Patent Description:
Three-dimensional printing systems and methods may be associated with various technologies including fused deposition modeling (FDM), electron beam freeform fabrication (EBF), selective laser sintering (SLS) as well as other kinds of three-dimensional printing technologies. <CIT> describes a printed encapsulation method and part. Another aspect uses a three-dimensional printing machine to emit material from an inkjet printing head to build up material attached to an insert. <CIT> describes that a printed 3D functional part includes a 3D structure comprising a structural material, and at least one functional electronic device is at least partially embedded in the 3D structure. <CIT> describes that a method serves to produce a three-dimensional object by additive construction in direct construction sequence from solidifiable material, which is either present in the starting state in a fluid phase or can be liquefied, where multiple material components are discharged alternately in a programmable manner by means of multiple discharge units and configure different parts of the object joined to one another as a result of the discharge.

The claimed invention is directed to an article of apparel as defined in claim <NUM>.

Other systems, methods, features and advantages of the embodiments will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description.

<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>. In addition, <FIG> depicts several elements <NUM> that may be incorporated, placed, or otherwise used during printing. Referring to <FIG>, printing system <NUM> may further comprise a printing device <NUM>, a computing system <NUM>, and a network <NUM>.

Structures may be formed and attached to an article using an additive manufacturing process, also referred to as three-dimensional printing (or simply "printing" hereafter). The term "additive manufacturing," also referred to as "three-dimensional printing," refers to any device and technology for making a three-dimensional object through an additive process where layers of material are successively laid down under the control of a computer. Exemplary additive manufacturing techniques that could be used include, but are not limited to, extrusion methods such as fused deposition modeling (FDM), electron beam freeform fabrication (EBF), direct metal laser sintering (DMLS), electron beam melting (EBM), selective laser melting (SLM), selective heat sintering (SHS), selective laser sintering (SLS), plaster-based 3D printing, laminated object manufacturing (LOM), stereolithography (SLA), and digital light processing (DLP). In one embodiment, an additive manufacturing device could be a fused deposition modeling type printer configured to print thermoplastic materials such as acrylonitrile butadiene styrene (ABS) or polyactic acid (PLA).

Additive manufacturing processes may be used to form structures on flat receiving surfaces as well as on contoured or non-flat surfaces. For example, some embodiments depicted in the figures may illustrate methods whereby material is printed onto a flattened surface of an article, such as a material section of an upper that has a flat or unassembled configuration. In such cases, printing material onto the surface may be accomplished by depositing material in thin layers that are also flat. Thus, a print head or nozzle may move in one or more horizontal directions to apply an Nth layer of material and then move in the vertical direction to begin forming the N+<NUM> layer. However, it should be understood that in other embodiments material could be printed onto a contoured or non-flat surface. For example, material could be printed onto a three-dimensional last, where the surface of the last is not flat. In such cases, the printed layers applied to the surface may also be contoured. In order to accomplish this method of printing, a print head or nozzle may be configured to move along a contoured surface and tilt, rotate or otherwise move so that the print head or nozzle is always aligned approximately normal to the surface where printed material is being applied. In some cases, a print head could be mounted to a robotic arm, such as an articulated robotic arm with six degrees of freedom. Alternatively, in still other embodiments, an object with a contoured surface could be reoriented under a nozzle so that contoured layers of printed material could be applied to the object. For example, embodiments could make use of any of the systems, features, components and/or methods disclosed in <CIT> (and filed as <CIT>), titled "Robotic fabricator. " Embodiments could also make use of any of the systems, features, components and/or methods disclosed in Cannell et al. , <CIT>, titled "Computerized apparatus and method for applying graphics to surfaces. " Thus, it may be appreciated that the present embodiments are not limited to printing processes used for printing to flat surfaces and may be used in conjunction with printing systems that can print to any kinds of surfaces having any kinds of geometry.

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

The term "lateral direction," as used throughout this detailed description and in the claims, refers to a side-to-side direction extending a width of a component. For example, the lateral direction 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. The term "lateral axis," as used throughout this detailed description and in the claims, refers to an axis oriented in a lateral direction.

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

The term "vertical," as used throughout this detailed description and in the claims, refers to a direction generally perpendicular to both the lateral and longitudinal directions, along a vertical axis. For example, in cases where a component is flat on a ground surface, the vertical direction 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 would be facing away from the foot when worn by a wearer. "inner surface," or "inner side" as used throughout this detailed description and in the claims, refers to the surface of a component that is facing inward, or the surface that faces toward the foot when worn by a wearer.

