Patent Description:
Basketball is a popular support worldwide. Basketballs are typically formed by an inflatable bladder wrapped in layers of fibers and overlaid with leather or rubber composite panels. Some basketballs are formed by a molded rubber sphere.

<CIT> discloses a sports ball comprises a surface layer comprising a plurality of panels. The sports ball further comprises a lattice structure extending below the surface layer, wherein the lattice structure comprises a plurality of lattice cells comprising radially extending elements. The lattice cells which are adjacent to the surface layer have at least one dimension which is smaller than an average diameter of the panels.

An aspect of the present disclosure relates to a basketball comprising:
a single integrally formed unitary body comprising:.

The outer lattice may be lobular with a plurality of lobes joined along the surface strips.

The radial beams comprise a first number of the radial beams interconnecting the first layer and the second layer beneath the surface strips. The radial beams comprise a second number of the radial beams interconnecting the first layer and the second layer circumferentially between the surface strips. Each of the first number of radial beams have a first height. Each of the second number of radial beams have a second height. The second height is greater than the first height.

Each of the first number of radial beams may have a first thickness. Each of the second number of radial beams may have a second thickness. The second thickness may be less than the first thickness.

The radial beams may comprise a third number of the radial beams interconnecting the first layer and the second layer in circumferential regions between the surface strip. Each of the third number of radial beams may have the second height and a third thickness. The third thickness may be greater than the second thickness.

The radial beams may comprise a first number of the radial beams interconnecting the first layer and the second layer inward of the surface strips. The radial beams may comprise a second number of the radial beams interconnecting the first layer and the second layer circumferentially between the surface strips. Each of the first number of radial beams may have a first thickness. Each of the second number of radial beams may have a second thickness. The second thickness may be less than the first thickness.

The inner lattice may be spherical and non-lobular. The inner lattice may be lobular.

The outer lattice may comprise outer lattice beams having flat outer surfaces.

The radial beams may have a uniform thickness between the inner lattice and the outer lattice.

The inner lattice and the outer lattice may each comprise a two-dimensional hexagonal lattice.

The inner lattice and the outer lattice may comprise cells having a center-to-center distance of at least <NUM> and no greater than <NUM>.

The inner lattice may comprise inner lattice beams having a thickness of at least <NUM> and no greater than <NUM>. The outer lattice may comprise outer lattice beams having a thickness of at least <NUM> and no greater than <NUM>.

The single integrally formed unitary body may be formed from a material having one of more material properties, measured as injection molded, of, for example:.

The basketball may further comprise an outer skin over an outer surface of the outer lattice. The outer skin may be imperforate. The skin may be transparent or translucent.

The basketball may further comprise an inner skin formed on an inner surface of one of the inner lattice and the outer lattice.

The outer lattice may comprise an outer textured surface.

The basketball may have a circumference of at least <NUM> and no greater than <NUM>. The basketball may have a mass of at least <NUM> and no greater than <NUM>. The basketball may have a rebound of at least <NUM> (<NUM> inches) and no greater than <NUM> (<NUM> inches).

An aspect of the present disclosure relates to a computer program comprising computer executable instructions that, when executed by a processor, cause the processor to control an additive manufacturing apparatus to manufacture a basketball in accordance with any aspect or definition disclosed herein.

An aspect of the present disclosure relates to a computer-readable medium storing data which defines both a digital representation of a basketball in accordance with any aspect or definition disclosed herein and operating instructions adapted to control an additive manufacturing device to fabricate the basketball using the digital representation of the basketball when said data is relayed to the additive manufacturing device.

An aspect of the present disclosure relates to a method of manufacturing a basketball in accordance with any aspect or definition disclosed herein.

The method may comprise manufacturing at least part of the basketball via additive manufacturing or 3D printing.

The method may comprise obtaining an electronic file representing a geometry of the basketball. The method may comprise controlling an additive manufacturing apparatus to manufacture, over one or more additive manufacturing steps, at least a portion of the basketball according to the geometry specified in the electronic file.

The method may comprise manufacturing a complete basketball via additive manufacturing. In some examples the method may comprise performing subsequent manufacturing steps following an additive manufacture process.

As used herein, "additive manufacturing" refers generally to manufacturing processes wherein successive layers of material(s) are provided on each other to "build-up" layer-by-layer or "additively fabricate", a three-dimensional component. The successive layers generally fuse together to form a monolithic component which may have a variety of integral sub-components.

Suitable additive manufacturing techniques in accordance with the present disclosure include, for example, Fused Deposition Modeling (FDM), Selective Laser Sintering (SLS), 3D printing such as by inkjets and laserjets, Sterolithography (SLA), Direct Selective Laser Sintering (DSLS), Electron Beam Sintering (EBS), Electron Beam Melting (EBM), Laser Engineered Net Shaping (LENS), Electron Beam Additive Manufacturing (EBAM), Laser Net Shape Manufacturing (LNSM), Direct Metal Deposition (DMD), Digital Light Processing (DLP), Continuous Digital Light Processing (CDLP), Direct Selective Laser Melting (DSLM), Selective Laser Melting (SLM), Direct Metal Laser Melting (DMLM), Direct Metal Laser Sintering (DMLS), Material Jetting (MJ), NanoParticle Jetting (NPJ), Drop On Demand (DOD), Binder Jetting (BJ), Multi Jet Fusion (MJF), Laminated Object Manufacturing (LOM) and other known processes.

Additive manufacturing processes typically fabricate components based on three-dimensional (3D) information, for example a three-dimensional computer model (or design file), of the component.

Accordingly, examples described herein not only include a basketball as described herein, but also methods of manufacturing such a basketball or components thereof via additive manufacturing and computer software, firmware or hardware for controlling the manufacture of such a basketball via additive manufacturing.

The entire structure, or the structure of one or more parts, of the basketball may be represented digitally in the form of a design file. A design file, or computer aided design (CAD) file, is a configuration file that encodes one or more of the surface or volumetric configuration of the shape of the basketball. That is, a design file represents the geometrical arrangement or shape of the product, which in this disclosure is a basketball.

Design files can take any now known or later developed file format. For example, design files may be in the Stereolithography or "Standard Tessellation Language" (. stl) format which was created for stereolithography CAD programs of 3D Systems, or the Additive Manufacturing File (. amf) format, which is an American Society of Mechanical Engineers (ASME) standard that is an extensible markup-language (XML) based format designed to allow any CAD software to describe the shape and composition of any three-dimensional object to be fabricated on any additive manufacturing printer.

Further examples of design file formats include AutoCAD (. dwg) files, Blender (. blend) files, Parasolid (. x_t) files, 3D Manufacturing Format (. 3mf) files, Autodesk (3ds) files, Collada (. dae) files and Wavefront (. obj) files, although many other file formats exist.

Design files can be produced using modelling (e.g. CAD modelling) software and/or through scanning the surface of a product to measure the surface configuration of the product.

Once obtained, a design file may be converted into a set of computer executable instructions that, once executed by a processer, cause the processor to control an additive manufacturing apparatus to produce a product (a basketball or part of a basketball in the present disclosure) according to the geometrical arrangement specified in the design file. The conversion may convert the design file into slices or layers that are to be formed sequentially by the additive manufacturing apparatus. The instructions (otherwise known as geometric code or "G-code") may be calibrated to the specific additive manufacturing apparatus and may specify the precise location and amount of material that is to be formed at each stage in the manufacturing process. As discussed above, the formation may be through deposition, through sintering, or through any other form of additive manufacturing method.

The code or instructions may be translated between different formats, converted into a set of data signals and transmitted, received as a set of data signals and converted to code, stored, etc., as necessary. The instructions may be an input to the additive manufacturing system and may come from a part designer, an intellectual property (IP) provider, a design company, the operator or owner of the additive manufacturing system, or from other sources. An additive manufacturing system may execute the instructions to fabricate the product using any of the technologies or methods disclosed herein.

Design files or computer executable instructions may be stored in a (transitory or non-transitory) computer readable storage medium (e.g., memory, storage system, etc.) storing code, or computer readable instructions, representative of the product (a basketball or part of a basketball in accordance with the present disclosure) to be produced. As noted, the code or computer readable instructions defining the product can be used to physically generate the object, upon execution of the code or instructions by an additive manufacturing system. For example, the instructions may include a precisely defined 3D model of the product and can be generated from any of a large variety of well-known computer aided design (CAD) software systems such as AutoCAD®, TurboCAD®, DesignCAD 3D Max, etc. Alternatively, a model or prototype of the component may be scanned to determine the three-dimensional information of the component.

