a direction generally aligned with longitudinal axis <NUM>. In some embodiments, it may be desired to continue printing along a different side or surface of second article <NUM>. In some cases, for example, printing may be desired along the bottom surface, or sole region, of second article <NUM>. In <FIG>, the orientation of second article <NUM> has been changed to allow a sole region <NUM> to comprise print surface <NUM>. In other words, in some embodiments, second article <NUM> may be rotated or otherwise re-oriented to accommodate or provide various areas of second article <NUM> to nozzle <NUM>. In one embodiment, the repositioning may be performed by second actuating system <NUM> (discussed in reference to <FIG>).

In <FIG>, second article <NUM> is disposed in a second position <NUM> within housing <NUM> (not shown) so that sole region <NUM> is presented as print surface <NUM> to nozzle <NUM>. Nozzle <NUM> has begun to deposit composite yarn <NUM> in a direction generally aligned with longitudinal axis <NUM> along forefoot region <NUM> of sole region <NUM> of second article <NUM>. In <FIG>, nozzle <NUM> is continuing to move in a direction generally aligned with longitudinal axis <NUM> and has moved past midfoot region <NUM> into heel region <NUM>.

Similarly, in some embodiments, it may be desired to continue printing along a different side or surface of second article <NUM>. In some cases, for example, printing may be desired along lateral side <NUM> of second article <NUM>. In <FIG>, the orientation of second article <NUM> has been changed to allow lateral side <NUM> to comprise print surface <NUM>. In other words, in some embodiments, second article <NUM> may be rotated or otherwise re-oriented to accommodate or provide different areas of second article <NUM> to nozzle <NUM>. In <FIG>, second article <NUM> is disposed in a third position <NUM> within housing <NUM> (not shown) so that lateral side <NUM> is presented as print surface <NUM> to nozzle <NUM>. Nozzle <NUM> has deposited composite yarn <NUM> in a direction generally aligned with longitudinal axis <NUM> from heel region <NUM> toward forefoot region <NUM> of lateral side <NUM> of second article <NUM>. Thus, in different embodiments, printing system <NUM> may print along three-dimensional objects, articles, and various curved or non-flat surfaces.

In <FIG>, a magnified area of a portion of second article <NUM> is depicted. Nozzle <NUM> is shown as it moves in fourth direction <NUM> along a curved region <NUM>. Nozzle <NUM> is at a first height <NUM> above a first surface <NUM>. In this case, first height <NUM> is substantially similar to print distance <NUM>. In <FIG>, nozzle <NUM> begins to move upward along first direction <NUM> during its motion in fourth direction <NUM> in order to accommodate a slope comprising a second surface <NUM> in curved region <NUM>. As nozzle <NUM> moves along second surface <NUM>, the height of nozzle <NUM> relative to first surface <NUM> is increasing. The change in height is depicted as nozzle <NUM> shifts from first height <NUM> and increases to a second height <NUM> relative to first surface <NUM>. Composite yarn <NUM> is deposited along the slope while nozzle <NUM> maintains a relatively constant print distance <NUM> from print surface <NUM> of second article <NUM>.

<FIG> depicts nozzle <NUM> having completed printing of composite yarn <NUM> along second surface <NUM> and beginning printing along a relatively flat third surface <NUM>. There is no longer movement of nozzle <NUM> in first direction <NUM> or second direction <NUM> while the movement of nozzle <NUM> continues along fourth direction <NUM> over third surface <NUM>. In this stage, nozzle <NUM> has increased to a third height <NUM> relative to first surface <NUM>. Third height <NUM> is greater than both first height <NUM> and second height <NUM>. In other embodiments, a curved region may include different curves and nozzle <NUM> may move downward in a direction aligned with vertical axis <NUM> (i.e., second direction <NUM>). In some embodiments, while nozzle <NUM> may vary in height relative to different contoured portions or surfaces of articles <NUM>, print distance <NUM> may be maintained at a constant distance, as illustrated in <FIG>. In other embodiments, nozzle <NUM> may move along print surface <NUM> in first direction <NUM> and/or second direction <NUM> while it also moves in a horizontally oriented direction, and print distance <NUM> may also be either increased or decreased.

It should be noted that while the illustrations included herein depict first position <NUM>, second position <NUM>, and third position <NUM> as stationary, the rotation or movement of second article <NUM> may be continuous throughout printing. In one embodiment, second article <NUM> may be rotated or otherwise moved (for example, by second actuating system <NUM>, shown in <FIG>) at different times or different points during printing. In some embodiments, second article <NUM> may be turned, moved, or rotated for continuous or intermittent periods of time to provide an optimal print surface <NUM> to nozzle <NUM>. Adjustments in the positioning or orientation of second article <NUM> may provide improved print quality and a better attachment of composite yarn <NUM> to a three-dimensional surface.