For purposes of this disclosure, the foregoing directional terms, when used in reference to an article of footwear or another article of apparel, shall refer to the article of footwear 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. 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" 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 foot-print 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, platform, tray or similar component to support, retain and/or hold a printed object or an object onto which printed material is being applied. In the embodiment of <FIG>, printing device <NUM> includes a tray <NUM>. In some embodiments, tray <NUM> may be fixed in place and act as a stable base. In other embodiments, however, tray <NUM> could move. For example, in some cases, tray <NUM> may be configured to translate within housing <NUM> in a horizontal direction (e.g., front-back and/or left right with respect to housing <NUM>) as well as a vertical direction (e.g., up-down within housing <NUM>). Moreover, in some cases, tray <NUM> may be configured to rotate and/or tilt about one or more axes associated with tray <NUM>. Thus it is contemplated that in at least some embodiments, tray <NUM> may be moved into any desired relative configuration with a nozzle or print head of printing device <NUM>. In other embodiments, printing device <NUM> may not include a tray <NUM>. In some embodiments, tray <NUM> may be curved, irregularly shaped, or shaped to provide a customized platform upon which an article or object may be placed or secured. In some embodiments, printing device <NUM> may include an open space or cavity formed within tray <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 tray <NUM>, a surface or portion of a partially printed structure and/or a surface or portion of a non-printed structure or component. The target location may also be referred to as a print surface <NUM>. In different embodiments, provisions for delivering printed materials 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>.

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. Horizontal directions can include longitudinal directions, referred to herein as a third direction <NUM>, and/or lateral directions, also referred to herein as a second direction <NUM>, or any other direction lying along the horizontal plane. First actuating system <NUM> may also include provisions to move nozzle assembly <NUM> in any vertical direction, identified herein as a first direction <NUM>. The movement of nozzle assembly <NUM> in various directions can facilitate the process of 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 <NUM> with one or more portions that include curves, bumps, and varying thickness. 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, 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 first direction <NUM>, second direction <NUM> and third direction <NUM>. As seen in <FIG>, first direction <NUM> may be associated with a vertical direction of housing <NUM>, while second direction <NUM> and third direction <NUM> may be associated with horizontal directions of housing <NUM> (e.g., length and width 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 three independent directions associated with a non-Cartesian coordinate system (e.g., a spherical coordinate system, a cylindrical coordinate system, etc.). Still further, in other cases an actuating system could move a nozzle through three different directions that may not be orthogonal (e.g., directions of an oblique coordinate system).

In certain embodiments, first direction <NUM> is approximately normal to a surface, such as a print surface <NUM>. As used herein, a direction is approximately normal to a surface when it is within <NUM> degrees from perpendicular to the surface. For example, as shown, first direction <NUM> is approximately normal to print surface <NUM>.

For purposes of this discussion, a print surface may correspond to the surface where a nozzle is printing. For example, in cases where nozzle <NUM> prints directly onto tray <NUM>, the print surface is associated with a surface of tray <NUM>. In the embodiment of <FIG>, print surface <NUM> is illustrated as the side of tray <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 to first direction <NUM>. Thus, print surface <NUM> may refer to the surface of an article that is attached to a printing material such as a thread or other material extruded or otherwise discharged or emitted from nozzle <NUM>.

In certain embodiments, printing system <NUM> can selectively move nozzle <NUM>. In one embodiment, printing system <NUM> simultaneously moves nozzle <NUM> in three directions. For example, printing system <NUM> may move nozzle <NUM> in first direction <NUM> away from tray <NUM> while simultaneously moving nozzle <NUM> in second direction <NUM> and/or in third 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 first direction <NUM> to or away from print surface <NUM> while simultaneously maintaining a base position of nozzle <NUM> in second direction <NUM> and in third direction <NUM> over print surface <NUM>. In another example, printing system <NUM> may maintain a print distance <NUM> (see <FIG>) from nozzle <NUM> in first direction <NUM> while simultaneously moving nozzle <NUM> parallel to print surface <NUM>.

For purposes of this description, print distance <NUM> (as shown in <FIG>) refers to the distance or height in the vertical direction 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 tray <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 tray <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.