Accordingly, by controlling an additive manufacturing apparatus according to the computer executable instructions, the additive manufacturing apparatus can be instructed to print out the basketball or part of the basketball.

In light of the above, embodiments include methods of manufacture via additive manufacturing. This includes the steps of obtaining a design file representing the product and instructing an additive manufacturing apparatus to manufacture the product in assembled or unassembled form according to the design file. The additive manufacturing apparatus may include a processor that is configured to automatically convert the design file into computer executable instructions for controlling the manufacture of the product. In these embodiments, the design file itself can automatically cause the production of the product once input into the additive manufacturing device. Accordingly, in this embodiment, the design file itself may be considered computer executable instructions that cause the additive manufacturing apparatus to manufacture the product. Alternatively, the design file may be converted into instructions by an external computing system, with the resulting computer executable instructions being provided to the additive manufacturing device.

Given the above, the design and manufacture of implementations of the subject matter and the operations described in this specification can be realized using digital electronic circuitry, or in computer software, firmware, or hardware, including the structures disclosed in this specification and their structural equivalents, or in combinations of one or more of them. For instance, hardware may include processors, microprocessors, electronic circuitry, electronic components, integrated circuits, etc. Implementations of the subject matter described in this specification can be realized using one or more computer programs, i.e., one or more modules of computer program instructions, encoded on computer storage medium for execution by, or to control the operation of, data processing apparatus. Alternatively, or in addition, the program instructions can be encoded on an artificially generated propagated signal, e.g., a machine-generated electrical, optical, or electromagnetic signal that is generated to encode information for transmission to suitable receiver apparatus for execution by a data processing apparatus. Moreover, while a computer storage medium is not a propagated signal, a computer storage medium can be a source or destination of computer program instructions encoded in an artificially generated propagated signal.

Although additive manufacturing technology is described herein as enabling fabrication of complex objects by building objects point-by-point, layer-by-layer, typically in a vertical direction, other methods of fabrication are possible and within the scope of the present subject matter. For example, although the discussion herein refers to the addition of material to form successive layers, one skilled in the art will appreciate that the methods and structures disclosed herein may be practiced with any additive manufacturing technique or other manufacturing technology.

Disclosed are example basketballs formed by additive or 3D printing. The example 3D printed basketballs are formed from materials and have features that provide the basketballs with the outer surface strips that basketball players are accustomed to when handling and gripping the basketball. At the same time, the 3D printed basketballs have a size, weight, and rebound consistency similar to that of standard or conventional competitive play basketballs currently sanctioned by various organizations such as the National Basketball Association (NBA), National Collegiate Athletic Association (NCAA), National Federation of High Schools (NFHS) and other organizations. In contrast to such standard or conventional competitive play basketballs, the disclosed 3D printing basketballs offer a unique aesthetic.

In some implementations, the example 3D printed basketballs are a single integral one-piece construction. The one-piece construction reduces the number of parts and may simplify assembly. In some implementations, the example 3D printed basketballs may largely comprise a one-piece construction, but wherein an outer, inner or middle skin is provided to reduce airflow resistance when the ball is shot or passed.

In some implementations, the 3D printed basketballs do not require inflation. As result, the task of maintaining the basketball at a proper inflation level or pressure is eliminated. In addition, rebound performance of the 3D printed basketballs may be more consistent over time.

For purposes of this disclosure, the term "coupled" shall mean the joining of two members directly or indirectly to one another. Such joining may be achieved with the two members, or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate member being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature.

For purposes of this disclosure, the phrase "configured to" denotes an actual state of configuration that fundamentally ties the stated function/use to the physical characteristics of the feature proceeding the phrase "configured to".

For purposes of this disclosure, the term "releasably" or "removably" with respect to an attachment or coupling of two structures means that the two structures may be repeatedly connected and disconnected to and from one another without material damage to either of the two structures or their functioning.

<FIG> illustrate an example basketball <NUM>. In the example illustrated, basketball <NUM> comprises a single integral or unitary one-piece construction formed by 3D printing an elastomeric polymeric material. Basketball <NUM> has a general spherical shape comprising a pair of opposite polar regions <NUM>-<NUM>, <NUM>-<NUM> with a series of surface strips <NUM>-<NUM>, <NUM>-<NUM> (collectively referred to as surface strips <NUM>), <NUM>-<NUM>, <NUM>-<NUM> (collectively referred to as surface strips <NUM>), <NUM>-<NUM>, <NUM>-<NUM> (collectively referred to as surface strips <NUM>) and <NUM>-<NUM>, <NUM>-<NUM> (collectively referred to as surface strips <NUM>). Surface strips <NUM>-<NUM>, <NUM>-<NUM> converge at and extend between polar center points <NUM>-<NUM> and <NUM>-<NUM> of basketball <NUM>. Surface strips <NUM>-<NUM>, <NUM>-<NUM> are coplanar, extending in a plane that that intersects a center point of basketball <NUM>. Surface strips <NUM>-<NUM>, <NUM>-<NUM> converge at and extend between polar center points <NUM>-<NUM> and <NUM>-<NUM>. Surface strips <NUM>-<NUM>, <NUM>-<NUM> are coplanar, extending in a second plane that is perpendicular to the first plane and that intersects a center point of basketball <NUM>. Surface strips <NUM>-<NUM>, <NUM>-<NUM> have endpoints offset from polar center points <NUM>-<NUM> and <NUM>-<NUM> and generally bisect portions of the outer circumference of basketball <NUM> between surface strips <NUM>-<NUM>, <NUM>-<NUM> and surface strips <NUM>-<NUM>, <NUM>-<NUM>.

In the illustrated examples, each of surface strips <NUM>, <NUM>, <NUM> and <NUM> additionally comprises a series of perforations <NUM> that extend completely through such surface strips. Perforations <NUM> comprise small openings that facilitate powder removal of cycle time during printing of the basketball <NUM>. In the example illustrated, such perforations <NUM> may have polygonal shapes. In other implementations, such perforations <NUM> may have other shapes, such as circular shapes. In some implementations, the perforations may have patterns so as to form a graphic or so as to spell out a logo or name.

Although the example illustrated perforations <NUM> extending substantially along the entirety of each of surface strips <NUM>, <NUM>, <NUM> and <NUM>, in other implementations, such perforations <NUM> may be located at the selected portions of selected surface strips <NUM>, <NUM>, <NUM> and <NUM>. For example, in some implementations, the provision of such perforations may be limited to those surface strips that extend along the equator and prime meridian of basketball <NUM>. Such perforations may be omitted and landings, such as landing <NUM>, wherein a logo or emblem may be provided. In yet other implementations, the provision of perforations <NUM> may be at other selected locations. In some implementations, perforations <NUM> may be omitted.

Surface strips <NUM>, <NUM>, <NUM> and <NUM> are integrally formed as part of an outer surface of basketball <NUM>. Each of surface strips <NUM>, <NUM>, <NUM> and <NUM> resides in a depressed portion or in a recessed portion of the outer circumferential surface of basketball <NUM>. In the example illustrated, each of surface strips <NUM>, <NUM>, <NUM> and <NUM> extends between consecutive circumferential regions that aesthetically appear as panels and that are lobular in shape. For purposes of this disclosure, the term "lobular" and "loby" refer to the surface of a region having a smaller radius of curvature as compared to the overall radius of the basketball. In the example illustrated, basketball <NUM> comprises eight loby circumferential regions or aesthetic panels <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM> (collectively referred to as panels <NUM>) that mimic the conventional appearance of a regulation or sanctioned competitive play basketball.

<FIG> and <FIG> are sectional views of basketball <NUM> taken along lines <NUM> and <NUM> of <FIG> and <FIG>, respectively. <FIG> is an enlarged view of a portion of basketball <NUM> opposite sides of surface strip <NUM>-<NUM>. <FIG> is an enlarged outer view of a portion of basketball <NUM> on opposite sides of surface strip <NUM>-<NUM>. As shown by <FIG> and <FIG>, basketball <NUM> comprise a single integral and continuous outer wall <NUM> that comprises an inner lattice <NUM>, an outer lattice <NUM> and radial beams <NUM>.

<FIG> is a sectional view of basketball <NUM> from an inside of basketball <NUM> to illustrate inner lattice <NUM>, wherein a portion <NUM> of wall <NUM> is illustrated without the inner lattice <NUM> and without the radial beams <NUM> to better illustrate outer lattice <NUM>. Inner lattice <NUM> forms an inner layer providing an inner surface of wall <NUM>, adjacent to a generally hollow interior of basketball <NUM>.