As previously noted, the various embodiments allow for any number of attaching surfaces, such as print surface <NUM>. Thus, different three-dimensional structures can be formed along contoured or three-dimensional surfaces. In some embodiments, structures can be formed using any of the methods described in U. Patent Publication Number <CIT> and titled "Footwear Assembly Method with 3D Printing". It should be understood that in cases where print surface <NUM> is non-flat, articles <NUM> may be repositioned to provide nozzle <NUM> with an optimal printing surface. In other words, articles <NUM> may move, rotate, or otherwise adjust position in order to accommodate the movement of nozzle <NUM>, as described with reference to <FIG>. Thus, in the embodiments discussed below, articles <NUM> may be moved between first position <NUM>, second position <NUM>, and other positions in order to allow, for example, nozzle <NUM> to form three-dimensional structures along any curved surfaces of articles <NUM>.

For example, in some embodiments, one or more traction elements may be formed along a portion of an article. In one embodiment, one or more cleats <NUM> may be printed. <FIG> illustrate isometric views of a printing sequence of multiple 3D layers forming a series of cleats <NUM>. In different embodiments, cleats <NUM> may be printed along irregular, curved, or otherwise substantially non-flat surfaces. Nozzle <NUM> may accommodate the varying curvature of print surface <NUM> during printing.

As previously mentioned, nozzle <NUM> is configured to extrude various materials. For example, as shown, nozzle <NUM> may extrude a substantially elongated continuous composite yarn <NUM>, or nozzle <NUM> may extrude multiple elongated continuous thread segments. Composite yarn <NUM> may include a composition as described in the embodiments of the Thread Structure Composition case.

In different embodiments, nozzle <NUM> may move in directions aligned with vertical axis <NUM>, directions aligned with longitudinal axis <NUM>, direction aligned with lateral axis <NUM>, or other directions, in order to print along a curved surface, as described with respect to <FIG>. In other words, the printing of three-dimensional structures along three-dimensional or substantially contoured surfaces may be provided through application and use of printing system <NUM>. Thus, in some embodiments, three-dimensional structures may be formed along different types of articles during varying points of the manufacture of the articles. For example, a structure may be printed on a partially formed article in some embodiments. In other embodiments, a structure may be printed on a fully formed or manufactured article. In one embodiment, an upper may be formed and shaped (for example, over a last) using any process known in the art, and subsequently there may be additional structures formed or printed over the upper using printing system <NUM>.

In <FIG>, cleats <NUM> are being formed along an outer curved surface of a sole structure <NUM> ("curved surface" <NUM>) of a third article <NUM>. <FIG> illustrates a printed material <NUM> being deposited onto curved surface <NUM> near forefoot region <NUM>. In <FIG>, a series of cleats <NUM> have been formed along heel region <NUM> and midfoot region <NUM>. A first portion <NUM> of a first layer <NUM> has been printed on curved surface <NUM>. It should be noted that first portion <NUM> and print surface <NUM> may be joined, attached, bound, coupled, or otherwise connected through one of the techniques described in the Thread Structure Composition case. For example, in one embodiment, heat may be applied during the printing process, forming a melted layer of material between first portion <NUM> and print surface <NUM>. The melted layer may bond first portion <NUM> (or portions thereof) to print surface <NUM>.

Printed material <NUM> may be ejected or otherwise emitted from nozzle <NUM> in the form of droplets, thread, yarn, or any viscosity liquid material or a semi-solid material. Printed material <NUM> may be any desired material or phase of material suitable for use in printing system <NUM> as described above.

One of ordinary skill in the art will recognize that the printed layers forming printed material <NUM> may originate with different materials, colors, chemistries, optional fillers, etc., in order to fully customize the desired properties of third article <NUM>. Printed material <NUM> may also comprise layers having gradients of colors blended amongst the layers, or may comprise gradients of elasticity due to variations in material ejected from nozzle <NUM> during printing of printed material <NUM>. For example, printed material <NUM> may comprise layers of low elasticity printed material alternated or in conjunction with layers of high elasticity material, as described in the Tack and Drag case.

One of ordinary skill in the art will also recognize that the printed layers forming printed material <NUM> may comprise layers of material having at least a first color alternated or in conjunction with layers having at least a second color. For example, printed material <NUM> may be designed to impart high strength and low elasticity in heel region <NUM>, while maintaining high elasticity and flexibility in forefoot region <NUM>, and such properties may be accomplished by varying the properties of printed material <NUM> through printing of different combinations of materials and layers in any desired manner on any surface of third article <NUM>.