In order to improve the efficiency of printing system <NUM>, in different embodiments, one or more elements <NUM> can be associated with a second actuating system <NUM> that may be included in printing system <NUM>. Although the exemplary embodiment generally depicts a 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 be varied according to factors including the article being printed on, the size, shape and dimension of parts that may be formed within printing device <NUM>, as well as possibly other factors.

Second actuating system <NUM> may include various components, devices and systems that facilitate the motion of elements <NUM> within housing <NUM>. In particular, second actuating system <NUM> may include provisions to move elements <NUM> in any horizontal direction and/or vertical direction to facilitate the position of elements <NUM> during printing. To this end, embodiments of second actuating system <NUM> may include one or more tracks, rails, and/or similar provisions to hold elements <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 elements <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 or other adjustable gripping member, in second actuating system <NUM>. Securing device <NUM> can provide a means of attachment between second actuating system <NUM> and elements <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 one embodiment, second actuating system <NUM> may include provisions for removing elements <NUM> from printed structures.

Thus, second actuating system <NUM> can be configured to move an element in one or more directions. In some embodiments, an actuating system could move an element in a single linear direction. In other embodiments, an actuating system could move an element in at least two perpendicular directions. In still other embodiments, an actuating system could move an element in three perpendicular directions. For example, in the exemplary embodiment shown in <FIG>, second actuating system <NUM> may be configured to move elements <NUM> in a first direction <NUM>, a second direction <NUM> and a third direction <NUM>. As seen in <FIG>, first direction <NUM> may be associated with a vertical direction of housing <NUM>, while second direction <NUM> and third direction <NUM> may be associated with horizontal directions of housing <NUM> (e.g., length and width directions). Of course while the exemplary embodiment depicts an actuating system capable of moving an element through three independent x-y-z or Cartesian directions, other embodiments may be configured to move an element in three independent directions associated with a non-Cartesian coordinate system (e.g., a spherical coordinate system, a cylindrical coordinate system, etc.). Still further, in other cases an actuating system could move an element through three 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 element using second actuating system <NUM> or another mechanism. In one embodiment, printing system <NUM> simultaneously moves elements <NUM> in three directions. For example, printing system <NUM> may move elements <NUM> in first direction <NUM> away from tray <NUM> while simultaneously moving elements <NUM> in second direction <NUM> and/or in third direction <NUM> in a direction generally parallel to tray <NUM>. In other embodiments, a position along a direction is maintained while printing system <NUM> selectively moves elements <NUM> in another direction. In certain embodiments, printing system <NUM> may move elements <NUM> in first direction <NUM> to or away from tray <NUM> while simultaneously maintaining a base position of elements <NUM> in second direction <NUM> and in third direction <NUM> along print surface <NUM>. In some embodiments, printing system <NUM> may maintain a print distance <NUM> from elements <NUM> in first direction <NUM> while simultaneously moving elements <NUM> parallel to print surface <NUM>. For example, printing system <NUM> may maintain a print distance <NUM> from elements <NUM> in first direction <NUM> while simultaneously moving elements <NUM> in second direction <NUM> and/or third direction <NUM>.

In some embodiments, first actuating system <NUM> and/or second actuating system <NUM> can be operated manually by a user. In other embodiments, there may be provisions for automating the operation of first actuating system <NUM> and second actuating system <NUM>. For example, some embodiments could include motors and/or other provisions for automatically driving nozzle <NUM> to various positions along one or more tracks. Moreover, in automated embodiments, the position or speed of nozzle <NUM> and/or elements <NUM> could be adjusted using controls provided in printing system <NUM>, or using an associated system, such as 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: wireless personal area networks (including, for example, Bluetooth), wireless local area networks (including networks utilizing the IEEE <NUM> WLAN standards), wireless mesh networks, mobile device networks as well as other kinds of wireless networks. In other cases, network <NUM> could be a wired network including networks whose signals are facilitated by twister pair wires, coaxial cables, and optical fibers. In still other cases, a combination of wired and wireless networks and/or connections could be used.

Printing system <NUM> may be operated as follows to provide one or more structures that have been formed 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 tray <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 fused filament 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. Moreover, still other embodiments could incorporate a combination of fused filament 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), 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 composition.