Outer lattice <NUM> and surface strips <NUM>, <NUM>, <NUM> and <NUM> form an outer layer of wall <NUM>, providing an outermost surface of basketball <NUM>. <FIG> is an enlarged sectional view of basketball <NUM> illustrating the general profile of the inner layer <NUM> formed by inner lattice <NUM> and the general profile of outer layer <NUM> formed by outer lattice <NUM>. As discussed above, the outer layer <NUM> is loby between consecutive surface strips. In contrast, inner layer <NUM> is circumferential, having the same radius as that of basketball <NUM>.

As shown by <FIG>, inner lattice <NUM> comprises a matrix of interconnected hexagonal cells <NUM>. Outer lattice <NUM> comprises a matrix of interconnected hexagonal cells <NUM> extending between surface strips <NUM>, <NUM>, <NUM> and <NUM>. <FIG> illustrate the example hexagonal cells <NUM> in more detail. In the example illustrated, cells <NUM> and <NUM> are identical in shape and size. Each of cells <NUM> and <NUM> has a center-to-center distance of at least <NUM> and no greater than <NUM>. Each of cells <NUM> and <NUM> has a hole size of at least <NUM> and no greater than <NUM>. The hole size of cells <NUM> is sufficiently small such that human adult fingers may not get stuck in the outer lattice <NUM>.

In other implementations, cells <NUM> and <NUM> may both be the same, but may have different shapes other than hexagonal shapes. For example, cells <NUM> and <NUM> may both have a circular shape, a pentagonal shape, and octagonal shape or the like. In other implementations, cells <NUM> and <NUM> may have different shapes, wherein cells <NUM> have a first shape while cells <NUM> have a second different shape. In some implementations, cells <NUM> and <NUM> sizes. For example, cells <NUM> may be larger than cells <NUM> or cells <NUM> may be larger than cells <NUM>.

Radial beams <NUM> extend between and interconnect inner layer <NUM> and outer layer <NUM>. Radial beams <NUM> extend between inner lattice <NUM> and outer lattice <NUM> of panel <NUM>. Radial beams <NUM> extend between inner lattice <NUM> and surface strips <NUM>, <NUM>, <NUM> and <NUM> of outer layer <NUM>. As shown by <FIG>, radial beams <NUM> extend along radial axes that intersect the center point of basketball <NUM>. As further shown by <FIG>, each of radial beams has a particular radial height RH. The radial height refers to the radial distance between a top of the beam <NUM> and a center point of the basketball <NUM>. The radial heights RHs may vary amongst different radial beams <NUM>. In the example illustrated, those particular beams <NUM> that underlie surface strips <NUM>, <NUM>, <NUM> and <NUM> have a shorter radial height RH as compared to other radial beams <NUM> that underlie outer lattice <NUM>. <FIG> illustrates a particular radial beam <NUM>-<NUM> that has a shorter radial height RH as compared to other radial beams <NUM> that underlie outer lattice <NUM>.

As shown by <FIG>, each of radial beams <NUM> has a beam length BL. Beam length refers to the radial distance between the top and the bottom of the particular beam <NUM>. Beam length may vary amongst different beams <NUM>. In the example illustrated, those particular beams <NUM> that underlie surface strips <NUM>, <NUM>, <NUM> and <NUM> have a shorter beam length BL as compared to other radial beams <NUM> that underlie outer lattice <NUM>. Beam <NUM>-<NUM> in <FIG> has a shorter beam length BL as compared to other radial beams <NUM> that underlie outer lattice <NUM>. In some implementations, a particular radial beam <NUM> may have a shorter radial height, but the same beam length as compared to other radial beams, where the inner lattice <NUM> has a corresponding smaller radius underlying the particular radial beams <NUM> that has a shorter radial height. Conversely, in some implementations, particular radial beams <NUM> may have the same radial height but a shorter beam length where the inner lattice <NUM> has a corresponding greater radius underlying the particular radial beams <NUM> that has the shorter beam length.

As shown by <FIG>, each of radial beams <NUM> of basketball <NUM> has a beam thickness BT. The beam thicknesses (or diameters) of individual beam <NUM> may vary. In the example illustrated, radial beams have a thickness ranging from <NUM> to <NUM>. Beam thickness may be uniform for a given beam or may be thicker or wider at the center of the beam to provide more stiffness and prevent buckling.

In the example illustrated, those radial beams <NUM> that underlie surface strips <NUM>, <NUM>, <NUM> and <NUM> have a greater thickness as compared to the thickness of those radial beams <NUM> that underlie portions of outer lattice <NUM>. Such distributions assist in providing a more consistent bounce or rebound performance along different circumferential portions of basketball <NUM>. As will be described hereafter, in some implementations, the beam thicknesses of those radial beams <NUM> located along the polar regions may have a lesser thickness as compared to those radial beams <NUM> located between the polar regions.

As discussed above, outer layer <NUM> is lobular in shape. As shown by <FIG>, inner layer <NUM> is circumferential or "flat", lacking any depressions. As shown by <FIG>, in other implementations, both inner layer <NUM> and outer layer <NUM> may be loby, wherein the depressions or recessed portions are circumferentially aligned with one another. In such implementations, the beam length of the radial beams <NUM> connecting the inner layer <NUM> and the outer layer <NUM> would be substantially constant, even in regions where the radial outer surfaces of layers <NUM> and <NUM> turn concave. In some implementations, although both layers <NUM> and <NUM> are loby, layers <NUM> and <NUM> may have different curvature radii. For example, inner layer <NUM> may have a slight inward depression or curvature between adjacent panels <NUM> while outer layer <NUM> has a greater inward depression or curvature between adjacent panels <NUM>.

As shown by <FIG>, in some implementations, both inner layer <NUM> and outer layer <NUM> may have generally circumferential or flat profiles, lacking any depression between panels. In such implementations, panel <NUM> may not be loby, but may have the same radius of curvature as that of basketball <NUM>. In such implementations, the surface strips may have outer circumferential surfaces that are flush or level with the outer circumferential surfaces of outer lattice <NUM>.

<FIG> illustrate the outer surface of basketball <NUM>. In the example illustrated, the circumferential beams <NUM>, forming inner lattice <NUM>, have a generally circular or oval cross-sectional shape. In contrast, as shown by <FIG>, the circumferential beams <NUM> forming outer lattice <NUM> have outer portions <NUM> that are cut or flat. As shown by <FIG>, this provides a smooth or flat outer surface for panels <NUM>.

<FIG> illustrates portions of an alternative outer lattice <NUM> for an example basketball <NUM>. Basketball <NUM> is similar to basketball <NUM> described above except the basketball <NUM> comprises outer lattice <NUM>. Outer lattice <NUM> is similar to outer lattice <NUM> in all respects except that outer lattice <NUM> comprises circumferential beams <NUM> which are not flat, but which are rounded. As a result, the tops <NUM> of beams <NUM> have a curved or rounded profile to provide a different grip for basketball <NUM>. In some implementations, all of such beams <NUM> are rounded. In some implementations, selected circumferential beams <NUM> at selected circumferential portions of basketball <NUM> are rounded.

<FIG> illustrates portions of an alternative outer lattice <NUM> for an example basketball <NUM>. Basketball <NUM> is similar to basketball <NUM> described above except the basketball <NUM> comprises outer lattice <NUM>. Outer lattice <NUM> is similar to outer lattice <NUM> in all respects except that the flat upper surfaces <NUM> of circumferential beams <NUM> are textured rather than being smooth. In the particular example illustrated, the flat tops <NUM> of circumferential beams <NUM> are provided with a pebble-like textured surface to enhance grip. In the example illustrated, surface strips <NUM>, <NUM>, <NUM> and <NUM> remain smooth and are not textured. In some implementations, all or some of surface strips <NUM>, <NUM>, <NUM> and <NUM> may include the same texture as that of top <NUM> of circumferential beams <NUM> or may be provided with a different distinct texture. In some implementations, different portions of each of surface strips <NUM>, <NUM>, <NUM> and <NUM> may be differently textured.

<FIG> illustrates portions of an alternative outer layer <NUM> of an example basketball <NUM>. Basketball <NUM> is similar to basketball <NUM> described above except that basketball <NUM> comprises outer layer <NUM>. The outer layer <NUM> is similar to outer layer <NUM> described above except that outer layer <NUM> comprises surface strips <NUM> corresponding to surface strips <NUM>, <NUM>, <NUM> and <NUM>, but wherein the surface strips have outer surfaces that are textured. In the example illustrated, the outer surfaces of such surface strips <NUM> are provided with a pebbled or cobblestone texture. In other implementations, the outer surfaces of such surface strips may have other textures. In some implementations, all or some of surface strips <NUM> may be provided with a different textures. In some implementations, different portions of each of surface strips <NUM> may be differently textured.