In different embodiments, the three-dimensional printed structures may be various shapes and sizes, and may be disposed along different areas and types of surfaces of third article <NUM>. For example, in <FIG>, cleats <NUM> include a first cleat <NUM> and a second cleat <NUM>. First cleat <NUM> and second cleat <NUM> are generally rounded cylindrical shapes. In the embodiment of <FIG>, first cleat <NUM> is larger relative to second cleat <NUM>. In addition, first cleat <NUM> includes a hollow interior area, whereas second cleat <NUM> has a solid or continuous interior volume and surface. Furthermore, second cleat <NUM> has been formed along a substantially curved area of heel region <NUM>, whereas first cleat <NUM> has been formed along a relatively flat area of heel region <NUM>. In other embodiments, first cleat <NUM> and second cleat <NUM> may be larger or smaller, may be other geometric or irregular three-dimensional shapes, and may be located along other areas of third article <NUM>.

In some embodiments, referring to <FIG> and <FIG>, first segment <NUM> may be cured by UV light. However, in other embodiments, first segment <NUM> may be deposited without the need to cure the deposited material. Depending on the material used for printing of printed material <NUM>, the material may be deposited in a liquid, semi-liquid, or otherwise gel-like or viscous phase. The material may then be solidified, at least partially, or cured, for various reasons, or to achieve desired properties, for example, to enhance durability, adhesion, or bonding of printed material <NUM> to curved surface <NUM>. For purposes of this description, "segments" of printed material <NUM> refer to the accumulation of one or more layers of printed material <NUM> forming at least a portion of a three-dimensional structure. In some embodiments, segments may comprise areas or portions of printed material <NUM> that are smaller than or larger than the segments illustrated in the figures below. In some cases, for example, cleats <NUM> may vary in height with respect to one another and may each comprise a different number of layers or segments.

In the depiction of <FIG>, printing is continuing. In <FIG>, a first segment <NUM> has been formed along curved surface <NUM>. First segment <NUM> is comprised of first layer <NUM>, where first layer <NUM> now includes first portion <NUM> and an additional second portion <NUM>. A bottom surface <NUM> of first segment <NUM> is in contact with curved surface <NUM>, and an upper surface <NUM> is associated with the top of first segment <NUM>. Thus, in some cases, curved surface <NUM> comprises the "print surface" <NUM> described with reference to <FIG>, providing a printing surface for nozzle <NUM>. In some embodiments, printing of cleats <NUM> may include movement of nozzle <NUM> in a generally repeating or irregularly round, cyclical, repetitive, or circular motion to form the structures. In other embodiments, nozzle <NUM> may move in other ways to form, for example, the solid (filled-in) structures, such as second cleat <NUM>.

In <FIG>, a first portion <NUM> of a second segment <NUM> (comprising at least one printed layer) of printed material <NUM> is being deposited onto upper surface <NUM> of previously printed first segment <NUM>. It should be noted that second segment <NUM> (and any subsequent segments) need not be deposited only on the immediately underlying segment. In different embodiments, variations in printing patterns or thicknesses of layers are possible. For example, second segment <NUM> may be deposited on any desired portion of curved surface <NUM>, which may include partial or complete coverage of first segment <NUM>, or may include no coverage of first segment <NUM>. For example, second segment <NUM> may be partially deposited on first segment <NUM> and partially deposited on the bottom surface of curved surface <NUM>. It should also be noted that first segment <NUM> and second segment <NUM> may be joined, attached, bound, coupled, or otherwise connected through one of the techniques described in the Thread Structure Composition case. For example, in one embodiment, heat may be applied during the printing process, forming a melted layer of material between upper surface <NUM> of first segment <NUM> and a bottom surface of second segment <NUM>. The melted layer may bond first segment <NUM> (or portions of first layer <NUM>) to second segment <NUM>.

<FIG> illustrates the completion of second segment <NUM> printed on first segment <NUM>, forming a first composite segment <NUM>, including first segment <NUM> and second segment <NUM> (see <FIG> and <FIG>). First composite segment <NUM> has an upper surface <NUM>. In <FIG>, a first portion <NUM> of a third segment <NUM> (also comprising at least one printed layer) is being formed on upper surface <NUM> of first composite segment <NUM>. It should be noted that while the printing of cleats <NUM> is depicted as comprising discrete segments or portions, the formation of a segment may be printed in a continuous manner. For example, first segment <NUM>, second segment <NUM>, and/or third segment <NUM> may be printed such that there is no discernible distinction between any segments.