Furthermore, additive printing systems used with the embodiments can make use of any printable materials. The term "printable material" or "print material" is intended to encompass any materials that may be printed, ejected, emitted, or otherwise deposited during an additive manufacturing process. Such materials can include, but are not limited to, thermoplastics (e.g., PLA and ABS) and thermoplastic powders, high-density polyurethylene, eutectic metals, rubber, modeling clay, plasticine, RTV silicone, porcelain, metal clay, ceramic materials, plaster, and photopolymers, as well as possibly other materials known for use in 3D printing.

As discussed above, in some embodiments, printed structures may be printed directly onto one or more articles <NUM>, or a portion of articles <NUM>. The term "articles" is intended to include articles of apparel (e.g., shirts, pants, footwear, etc.), as well as other objects, textiles, or materials. As used throughout this disclosure, the terms "article of footwear" and "footwear" include any footwear and any materials associated with footwear, including an upper, lacing elements, and sole structures, and may also be applied to a variety of athletic foqtwear 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 the embodiment of <FIG>, articles <NUM> comprise exemplary articles that may receive a printed structure directly from printing device <NUM>, including an upper <NUM> or a shirt <NUM>.

Furthermore, while the disclosed embodiments are described in the context of footwear, the disclosed embodiments may further be equally applied to any article of apparel or equipment that may receive 3D printing. Thus, as used throughout this disclosure, the term "article of apparel" may refer to any apparel or clothing, including any article of footwear, as well as hats, caps, shirts, jerseys, jackets, socks, shorts, pants, undergarments, athletic support garments, gloves, wrist/arm bands, sleeves, headbands, any knit material, any woven material, any nonwoven material, etc. Other examples of articles include, but are not limited to: shin guards, knee pads, elbow pads, shoulder pads, as well as any other type of protective equipment. Additionally, in some embodiments, the article could be another type of article that is not configured to be worn, including, but not limited to: balls, bags, purses, backpacks, as well as other articles that may not be worn.

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 of them, 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/bonded to the fabric and where the material does not generally delaminate when flexed, rolled, worked, or subject to additional assembly processes/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, and foam.

Although some embodiments may use printing device <NUM> to print structures directly onto the surface of a material, other embodiments may include steps of printing a structure onto a tray or release paper, and then joining the printed structure to an article in a separate step. In other words, in at least some embodiments, printed structures need not be printed directly to the surface of articles <NUM>.

Furthermore, in some embodiments, printing device <NUM> may be configured to print one or more structures that incorporate or utilize one or more elements <NUM> (for example, elements may be placed within or along the printed structure). Elements <NUM> comprise exemplary elements that may be inserted, disposed, laid adjacent to, placed in contact with, or otherwise incorporated into at least a portion of a printed structure. In some embodiments, elements <NUM> may include a lacing element <NUM> or a shaft <NUM>. Elements <NUM> may also include other objects or substrates which can vary in size, dimension, geometry, material composition, rigidity, texture and other properties. An element for purposes of this disclosure may include but are not limited to cords, cables, laces, shafts, cylinders, tubes, strands, wire, or any other object or material that can be disposed adjacent to printed materials or a printed structure. Elements <NUM> will be discussed in detail further below.

As previously noted, printing device <NUM> may be configured to print directly onto various articles <NUM>. For example, as shown in <FIG>, a first article <NUM> is depicted. First article <NUM> comprises an unassembled upper for an article of footwear. 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 lateral side <NUM> and a medial side <NUM>. In other embodiments, first article <NUM> can include any type of surface, object, or material. In some embodiments, first article <NUM> may be an upper or a shirt, for example. In the exemplary embodiment of <FIG>, first article <NUM> is a portion of an upper. For purposes of this description, the surface of the article or material upon which printing occurs will be referred to as print surface <NUM>.

As previously mentioned, nozzle <NUM> is configured to emit, discharge, or extrude various materials. In different embodiments, the printed material may be discharged, ejected or otherwise emitted via nozzle <NUM> in the form of droplets <NUM>. One of ordinary skill in the art will recognize that the form of droplets <NUM> may vary depending on the actual material ejected or otherwise emitted from nozzle <NUM>. In some embodiments, droplets <NUM> may thus be any viscosity liquid material, or even a semi-solid material. Consistent with an embodiment, droplets <NUM> may be any desired material or phase of material suitable for use in printing system <NUM>. In some embodiments, the nozzle system employed may be equivalent or identical to that used in inkjet printing systems, such as piezo inkjet systems. Thus, in some other embodiments, a nozzle may be associated with a piezoelectric inkjet head.