<FIG> illustrate an example of basketball <NUM>, wherein the radial beams <NUM> are provided with a varying radial beam diameter or thickness, wherein different radial beams in different circumferential portions of basketball <NUM> have different beam diameters or thicknesses. <FIG> are heat maps, wherein the different patterns correspond to different beam thicknesses/diameter as measured in millimeters. <FIG> illustrates basketball <NUM> without outer layer <NUM>.

The location of surface strips <NUM>, <NUM>, <NUM> and <NUM> are indicated in <FIG>, <FIG> by broken lines. As shown by <FIG>, at opposite pole regions <NUM>-<NUM> and <NUM>-<NUM>, the regions where the surface strips <NUM>, <NUM>, <NUM> and <NUM> converge, the radial beams <NUM> (the polar cap beams <NUM>) have a lesser thickness/diameter than the radial beams at other locations about basketball <NUM>. The polar cap beams <NUM> form a generally uniform circular region wherein the polar cap beams <NUM> have substantially the same reduced thickness.

Because the surface strips <NUM>, <NUM>, <NUM>, <NUM> have a solid density of polymeric material, such surface strips tend to increase the rebound height when the basketballs bounced off of such surface strips. Because the surface strips <NUM>, <NUM>, <NUM> and <NUM> converge at pole regions <NUM>, strips <NUM>, <NUM>, <NUM> and <NUM> are closest at the pole regions <NUM> and have the greatest surface concentration. But for the reduced thickness or diameter of polar cap radial beams <NUM>, the high concentration of the solid surface strips <NUM>, <NUM>, <NUM> and <NUM> might otherwise increase the rebound or bounce height of the basketball when bounced off of the pole regions <NUM>. The reduced thickness of the polar cap beams <NUM> at the pole regions <NUM> tends to reduce rebound height. The reduced thickness of the polar cap beams <NUM> at the pole regions <NUM> reduces bounce to neutralize or offset any bounce increase caused by the greater concentration (surface area density) of the converging surface strips. The reduced thickness or diameter of the polar cap beams <NUM> at the pole regions <NUM>-<NUM>, <NUM>-<NUM> facilitate a more uniform rebound or bounce. In other words, basketball <NUM> bounces approximately the same whether the basketball <NUM> bounces off of the pole regions or other portions of the basketball <NUM>.

Those radial beams <NUM> that are located along a circumferential perimeter of polar regions <NUM> and that form ring <NUM> (as seen in <FIG>) around the polar cap beams <NUM> (polar ring beams <NUM>) have a reduced diameter or thickness. The polar ring beams <NUM> have a thickness that is less than the thickness of the polar cap beams <NUM> due to the lesser concentration of surface strips <NUM>, <NUM>, <NUM> and <NUM> further away from the converging points of the surface strips but still less than those radial beams <NUM> located at other portions of basketball <NUM>. The reduced thickness of the polar ring beams <NUM> reduce or neutralize the enhanced bounce that otherwise might exist at the edges of the regions <NUM> due to the convergence and concentration of the surface strips. The reduced thickness of the polar ring beams <NUM> facilitates more consistent uniform bounce across different regions of basketball <NUM>.

Similarly, those radial beams <NUM> that directly underlie those portions of surface strips <NUM>, <NUM>, <NUM> and <NUM> that extend from ring <NUM> in the shape of fingers outwardly projecting from the ring <NUM> (polar flare beams <NUM>) also have a reduced diameter or thickness. In the example illustrated, the polar flare beams <NUM> have a diameter or thickness similar to the diameter thickness of polar ring beams <NUM>. The reduced thickness or diameter of the polar flare beams <NUM> neutralizes the additional bounce that might otherwise occur along the surface strips proximate to where the surface strips converge at the polls. The reduced thickness of the polar flare beams <NUM> facilitates more consistent uniform bounce across different regions of basketball <NUM>.

As shown by <FIG>, the thickness or diameter of the radial beams <NUM> also varies based upon its proximity or relationship to the intermediate portions of surface strips <NUM>, <NUM>, <NUM> and <NUM> that extend between the pole regions <NUM>. In the example illustrated, those radial beams <NUM> between the pole regions <NUM> (other than the polar flare beams <NUM>) have three general thicknesses. Those radial beams <NUM> directly underlying or in close proximity to the sides of surface strips <NUM>, <NUM>, <NUM> and <NUM> (surface strip beams <NUM>) have a first thickness or diameter that is greater than the thickness or diameter of the polar cap beams <NUM> at the pole regions <NUM>. The greater thickness or diameter of the surface strip beams <NUM> accounts for the shorter height and shorter beam length of such surface strip beams <NUM> (providing the loby shape).

Those radial beams <NUM> that are equidistantly circumferentially spaced between the surface strips (middle region beams <NUM>) are the farthest from both of the surface strips. To enhance the rebound or bounce of such beams in such regions, the middle region beams <NUM> are provided with a greater thickness as compared to the thickness of the polar ring beams <NUM> and a thickness slightly less than the thickness of the surface strip beams <NUM>.

Those radial beams <NUM> that extend between the surface strip beams <NUM> and the middle region beams <NUM> (the spacer beams <NUM>) have a thickness less than the thickness of surface strip beams <NUM> and middle region beams <NUM>. Spacer beams <NUM> have a thickness or diameter substantially equal to or slightly greater than the thickness of the polar ring beams <NUM>. The thickness of spacer beams <NUM> distributes, spreads or evens out any increase in bounce that may occur at locations where the surface strip beams <NUM> and the middle region beams <NUM> are located.

Overall, the above-described distribution or variation of different radial beam thicknesses/diameters solves rebound or bounce irregularities that might otherwise exist due to the presence and layout of the surface strips <NUM>, <NUM>, <NUM> and <NUM>. In implementations where basketball <NUM> is provided with a different layout of surface strips or where the surface is not loby, the above-described layout or pattern of thickness variations may likewise be different. For example, in non-loby basketballs, basketballs having a constant outer diameter, the thickness of the radial beams underlying the surface strips need not be increased to accommodate a decrease in beam length. In basketballs where the surface strips converge at regions other than the poles of the basketball, the location of those beams <NUM> having a reduced thickness may likewise shift to the locations where the surface strips converge. The provision of radial beams <NUM> having different diameters or thicknesses in different regions of the basketball may be omitted where surface strips are also omitted.

<FIG> illustrates portions of an example basketball <NUM>. <FIG> illustrates just the radial beams <NUM> and surface strips <NUM>, <NUM>, <NUM> and <NUM>, omitting inner lattice <NUM> and outer lattice <NUM>. The radial beams <NUM> are further patterned to provide a heat map indicating their different diameters or thicknesses. <FIG> illustrates another example of how the diameters or thicknesses of the radial beams may be varied and are patterned to provide a more uniform and consistent bounce when the basketball bounces off different portions of its circumference. Basketball <NUM> comprises the same surface strips <NUM>, <NUM>, <NUM> and <NUM> as basketball <NUM>. Like basketball <NUM>, basketball <NUM> comprises the above-described inner layer <NUM> and an outer layer similar to outer layer <NUM> but being non-loby. The radial beams <NUM> have a different pattern of radial beam thicknesses. In the example illustrated, those radial beams <NUM> extending along the surface strips (surface strip beams <NUM>) have a reduced thickness. Those radial beams circumferentially and centrally located between the surface strips (middle region beams <NUM>) have an increased thickness, a thickness greater than that of surface strip beams <NUM>. Those radial beams that extend between the surface strip beams <NUM> and the middle region beams <NUM> (spacer beams <NUM>) have a thickness greater than that of surface strip beams <NUM>, but less than that of middle region beams <NUM>.

<FIG> is an enlarged view of a portion of a basketball <NUM>, with outer layer <NUM> omitted. Basketball <NUM> is similar to basketball <NUM> except that basketball <NUM> comprises radial beams <NUM> in place of radial beams <NUM>. Radial beams <NUM> each have varying thicknesses along their length and have non-circular cross-sectional shapes. In the example illustrated, beams <NUM> have triangular cross-sectional shapes. The varying beam thickness profiles in the alternative shapes may be used to vary axial stiffness and thereby vary or control rebound characteristics for the region of the basketball <NUM> including such radial beams <NUM>.