In <FIG>, a third cleat <NUM> has been formed, including first segment <NUM>, second segment <NUM>, and third segment <NUM>. Upon completion of a three-dimensional structure along contoured print surface <NUM>, nozzle <NUM> may move in any direction in order to detach printed material <NUM> from third cleat <NUM>. For example, in <FIG>, nozzle <NUM> has moved upward along the vertical axis and toward forefoot region <NUM> in a direction aligned with the longitudinal axis, and detached from third cleat <NUM>.

In other embodiments, printing system <NUM> may be used to form various patterns, designs, color forms, and other fabric work along a flat or curved surface. For example, in some embodiments, printing system <NUM> may be used to print decorative accents that provide an article with patterns similar to patterns made through embroidery. As is known to one with ordinary skill in the art, embroidery can be used to decorate fabric or other materials with a needle and thread or yarn. Embroidery may also incorporate other materials such as metal strips, pearls, beads, quills, and sequins in its patterns. For purposes of this description, the term "embroidered patterns" refers to any type of design, decorative art, fabrication, or other representation added to a material. "Embroidered patterns" have been traditionally formed through stitching or sewing. However, in different embodiments, printing system <NUM> may be used to provide, form, or attach embroidered patterns to a curved surface. Such an application of printing system <NUM> may allow the formation of embroidered-like designs without the need to pierce the surface of a fabric or textile, improve the efficiency of embroidered pattern formation, and allow embroidered patterns to be more readily formed on a variety of objects. In one embodiment, an embroidered pattern may be added to pre-manufactured or pre-fabricated three-dimensional articles <NUM>.

For example, in <FIG>, nozzle <NUM> is shown as it prints along medial side <NUM> of a fourth article <NUM>, extruding a printed material <NUM>. In <FIG>, printing system <NUM> moves nozzle <NUM> from a non-zero print distance <NUM> (as described with reference to <FIG>) into print surface <NUM>, such that nozzle <NUM> directly contacts print surface <NUM>, and print distance <NUM> becomes zero. Thus, as shown in <FIG>, printing system <NUM> has moved nozzle <NUM> from print distance <NUM> into print surface <NUM>, so that nozzle <NUM> is in direct contact with the attaching surface. In other embodiments, embroidered patterns <NUM> may be formed while maintaining a non-zero print distance <NUM>.

Claim 1:
An apparatus for printing onto a curved surface of a sole structure (<NUM>), the apparatus comprising:
a housing (<NUM>), the housing (<NUM>) including a base (<NUM>) disposed along the bottom of the housing (<NUM>);
a nozzle (<NUM>) configured to discharge a composite yarn (<NUM>) onto the curved surface;
a computing system (<NUM>) configured to control a position adjustment of the nozzle (<NUM>) and the sole structure (<NUM>);
a first actuating system (<NUM>) configured to move the nozzle (<NUM>), wherein the first actuating system (<NUM>) moves the nozzle (<NUM>) along a direction aligned with a vertical axis (<NUM>), the vertical axis (<NUM>) extending normal to a surface of the base (<NUM>), and wherein the first actuating system (<NUM>) moves the nozzle (<NUM>) along a direction aligned with a first horizontal axis (<NUM>, <NUM>), the first horizontal axis (<NUM>, <NUM>) being approximately parallel with respect to the base (<NUM>);
a second actuating system (<NUM>) configured to adjust the position of the sole structure (<NUM>) with respect to the nozzle (<NUM>), wherein the second actuating system (<NUM>) moves the sole structure (<NUM>) along a direction parallel to the vertical axis (<NUM>), and wherein the second actuating system (<NUM>) moves the sole structure (<NUM>) along a direction parallel to the first horizontal axis (<NUM>, <NUM>),
the apparatus being configured to attach the composite yarn (<NUM>) to the curved surface by moving the nozzle (<NUM>) downward toward the curved surface in a direction aligned with the vertical axis (<NUM>); and
the apparatus being configured to attach the composite yarn (<NUM>) to the curved surface by moving the nozzle (<NUM>) in a direction aligned with the first horizontal axis (<NUM>, <NUM>),
the apparatus being configured to attach the composite yarn (<NUM>) to the curved surface of the sole structure (<NUM>) by moving the sole structure (<NUM>) in a direction parallel to the vertical axis (<NUM>), and
the apparatus being configured to attach the composite yarn (<NUM>) to the curved surface of the sole structure (<NUM>) by moving the sole structure (<NUM>) in a direction parallel to the first horizontal axis (<NUM>, <NUM>).