It should be noted that in other embodiments, nozzle <NUM> may extrude other materials. For example, nozzle <NUM> may extrude a continuous thread or discrete thread segments. Such a thread may include a composition as described in Thread Structure Composition and Method of Making.

As will be described further below, in different embodiments, various structures may be printed along first article <NUM>. For example, in <FIG>, a first structure <NUM> is being completed along lateral side <NUM> of midfoot region <NUM> of first article <NUM>. A second structure <NUM> is adjacent to first structure <NUM>. In some embodiments, printed structures <NUM> may integrate or otherwise be associated with an element <NUM>. This can be seen in <FIG>, where element <NUM> comprising a length of lace is disposed along midfoot region <NUM> of first article <NUM>. In some embodiments, element <NUM> may be inserted or be joined to printed structures <NUM>. In one embodiment, element <NUM> may be placed onto print surface <NUM> using second actuating system <NUM> (described with reference to <FIG>).

In <FIG>, element <NUM> is shown as looped through printed structures <NUM>, whereby each printed structure <NUM> has an opening or tunnel through which element <NUM> is incorporated or placed. It should be noted that the openings or tunnels need not be round.

First structure <NUM> in <FIG> is shown with a portion of element <NUM> disposed upon part of its surface. In some embodiments, as printing continues, one or more portions of element <NUM> may be enclosed or partially enclosed within first structure <NUM>. Some embodiments of this process will be described in further detail below. For purposes of this description, an element is enclosed or partially enclosed when it is in contact with the printed structure along an upper side or surface. In other words, an element is partially enclosed when the element has had printed material deposited to at least partially cover the element, and/or is at least partially contacting the printed structure. An element is fully enclosed when the element is encapsulated or made "captive" within the structure, and the entire surface area of the element is located within the printed structure. In other words, an element that is fully enclosed has no portion or surface area exposed.

In the figures that follow, 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.

<FIG> provide a partial view of printing device <NUM>, illustrating a method of printing a three-dimensional structure including various openings or other designs within the interior of the printed structure through the utilization of an element. The methods illustrated herein may be implemented on various devices, may utilize various materials, use different types of bases, etc. Accordingly, the methods illustrated in <FIG> are for illustrative purposes only. In some embodiments, the printing can occur over print surfaces <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.

In the exemplary embodiment shown in <FIG>, structures are shown being printed directly onto a tray of a printing system for purposes of clarity. It may be appreciated, however, that in some cases structures can be printed directly onto the base layer of an article (e.g., an upper or other apparel).

For example, in <FIG>, a portion of a printing device <NUM> is depicted. Droplets <NUM> are being deposited by nozzle <NUM> onto print surface <NUM> of tray <NUM>. In <FIG>, printed material <NUM> comprising multiple droplets <NUM> is beginning to coalesce. In <FIG>, a first layer <NUM> has been formed by droplets <NUM>. Nozzle <NUM> has moved in a horizontal plane (e.g., in second direction <NUM> and/or third direction <NUM>) as well as in the vertical direction (e.g., first direction <NUM>) to add further droplets to first layer <NUM>. Thus, a second layer <NUM> is beginning to be formed. Similarly, in <FIG>, second layer <NUM> has been completed, forming a first composite layer <NUM> comprising first layer <NUM> and second layer <NUM>, while a third layer <NUM> is being formed. In some embodiments, the process depicted in <FIG> may be repeated multiple times to build a structure of desired thickness, shape, and/or area.

As described with reference to <FIG>, in some embodiments, printing system <NUM> can maintain a print distance between nozzle <NUM> and print surface <NUM> to attach droplets <NUM> to print surface <NUM>. The print distance and other aspects of printing relevant to the disclosed process may vary or be otherwise adjusted. In some embodiments, structures can be formed using any of the methods described in Jones et al. , <CIT> and titled "Footwear Assembly Method With 3D Printing.