<FIG> is an enlarged view of a portion of a basketball <NUM>, with outer layer <NUM> omitted. Basketball <NUM> is similar to basketball <NUM> except that Best Basketball <NUM> comprises radial beams <NUM> in place of radial beams <NUM>. Radial beams <NUM> have circular cross-sections but have non-uniform thicknesses along their beam lengths. In the example illustrated, each of radial beams <NUM> has a middle or central portion <NUM> having a first diameter or thickness and opposite end portions <NUM> having a second smaller diameter or thickness. In some implementations, the location of the central portion <NUM> relative to the end portions may be moved up or down, towards inner layer <NUM> or outer layer <NUM> to vary or control rebound performance. Likewise, the thickness or diameter of the central portion <NUM> and/or the end portions <NUM> may be varied to vary and control rebound performance.

<FIG> illustrates portions of an example basketball <NUM>. Basketball <NUM> is similar to basketball <NUM> except that basketball <NUM> various a density of radial beams <NUM> and additionally comprises an internal skeleton <NUM>. In contrast to basketball <NUM>, outer layer <NUM> is loby. <FIG> omits inner and outer layer <NUM> for purposes of illustration. <FIG> omits surface strips <NUM>, <NUM>, <NUM> and <NUM> for purposes of illustration. As with basketball <NUM> in <FIG>, the radial beams <NUM> are further colored to provide a heat map indicating their different diameters or thicknesses.

In the two opposite pole regions <NUM>-<NUM> and <NUM>-<NUM> (not shown), basketball <NUM> has a lower density of radial beams <NUM>. The lower density of radial beams <NUM> reduces, offsets or neutralizes any extra rebound or bounce that may occur due to the increased concentration of surface strips <NUM>, <NUM>, <NUM> and <NUM>, as well as the higher concentration of portions of skeleton <NUM>. The density of radial beams <NUM> increases outside of closure <NUM> formed by the converging portions of skeleton <NUM>. The density of radial beams <NUM> is reduced in those regions adjacent to or underlying those portions of surface strips <NUM>, <NUM>, <NUM> and <NUM> that are in close proximity to closure <NUM>.

Inner skeleton <NUM> is provided by added reinforcing channels <NUM> on the outer wall of the inner lattice <NUM>. The reinforcing channels <NUM> provide additional rebound performance in such regions. Although the reinforcing channels <NUM> converge to form closure <NUM>, the additional rebound at such pole regions <NUM>-<NUM>, <NUM>-<NUM> is offset by the lower density of radial beams <NUM> and their reduced thicknesses.

<FIG> illustrate various examples of how any of the above-described basketballs may be provided with branding, logos or other information (customized information, manufacture date, style or version data, patent data, advertising or the like) at different locations (hereinafter referred to as an "information landing", a "landing" or "landings"). <FIG> illustrate various examples of how such information may be presented and located so as to have a reduced impact upon the feel and rebound performance/consistency of the basketball. <FIG> illustrate various information locations on a single basketball <NUM>. As should be appreciated, basketball <NUM> may omit all or at least some of the particular information landings.

<FIG> illustrate information landing <NUM>. Information landing <NUM> is located or formed along surface strip <NUM>-<NUM> and is wider than those portions of surface strip <NUM>-<NUM> which extend from opposite ends of information landing <NUM>. Information landing is located nearer within polar region <NUM>-<NUM>, proximate to where surface strip <NUM>-<NUM> connects to surface strip <NUM>-<NUM>. In the example illustrated, landing <NUM> has embossed thereon logo information comprising "W" and "NBA". In other implementations, other information may be branded on landing <NUM>, such as shown in <FIG>. In yet other implementations, the information may be provided are formed upon landing <NUM> in other fashions. For example, the information may be placed upon landing <NUM> by printing, stamping or molding. The recessed nature of such embossing lessons any rebound impact.

<FIG> illustrate an example landing <NUM>. Landing <NUM> is formed at the center of pole region <NUM>-<NUM> of basketball <NUM>. Landing <NUM> is formed along a conjunction of surface strips <NUM>-<NUM> and <NUM>-<NUM>. Landing <NUM> has a width greater than the width of surface strips <NUM>-<NUM> and <NUM>- and is recessed along with surface strips <NUM>-<NUM> and <NUM>-<NUM> (due to the loby shape). In other implementations, landing <NUM> may be formed at pole region <NUM>-<NUM>. In other implementations, landing <NUM> may be formed at a conjunction of surface strips <NUM>-<NUM> and <NUM>-<NUM> at home region <NUM>-<NUM> or at pole region <NUM>-<NUM>. As with landing <NUM>, landing <NUM> has embossed thereon logo information comprising "Wilson" and "NBA". In other implementations, information may be provided on landing <NUM> in other fashions such as by printing, stamping or molding.

<FIG> illustrate an example landing <NUM>. Landing <NUM> is formed at a center point of surface strip <NUM>-<NUM>, centered between the centers of pole regions <NUM>-<NUM> and <NUM>-<NUM>. Landing <NUM> has a width greater than the width of surface strip <NUM>-<NUM> and is recessed along with surface strip <NUM>-<NUM> (due to the loby shape). In other implementations, landing <NUM> may alternatively be formed along at center points between the pole regions <NUM>-<NUM> and <NUM>-<NUM> along any of the surface strips <NUM>, <NUM>, <NUM> and <NUM>. Like the other landings, landing <NUM> has embossed thereon logo information comprising "Wilson," the Jerry West NBA logo, and "NBA". In other implementations, information may be provided on landing <NUM> in other fashions such as by coating, printing, stamping or molding.

<FIG> illustrate an example landing <NUM> of basketball <NUM>. Landing <NUM> is formed as part of a central portion of surface strip <NUM>-<NUM>. Landing <NUM> does not alter the width of surface strip <NUM>-<NUM>. In the example illustrated, landing <NUM> includes information that projects from the outer surface of surface strip <NUM>-<NUM>. The height of the raised portions providing the information is less than the extent to which the outer surface of surface strip <NUM>-<NUM> is recessed. Because landing <NUM> does not alter the width of surface strip <NUM>-<NUM> and because the raised data portions have a height less than an extent to which surface strip <NUM>-<NUM> is recessed, the provision of landing <NUM> and his information has a lower impact upon any rebound or bounce variation that might otherwise result from its presence. As should be appreciated, landing <NUM> may be formed on any of the surface strips a central point along such surface strips between the polar regions <NUM> or at other locations along the surface strips.

<FIG> illustrates a portion of basketball <NUM> provided with external information <NUM>. <FIG> illustrates an example of how information may be integrated and outer lattice each of the above-described 3D printed basketballs. In the example illustrated, the information is in the form of an example logo "Wilson". The logo is formed by 3D printing a line of material over and across voids of the cells of the outer lattice. The example presents information in a subtle fashion and is thus likely to have a large impact on the rebound performance of basketball <NUM> due to the inclusion of the example logo.

<FIG> illustrates a portion of basketball <NUM> provided with external information coating <NUM>. Information coating <NUM> is applied with a post process application. For example, information coating <NUM> may be coated, painted or otherwise formed on the exterior of outer lattice <NUM> of basketball <NUM>. In the example illustrated, the coating may cover and span across the open cells of outer lattice <NUM>. In the example illustrated, information coating <NUM> is presented in the shape of a panel. The panel may be provided with various customized colors and other ornamentation.

In some implementations, what is shown in <FIG> may be in the form of a mask <NUM> which is positioned over or more removably applied to the outer surface of basketball <NUM>. In such an implementation, a paint or other durable coating may be sprayed or otherwise applied across the mask <NUM>, through which openings, forming a patterned coating on outer lattice <NUM>. Depending upon factors such as the viscosity of the coating and the amount of coating, the coating applied through the openings in the mask <NUM> may cover the openings or voids of the individual cells of outer lattice <NUM> or may alternatively cover the outer surfaces of the outer circumferential beams <NUM> while leaving intact the openings or voids of the individual cells <NUM>.

<FIG> illustrates one example process or method for forming a 3D printed basketball, such as basketball <NUM>. In one implementation, basketball <NUM> is formed from an additive printing process such as a selective laser sintering or multi-jet fusion. With selective laser sintering and multi-jet fusion, basketball <NUM> is formed or built in a layer-by-layer fashion in the z direction (the vertical direction) resulting in multiple x-y plane layers. With selective laser sintering and multi-jet fusion, bed <NUM> is provided with a polymeric powder capable of being sintered (fused or melted).

With selective laser sintering (SLS), a laser is selectively applied to the powder to selectively heat and sinter/melt portions of the powder to form a particular x-y plane layer. The selective application the layer may involve a computer program which controls the x-y (horizontal) positioning of a laser and which controls lowering of the bed, all based upon a sintering pattern or architecture corresponding to the different structures and features of basketball <NUM> and embodied as code in a non-transitory computerized readable medium. The bed may be lowered and a new layer of fresh powder formed overtop the previously formed x-y plane layer. After the two-dimensional layer of sintered or fused material is made, the platform or floor <NUM> advances (is lowered) and a new layer of powder is swept over the prior completed layer. The laser is once again selectively applied to selectively heat and fuse/melt/sinter selected portions of the fresh powder to form the next x-y plane layer, potentially stacked upon the prior x-y plane layer, to form a 3D shape. This process continues until basketball <NUM> is completed.