In <FIG>, a first partial structure <NUM> comprising multiple layers of printed material is depicted. First partial structure <NUM> includes a first recess <NUM>. In some embodiments, first recess <NUM> is formed by adding multiple layers in a step pattern that comprise the portion of first partial structure <NUM> which include first recess <NUM>. For example, as seen in magnified area <NUM>, the edges of first recess <NUM> are a plurality of steps <NUM> along the surface of first partial structure <NUM>, including a first step <NUM> and a second step <NUM>. In other words, in some embodiments, various portions of a printed structure may include differences in thickness, area, material, shape, design in order to form recesses, openings, or other features. It should be noted that in other embodiments, first recess <NUM> may be formed at an earlier point in printing, or at a later point.

In different embodiments, first recess <NUM> may vary in size or dimension. For example, first recess <NUM> may be larger or smaller than shown in <FIG>. In other embodiments, first recess <NUM> may include portions that are more narrow or wider than depicted in <FIG>. In some embodiments, there may be multiple recesses, or the structure may include no recess.

In different embodiments, a printed structure may incorporate various elements. For example, in <FIG>, first partial structure <NUM> is shown adjacent a second lace <NUM>. Second lace <NUM> may be inserted, placed, disposed, laid down along or otherwise provided to first partial structure <NUM> at different points of the printing process. In some embodiments, second lace <NUM> may be presented before first recess <NUM> is formed. In other embodiments, second lace <NUM> may be provided during or after the formation of first recess <NUM>.

In some embodiments, printing may be paused or interrupted to allow the incorporation of elements such as second lace <NUM>. However, in other embodiments, printing may be ongoing while second lace <NUM> is added to first partial structure <NUM>. In one embodiment, second actuating system <NUM> may be used to place second lace <NUM> within recess <NUM> of first partial structure <NUM>.

In some embodiments, the size, shape and dimension of first recess <NUM> may be formed to generally correspond at least in part to the size, shape, and dimensions of an element. For example, in <FIG>, first recess <NUM> provides a recess that generally matches the contours of at least a portion of second lace <NUM>. In other words, as second lace <NUM> is moved vertically down into recess <NUM> (i.e., in the direction of indicated by arrow <NUM>), and is laid along a recess surface <NUM>, at least a portion of second lace <NUM> fits snugly and securely within the curvature provided by first recess <NUM>. In other embodiments, first recess <NUM> may be substantially larger than second lace <NUM> or otherwise provide a less secure fit to second lace <NUM>. For example, in one embodiment, there may be no recess, or the curvature of the recess may be nearly flat such that second lace <NUM> rests on a surface that does not securely hold second lace <NUM>.

In <FIG>, second lace <NUM> has been placed along recess surface <NUM> of first partial structure <NUM>. As printing continues in <FIG>, additional layers are laid over first partial structure <NUM>, as well as second lace <NUM>, forming a second partial structure <NUM>. Second partial structure <NUM> includes a first tunnel <NUM>, formed in part with previously formed first recess <NUM>. Thus, a portion of second lace <NUM> is now covered by or enclosed within first tunnel <NUM> of second partial structure <NUM>. In <FIG>, printing is completed, and a third structure <NUM> has been formed. Second lace <NUM> is positioned such that a portion of second lace <NUM> is disposed entirely within an interior portion of third structure <NUM>. In some embodiments, second lace <NUM> may be attached within first tunnel <NUM>, whereby second lace <NUM> is substantially anchored and immobilized within third structure <NUM>. In other embodiments, second lace <NUM> may retain some mobility, and be able to move in a generally horizontal direction <NUM> through first tunnel <NUM>, at least to some extent.

It should be noted that in different embodiments, multiple printed structures may be formed that include or incorporate a single lace. For example, in one embodiment, third structure <NUM> may be formed with second lace <NUM>, and a fourth structure may also be formed that includes second lace <NUM>. Additional structures may also be printed that include second lace <NUM>. In other embodiments, multiple lace elements (or other types of elements) may be used to form neighboring printed structures.

In addition, while the embodiments herein depict first tunnel <NUM> as formed entirely of printed material, it should be noted that in other embodiments one or more portions of a tunnel may be comprised of the substrate upon which the structure is printed. In other words, in some embodiments, the bottom portion of a tunnel may be formed (or provided) by the underlying object, including a base material such as an upper or other material, to which the tunnel is attached.

In different embodiments, elements <NUM> may be utilized to form other types of tunnels within a printed structure. In some embodiments, tunnels may refer to any opening in the interior of the printed structures. As will be discussed further below, tunnels may include various sizes, shapes, dimensions, and/or thicknesses. Tunnels may also be asymmetrical or symmetrical, and include a through-hole or blind-hole. It should be noted that tunnels may comprise various shapes, and need not be round or cylindrical in shape, as will be discussed below with reference to <FIG>.

For example, in <FIG>, a portion of a printing device <NUM> is depicted. Droplets <NUM> are being deposited by nozzle <NUM> onto print surface <NUM> of tray <NUM>. In <FIG>, printed material <NUM> comprising multiple droplets <NUM> is beginning to coalesce. In some embodiments, as shown in <FIG>, after repeating the process described above with respect to <FIG>, a third partial structure <NUM> comprising multiple layers of printed material is formed. Third partial structure <NUM> includes a second recess <NUM>. In some embodiments, second recess <NUM> is formed by adding multiple layers in a step pattern that comprise the portion of third partial structure <NUM> that is associated with second recess <NUM>, as described above with reference to <FIG>.

In different embodiments, a printed structure may incorporate various elements <NUM>. For example, in <FIG>, third partial structure <NUM> is shown below a first shaft <NUM>. First shaft <NUM> may be inserted, placed, disposed, laid down along or otherwise provided to third partial structure <NUM> at different points of the printing process. In some embodiments, first shaft <NUM> may be presented before second recess <NUM> is formed. In other embodiments, first shaft <NUM> may be provided during or after the formation of second recess <NUM>.

In different embodiments, a shaft may comprise a variety of materials, including but not limited to: a low-friction polymer material, metals, alloys, plastic, porcelain, as well as possibly other kinds of materials known in the art.

In some embodiments, printing may be paused or interrupted to allow the incorporation of elements such as first shaft <NUM>. However, in other embodiments, printing may be ongoing while first shaft <NUM> is added to third partial structure <NUM>. In one embodiment, second actuating system <NUM> may be used to provide first shaft <NUM> to third partial structure <NUM>.

In some embodiments, the size and shape of second recess <NUM> may be selected to generally correspond at least in part to the size, shape, and dimensions of an element. For example, in <FIG>, second recess <NUM> provides a recess surface <NUM> that generally matches the contours of at least a portion of first shaft <NUM>. In other words, as first shaft <NUM> is moved in the direction of an arrow <NUM>, and is laid along recess surface <NUM>, at least a portion of first shaft <NUM> can fit snugly and securely within the curvature provided by second recess <NUM>. In other embodiments, second recess <NUM> may be substantially larger than first shaft <NUM> or otherwise provide a less secure fit to first shaft <NUM>. For example, in one embodiment, there may be no recess, or the curvature of second recess <NUM> may be nearly flat such that first shaft <NUM> rests on a surface that does not securely hold first shaft <NUM>.

In <FIG>, first shaft <NUM> has been placed along recess surface <NUM> (see <FIG>) of third partial structure <NUM>. First shaft <NUM> can be seen to include a first portion <NUM>, a second portion <NUM>, and a third portion <NUM>. In some embodiments, first portion <NUM> and third portion <NUM> are associated with the areas of first shaft <NUM> that remain exposed, while second portion <NUM> corresponds to the area of first shaft <NUM> that is in contact with the printed structure.

As printing continues in <FIG>, additional layers are laid over third partial structure <NUM>, as well as over first shaft <NUM>, forming a fourth partial structure <NUM>. Fourth partial structure <NUM> includes a second tunnel <NUM>, formed in part with the previously formed second recess <NUM>. Thus, second portion <NUM> of first shaft <NUM> is now covered by or enclosed within second tunnel <NUM> of fourth partial structure <NUM>. In <FIG>, printing is completed, and a fourth structure <NUM> has been formed. First shaft <NUM> is positioned such that second portion <NUM> of first shaft <NUM> is disposed entirely within an interior portion of fourth structure <NUM>, while first portion <NUM> and third portion <NUM> are positioned outside of fourth structure <NUM>.