Multi-jet fusion (MJF) printing is similar to selective laser sintering except that an absorptive die is printed, such as through inkjet printing, on the powder to form a sinter pattern for a particular x-y plane of the basketball being formed. The dye, when activated with a laser or other radiation, causes the powder to melt and fuse/sinter. The printed sinter pattern of dye defines where powder is fused/melted/sintered upon being activated by a potentially less selective laser or application of a wide band of powder sintering heat or radiation. The selective application of the dye may involve a computer program which controls the x-y (horizontal) positioning of a printer or its printhead(s), such as an inkjet printer, and which controls lowering of the powder bed, all based upon a sintering pattern or architecture corresponding to the different structures and features of basketball <NUM> and embodied as code in a non-transitory computerized readable medium. As with selective laser sintering, the layer-by-layer process is repeated, wherein the sequentially formed layers of sintered powder form basketball <NUM>.

As shown by <FIG>, basketball <NUM> may be formed in a layer-by-layer fashion using SLS or MJF in the example powder bed <NUM>. The panel or floor <NUM> of powder bed <NUM> may be sequentially lowered along the z-axis during the formation of each of the layers of basketball <NUM>. As discussed above, a laser may be selectively positioned or a sinter activating pattern of "a dye" may be selectively applied to the fresh powder of each layer to form the features of basketball <NUM>.

Material properties of different portions or regions of basketball <NUM> may vary depending upon the orientation at which basketball <NUM> is printed in bed <NUM>. Because basketball <NUM> may be printed in a layer-by-layer method using SLS or MJF properties of basketball <NUM> may have stronger/stiffer/higher elongation in the horizontal or x-y plane and be weaker in the z axis or vertical direction. As shown by <FIG>, the additive printing of basketball <NUM> is performed such that the centers of the regions <NUM>-<NUM> and <NUM>-<NUM> are aligned in the x-y plane (any rotation about the z-axis). Said another way, with basketball <NUM>, the additive or 3D printing of basketball <NUM> using SLS or MJF is performed such that the center point of polar regions <NUM>-<NUM> and <NUM>-<NUM> are formed in the same x-y plane or layer of sintered/fused powder. The center point of the polar regions <NUM> may be maintained in the same x-y plane or layer of fused powder with any rotation about the X axis. The particular orientation of the basketball <NUM> being formed within bed <NUM> may be defined by the particular programming, instructions or code contained in the non-transitory computerized readable medium which directs the lowering of floor <NUM> as well as the selective application of a laser beam or the selective application of the dye during the layer-by-layer printing process. Because basketball <NUM> is printed with the center point of the polar regions <NUM>-<NUM>, <NUM>-<NUM> aligned in the x-y plane during printing, basketball <NUM> may have a more consistent shape and rebound along its various circumferential regions as compared to orienting or centering the center points of pole regions <NUM>-<NUM>, <NUM>-<NUM> along the z-axis. Printing with the polls on the sides achieves more uniform material properties, increases overall rebound and reduces dead spot.

Because the 3D printed material may be stiffer at the top and bottom of the basketball <NUM> as compared to the sides of basketball <NUM> due to layer-by-layer deposition (stiffer may equate to higher rebound), in some implementations, those radial beams <NUM> proximate to a top and bottom of basketball <NUM> (as seen in <FIG>) may be provided with a thickness that is relatively less than the corresponding thickness of the beams along the sides of the basketball (as seen in <FIG>) to provide more uniform rebound. The radial beams not reinforced by surface strips (also referred to as reinforcing channels) may also be stiffened with increased stiffness as shown in <FIG>.

In addition to rebound, the shape of the basketball may also be influenced by the layer-by-layer 3D printing process. The size of basketball may impact the player's ability to the ball and perform maneuvers during play. Successively formed layers that make up the basketball may result in dimensions of the basketball varying which affect both grip performance as well as rebound and role characteristics. To address such variations, the X-Y-Z scale factors are adjusted for such layer-by-layer 3D printing in a manner specific to each additive powder method, ball geometry, material and such or machine and may be tuned.

Material properties of basketball <NUM> may be sensitive to how basketball <NUM> is printed. Typical data sheets regarding materials report material properties as injection molded values. However, material properties vary greatly based on: (<NUM>) print method, e.g., selective laser sintering (SLS) or multi-jet fusion (MJF), (<NUM>) depending on print geometry due to skinning effects, and (<NUM>) print orientation, as both SLS and MJF are built layer-by layer in z direction, resulting in multiple x-y plane layers.

In some implementations, basketball <NUM> (or any of the other above-described 3D printed basketballs) may be formed from a polymer having the following properties (measured as injection molded):.

In some implementations, any of the above-described 3D printed basketballs may be 3D printed from a thermoplastic polymer. In some implementations, any of the above-described 3D printed basketballs may be formed from a polyether block amide or PEBA thermoplastic elastomer such as PEBAX (Registered Trademark) <NUM> commercially available from Arkema imprinted on EOS branded or DTM/ISI (Non-EOS branded equipment) printers. In some implementations, any of the above-described 3D printed basketballs may be 3D printed from an Evonik thermoplastic polyamide (a chemical copolymer of a thermoplastic elastomer and a highly flexible nylon) (grades; racial soft to hard segment).

In some implementations, any of the above-described 3D printed basketballs may be 3D printed from an Evonik thermoplastic copolyester, Infinam 8008P printed on Hewlett-Packard or other powder-based printers. In some implementations, any of the above describe 3D printed basketballs may be 3D printed from a material such as PA12. From a rigidity/energy return standpoint, PA12 has value of <NUM>-<NUM> GPa young's modulus, but elongation to break is only ~<NUM>%, which may be especially beneficial given the high frequency at which the basketball is to be bounced or dribbled. Higher elongation is important because the material undergoes high strain rate deformation to relatively high strains, with repeated cycles with limited recovery time between impacts. If the elongation to break is <NUM>% for example, an event may cause a strain of <NUM>% within <NUM>.

Basketball <NUM>, formed from the above materials and having the above-described configuration has a size and performance characteristics equivalent or similar to that of officially sanctioned competitive play basketballs, such as competitive play basketballs sanctioned by the NBA, NCAA and NFHS (National Federation of High Schools). For example, when dropped from a height of <NUM> (<NUM> inches) measured from the bottom of the ball, minimum rebound for a retail ball is <NUM> (<NUM> inches) (measured from top of ball) and for an NBA game ball it is <NUM> (52inches). The maximum rebound for an NBA ball is <NUM> (<NUM> inches). Basketball <NUM> may have a rebound of at least <NUM> (<NUM> inches) and slightly above <NUM> (<NUM> inches) when dropped from a height of <NUM> (<NUM> inches). Basketball <NUM> further has a reduced "dead spot" (max rebound - min rebound across different locations on the ball) of under <NUM> (<NUM> inches), comparable to NBA sanctioned competitive play basketballs.

In some implementations, basketball <NUM> formed according to the above-described parameters, has the following characteristics relative to an NBA sanctioned competitive play basketball.

The open celled exterior of the above-described basketballs, due to the open cells of outer lattice <NUM> and inner lattice <NUM>, may result in aerodynamic resistance which may impact the passing of the basketball and the flight of the basketball during a shot. In other words, the basketball is hollow and generally perforate with air flow passages from the exterior of the basketball communicating with the hollow interior and the center point of the basketball. The air flow passages also continuously extend through the basketballs from one outer side to another outer side of the basketballs. In some implementations, any of the above describe 3D printed basketballs may be additionally provided with a skin which covers, blocks, or occludes the cell openings of the inner lattice <NUM> and/or the outer lattice <NUM>. In some implementations, the skin may be translucent or transparent to maintain the ability to view the unique and aesthetically pleasing pattern of at least outer lattice <NUM>. To reduce any breaks or seams, and assembly complexity, the skin may comprise a one-piece skin having a single pair of opposing edges, a single opening or no openings or edges. In some implementations, the skin may serve as a bladder having an interior that may be inflated. In other implementations, the skin may have an interior that is exposed to atmosphere, wherein the interior is not inflated and is at atmospheric pressure. The resilient nature of wall <NUM> facilitates basketball <NUM> having an interior that may be at pressure, eliminating the need to monitor or maintain inflation of the basketball.

<FIG> and <FIG> are sectional views schematically illustrating an example basketball <NUM> provided with a skin. <FIG> illustrates a portion of outer lattice <NUM> covered by a skin. Basketball <NUM> comprises basketball <NUM> (described above) provided with an outer skin <NUM>. In some implementations, outer skin <NUM> is translucent or transparent to facilitate and maintain the visibility of outer layer <NUM> of basketball <NUM>. Outer skin <NUM> is in close conformal contact with the outer surface of outer layer <NUM>, having a contour profile that matches the outer contour profile of outer surface of outer layer <NUM>. For example, outer skin <NUM> may dip in those regions of outer skin <NUM> that overlie the recessed surface strips <NUM>, <NUM>, <NUM> and <NUM>, maintaining the loby shape or profile of the internal basketball <NUM> and the final skin covered basketball <NUM>.

Outer skin <NUM> may be formed from a durable polymeric material and may be extremely thin so as to have a reduced impact on the overall weight, size and rebound characteristics of basketball <NUM>. In some implementations, outer skin <NUM> may have a thickness of at least <NUM> and no greater than <NUM>. In some implementations, outer skin <NUM> may have a thickness of less than <NUM>. In some implementations, outer skin <NUM> may be formed from material such as thermoplastic polyolefin or thermoplastic/thermoset polyurethane. As shown by <FIG>, outer skin <NUM> may span across the outer circumferential beams <NUM> of outer lattice <NUM>. Outer skin <NUM> may cover the tops <NUM> of such beams <NUM>. Outer skin <NUM> may additionally overlap and cover surface strips <NUM>, <NUM>, <NUM> and <NUM> (illustrated in the figures described above).

In some implementations, outer skin <NUM> may comprise a single unitary one-piece layer or film having a single set of opposing edges <NUM>. The opposing edges <NUM> may form an opening into which basketball <NUM> may be inserted. In some implementations, the opposing edges <NUM> are aligned with one or more of the surface strips, such as surface strips <NUM>-<NUM>, <NUM>-<NUM> (schematically shown in <FIG>) so as to lessen any variation that may occur along such edges <NUM>. In some implementations, edges <NUM> may be recessed within the recess channel or groove provided by the loby shape of basketball <NUM>.

In some implementations, outer skin <NUM> may be shrunk wrap about basketball <NUM>. For example, outer skin <NUM> may be provided as a film which is wrapped about basketball <NUM> and was subsequently heated so as to shrink the film into close conformal contact and even fused to the outer surface of outer layer <NUM>. In some implementations, outer skin <NUM> may be co-molded about basketball <NUM>. As shown by <FIG>, in some implementations, outer skin <NUM> may be applied to basketball <NUM> so as to be flush or level with tops <NUM> of beams <NUM> of outer lattice <NUM>.

As shown by <FIG>, in some implementations, outer skin <NUM> may be applied to basketball <NUM> so as to at least partially encapsulate or wrap around circumferential beams <NUM> of outer lattice <NUM>. This construction may provide a greater surface area for fusion, melting, bonding or adhering of outer skin <NUM> to the outer surface of outer layer <NUM>. This construction may also provide a form of a mechanical lock between circumferential beams <NUM> of outer lattice <NUM> and outer skin <NUM>. In some implementations, outer skin <NUM> may be pressed against the exterior of basketball <NUM> with a mold having an interior surface provided with projections that press portions of outer skin <NUM> partially into the hexagonal voids of the hexagonal cells formed by circumferential beams <NUM>. In some implementations, a needle may be passed between edges <NUM>, wherein a vacuum may be applied through the needle to the interior of basketball <NUM> to suck or draw outer skin <NUM> (while in a flexible, pliable or partially melted state) into close conformal contact with the outer surface of outer layer <NUM> and, in the implementation shown in <FIG>, to draw portions of outer skin <NUM> into the hexagonal cells formed between circumferential beams <NUM>. Thereafter, the needle may be withdrawn, leaving outer skin <NUM> either fused to beams <NUM>, mechanically locked to beams <NUM> and/or bonded to tops <NUM> and sides of beams <NUM> (via an adhesive applied to beams <NUM> prior to the application of outer skin <NUM> or applied to a face of outer skin <NUM>). In such implementations, the interior of the completed basketball <NUM>, with skin <NUM>, may be exposed to atmospheric pressure through the openings through which the needle was inserted.

<FIG> are sectional views schematically illustrating portions of an example basketball <NUM> provided with an inner skin <NUM>. <FIG> illustrates a portion of inner lattice <NUM> covered by or supporting inner skin <NUM>. Basketball <NUM> comprises basketball <NUM> (described above) provided with an inner skin <NUM>. In some implementations, inner skin <NUM> is translucent or transparent to facilitate and maintain the visibility through and across basketball <NUM>. In some implementations, inner skin <NUM> may be opaque. Inner skin <NUM> is in close conformal contact with the inner surface of inner layer <NUM>, inner lattice <NUM>, having a contour profile that matches the inner contour profile of inner surface of inner layer <NUM>.

Inner skin <NUM> may be formed from a durable polymeric material and may be extremely thin so as to have a reduced impact on the overall weight, size and rebound characteristics of basketball <NUM>. In some implementations, inner skin <NUM> may have a thickness of at least <NUM> and no greater than <NUM>. In some implementations, inner skin <NUM> may have a thickness of less than <NUM>. In some implementations, inner skin <NUM> may be formed from material such as thermoplastic polyolefin or thermoplastic/thermoset polyurethane. As shown by <FIG>, inner skin <NUM> may span across the circumferential beams <NUM> of inner lattice <NUM>. Inner skin <NUM> may cover the interior facing surfaces of such beams <NUM>.

In some implementations, inner skin <NUM> may be adhesively bonded to the interior surface of beams <NUM>. For example, an adhesive may be applied to such surfaces of beams <NUM> or to a face of inner skin <NUM>. In other implementations, inner skin <NUM> may be melted or fused to inner surfaces of beams <NUM> through the application of heat. As shown by <FIG>, in some implementations, a cannula, trocar or needle <NUM> may be inserted through the open cells formed by outer lattice <NUM> and inner lattice <NUM>, into the interior <NUM> of basketball <NUM>. Thereafter, a collapsed balloon, formed by inner skin <NUM>, may be inserted through the needle <NUM> into the interior and inflated through needle <NUM>. The collapsed balloon may be inflated to a state such that its outer surface or outer wall (skin <NUM>) expands and is brought into contact with the inner surface portions of beams <NUM>.

As noted above, in some implementations, skin <NUM> is adhesively bonded to beams <NUM>. In other implementations, the gas inflating the balloon may be at a temperature sufficient to heat the wall of the balloon to a temperature to fuse the wall of the balloon (skin <NUM>) to beams <NUM>. In yet other implementations, heat may be applied to the exterior basketball <NUM>, the heat being insufficient to melt or deformed basketball <NUM> but being sufficient to melt and fuse skin <NUM> to beams <NUM>. Thereafter, needle <NUM> may be withdrawn leaving inner skin <NUM> either fused to beams <NUM> and/or bonded to tops <NUM> and sides of beams <NUM> (via an adhesive applied to beams <NUM> prior to the application of outer skin <NUM> or applied to a face of outer skin <NUM>). In such implementations, the interior of the completed basketball <NUM>, with skin <NUM>, may be exposed to atmospheric pressure through the openings through which the needle was inserted.

In some implementations, inner skin <NUM> may alternatively be injected through needle <NUM> along the interior surfaces of layer <NUM> and inner lattice <NUM> or may be sprayed onto such surfaces and using needle <NUM>. The material may be deposited so as to form a continuous and imperforate film across inner lattice <NUM>.

As shown by <FIG>, in some implementations, the interior <NUM> may be inflated through needle <NUM> to an extent such projects into the cell formed by beams <NUM> of inner lattice <NUM>, at least partially wrapping about or encapsulating beams <NUM>. By wrapping skin <NUM> at least partially about beams <NUM>, a greater surface area is provided for adhesively bonding or fusing skin <NUM> to beams <NUM> of inner lattice <NUM>. In some implementations, such wrapping, or at least partial encapsulation, may additionally form a mechanical lock to further enhance retention of skin <NUM> to beams <NUM>.

<FIG> are sectional views schematically illustrating portions of an example basketball <NUM> having an intermediate or middle skin <NUM>. <FIG> illustrates middle skin <NUM> and circumferential beams <NUM> of outer lattice <NUM>. Basketball <NUM> comprises basketball <NUM> (described above) provided with middle skin <NUM>. In some implementations, middle skin <NUM> is translucent or transparent to facilitate and maintain the visibility through and across basketball <NUM>. In some implementations, middle skin <NUM> may be opaque. Middle skin <NUM> is in close conformal contact with the inner surface of inner layer <NUM>, inner lattice <NUM>, having a contour profile that matches the inner contour profile of inner surface of inner layer <NUM>.

Middle skin <NUM> may be formed from a durable polymeric material and may be extremely thin so as to have a reduced impact on the overall weight, size and rebound characteristics of basketball <NUM>. In some implementations, middle skin <NUM> may have a thickness of at least <NUM> and no greater than <NUM>. In some implementations, middle skin <NUM> may have a thickness of less than <NUM>. In some implementations, middle skin <NUM> may be formed from material such as thermoplastic polyolefin or thermoplastic/thermoset polyurethane. As shown by <FIG>, middle skin <NUM> may span across the circumferential beams <NUM> of inner lattice <NUM>. Middle skin <NUM> may cover the interior facing surfaces of such beams <NUM>.

In some implementations, middle skin <NUM> may be adhesively bonded to the interior surface of beams <NUM>. For example, an adhesive may be applied to such surfaces of beams <NUM> or to a face of middle skin <NUM>. In other implementations, middle skin <NUM> may be melted or fused to inner surfaces of beams <NUM> through the application of heat.

As shown by <FIG>, in some implementations, a cannula, trocar or needle <NUM> may be inserted through the open cells formed by outer lattice <NUM> and into the middle space <NUM> circumferentially extending between layers <NUM> and <NUM> of basketball <NUM>. Thereafter, a material may be sprayed or jetted into middle space <NUM>. In some implementations, basketball <NUM> may be placed within an outer spherical shell formed by two halves) having multiple inwardly facing cannulas, trocars or needles <NUM> that simultaneously project through multiple cells of outer lattice <NUM> about basketball <NUM>, wherein the material may be concurrently jetted into inner space <NUM> about basketball <NUM>. Thereafter, the completed basketball may be removed from the outer spherical injection shell, resulting in the multiple needles also being withdrawn.

In some implementations, the material may comprise a fluid. In other implementations, the material may be carried by an aerosol. The material injected by needle <NUM> may solidify or coagulate to form skin <NUM> which spans across the cells formed by circumferential beams <NUM>. In some implementations, needle <NUM> may be inserted through multiple spaced cells of outer lattice <NUM>, wherein the material is injected or sprayed multiple times into inner space <NUM> at different locations, wherein the material may bond to itself and overlap or connect along edges to form a continuous middle skin <NUM>. In some implementations, the material concurrently projected into different portions about basketball <NUM> by multiple needles <NUM>.

In some implementations, the material injected by needle <NUM> through one of the open cells of outer lattice <NUM>, sequentially through a plurality of the open cells of outer lattice <NUM> at different locations about basketball <NUM>, or concurrently through a plurality of open cells of outer lattice <NUM> by multiple needles <NUM> at different locations about basketball <NUM> may instead adhere to or bond to the inner surface of layer <NUM>, the inner surface of inner lattice <NUM>. In such an implementation, the material injected by needle <NUM> may not be sufficiently thick to contact the inner surface of outer layer <NUM>.

In yet other implementations, as indicated by <FIG>, the material injected by needle <NUM> through one of the open cells of outer lattice <NUM> or through different spaced open cells of open lattice <NUM> at different locations about basketball <NUM> may have a sufficient thickness so as to contact and bond to both inner layer <NUM> and outer layer <NUM>, both the outer surface of inner lattice <NUM> and the inner surface of outer lattice <NUM>. In some implementations, the material injected by needle(s) <NUM> may comprise a foam material or a material that once injected expands and foams to form a foamed middle skin <NUM>. In some implementations, the material may expand to a sufficient degree so as to fill inner space <NUM>, contacting both inner layer <NUM> and outer layer <NUM>. For example, the foamed middle skin <NUM> may partially wrap about or expand about both the circumferential beams <NUM> of inner lattice <NUM> and the circumferential beams <NUM> of outer lattice <NUM>. In such implementations, the foamed middle skin <NUM> may encircle and encapsulate radial beams <NUM> to further lock and retain the middle layer or skin <NUM> in place. In some implementations, the material injected via needle <NUM> may be translucent or transparent. In other implementations, the material injected by needle <NUM> and forming middle skin <NUM> may be opaque.

<FIG> are sectional views illustrating portions of an example 3D printed basketball <NUM>. Basketball <NUM> comprises basketball <NUM> (described above) provided with an outer skin <NUM> and inner skin <NUM> described above. Although outer skin <NUM> is illustrated as extending in a circumferential plane across top <NUM> of beams <NUM> of outer lattice, similar what is shown in <FIG>, in some implementations, outer skin <NUM> in basketball <NUM> may be configured similar to the configuration shown in <FIG>. Although inner skin <NUM> is illustrated as extending in a circumferential plane, skimming along the inner surfaces of circumferential beams <NUM> of inner lattice <NUM>, in some implementations, inner skin <NUM> may have a configuration similar to that shown in <FIG>. In yet other implementations, inner space <NUM> may additionally be filled with inner skin <NUM> as described above with respect to <FIG>.

In some implementations, the skins <NUM>, <NUM> and <NUM> have uniform characteristics and thicknesses. In yet other implementations, different portions of each of the skins <NUM>, <NUM> and <NUM> may have different characteristics or different thickness depending upon what portion of the basketball <NUM> the particular portion of the skin resides. For example, different portions of the same skin may have a different thickness depending upon whether the skin is adjacent to a pole region <NUM> of the basketball, a side of the basketball. The thickness may be varied in a continuous or in a stepwise fashion to provide the basketball with a more uniform or consistent bounce or rebound. For example, portions of the skin adjacent to the polar regions may be thinner as compared to portions of the skin along the sides of the basketball.

In some implementations, different portions of the same skin may have different chemical compositions or architectures to provide a more uniform rebound or weight distribution for the basketball. For example, with respect to implementations where middle skin <NUM> is foamed, selected portions of the middle skin <NUM> may have a greater degree of foaming while other portions of middle skin <NUM> may have a lower degree of foaming (lesser blowing agent, greater density, a smaller number of or smaller sized cells). In some implementations where different regions of the inner space <NUM> concurrently receive an injected material through different needles (as described above with respect to the spherical shell), the different needles may inject different amounts of material to provide different thickness for the scanning different regions about basketball <NUM> or may project different materials having different compositions in different regions about basketball <NUM>.

In the example illustrated, each of the skins <NUM>, <NUM> and <NUM> may be transparent or translucent to permit viewing of the inner lattice <NUM> and the outer lattice <NUM>. In some implementations, the skins may be translucent with one or more colors or color shades, allowing one to see through the skins, but wherein the skins have a color. In some implementations, the skins may include information, such as branding or logos. In some implementations, any of the skins may have different colored portions or simulated seams or joints so as to aesthetically appear as separate panels even though such skins are each a single continuous unitary film or sheet. In some implementations, such skins may be customized to provide graphics, personalized information or team information, training marks or the like. In some implementations, the skins may be personalized with a player's name, a player's team, a particular year, a league name or the like. In some implementations, the intermediate or middle skin <NUM> may be opaque and be provided with portions with different colors, graphics or the like. In some implementations, the outer skin <NUM> may be textured for example, the outer skin may have an outer surface provided with a pebble -like texture extending across an entire outer surface area of the outer skin <NUM>, extending in those regions that overlap or overlie the surface strips <NUM>, <NUM>, <NUM> and <NUM>, extending in those regions that extend between the surface strips <NUM>, <NUM>, <NUM> and <NUM> (the simulated panel <NUM>).

Claim 1:
A basketball (<NUM>) comprising:
a single integrally formed unitary body (<NUM>) comprising:
first layer (<NUM>) comprising an inner lattice (<NUM>);
second layer (<NUM>) comprising an outer lattice (<NUM>) and surface strips (<NUM>, <NUM>, <NUM>, <NUM>); and
radial beams (<NUM>) interconnecting the first layer (<NUM>) and the second layer (<NUM>), wherein the radial beams (<NUM>)_comprise a first number of the radial beams (<NUM>) interconnecting the first layer (<NUM>) and the second layer (<NUM>) beneath the surface strips (<NUM>, <NUM>, <NUM>, <NUM>) and a second number of the radial beams interconnecting the first layer and the second layer circumferentially (<NUM>) between the surface strips (<NUM>, <NUM>, <NUM>, <NUM>) and wherein each of the first number of radial beams (<NUM>) has a first height and wherein each of the second number of radial beams (<NUM>) has a second height greater than the first height.