In some embodiments, first shaft <NUM> may be removed or detached from fourth structure <NUM>. In one embodiment, second actuating system <NUM> may be used to remove first shaft <NUM> from fourth structure <NUM>. For example, in <FIG>, first shaft <NUM> is pulled from second tunnel <NUM> in direction of an arrow <NUM>. In some embodiments, first shaft <NUM> may be only partially removed from fourth structure <NUM>, or first shaft <NUM> may be repositioned within fourth structure <NUM>. In some embodiments, as first shaft <NUM> moves through second tunnel <NUM>, first portion <NUM> is enclosed within fourth structure <NUM>, while second portion <NUM> moves out of second tunnel <NUM> and becomes exposed along with third portion <NUM>. In other embodiments, first shaft <NUM> may be removed from another direction, such that third portion <NUM> becomes enclosed within fourth structure <NUM>, while second portion <NUM> moves out of second tunnel <NUM> and becomes exposed along with first portion <NUM>. In an alternative embodiment, first shaft <NUM> may remain within second tunnel <NUM>. It should be noted that upon removal of first shaft <NUM>, first shaft <NUM> may be reused.

In one embodiment, as shown in <FIG>, upon removal of first shaft <NUM> as depicted by an arrow <NUM>, a fifth structure <NUM> with a hollow or emptied second tunnel <NUM> is formed. Various aspects of fifth structure <NUM> are depicted in <FIG>. For example, in <FIG>, an isometric view of fifth structure <NUM> is presented. Second tunnel <NUM> of fifth structure <NUM> can be seen to include a first end <NUM> and a second end <NUM> (represented by dotted lines). The opening of first end <NUM> is in fluid communication with the opening of second end <NUM>. In <FIG>, a side-view of fifth structure <NUM> is shown. The side-view depicts the path of second tunnel <NUM> through fifth structure <NUM>, from first end <NUM> to second end <NUM>, represented by a dotted line. <FIG> is a front view and <FIG> is a rear view of fifth structure <NUM>. In <FIG>, the opening associated with first end <NUM> of second tunnel <NUM> can be seen, and similarly, in <FIG>, the opening associated with second end <NUM> of second tunnel <NUM> can be seen. Thus, second tunnel <NUM> provides a through-hole aperture or opening through the length of fifth structure <NUM>. In some embodiments, this aperture may have any additional object or material inserted or incorporated within the aperture (including but not limited to first shaft <NUM> or another element), or it may remain unfilled.

Thus, in different embodiments, printing system <NUM> may allow formation of printed structures that include through-holes or other types of openings. In one embodiment, upon removal of elements, the tunnels may be hollow or provide a space within the printed structure. It should be noted that in other embodiments, printing system <NUM> may also be utilized to form blind-hole openings within a printed structure. For example, as seen in <FIG>, various aspects of a sixth structure <NUM> are depicted. In <FIG>, an isometric view of sixth structure <NUM> is presented. A third tunnel <NUM> of sixth structure <NUM> can be seen to include a first end <NUM> and a second end <NUM> (represented by dotted lines). However, second end <NUM> of third tunnel <NUM> is disposed within the interior of sixth structure <NUM>. In other words, the opening of first end <NUM> does not share a fluid opening beyond second end <NUM> to a rear side <NUM> of sixth structure <NUM>. Thus, sixth structure <NUM> includes a blind-hole aperture, so that there is an opening disposed along only a front side <NUM> of sixth structure <NUM>. In <FIG>, a side-view of sixth structure <NUM> is shown. The side view depicts the path of third tunnel <NUM> through sixth structure <NUM>, from first end <NUM> to second end <NUM>, represented by a dotted line. <FIG> is a front view and <FIG> is a rear view of sixth structure <NUM>. In <FIG>, the opening associated with first end <NUM> of third tunnel <NUM> can be seen along front side <NUM>. However, in <FIG>, there is a substantially solid printed area comprising rear side <NUM>, without an opening as described in <FIG>. In other words, third tunnel <NUM> provides a blind-hole aperture or opening through a portion of the length of sixth structure <NUM>. In some embodiments, the aperture may have any object or material inserted or incorporated within, or it may remain unfilled.

In different embodiments, it may be useful to form composite printed structures that retain an incorporated element within the structure. For example, printed structures that retain an element may be more resilient, sturdy, and resist deformation. Furthermore, composite printed structures can provide additional components preassembled for use in other articles. In <FIG>, a fifth partial structure <NUM> is depicted as formed on tray <NUM> in a partial representation of printing device <NUM>. Fifth partial structure <NUM> includes a third recess <NUM>. Depicted above fifth partial structure <NUM> is a second shaft <NUM>. As described above, in some embodiments, the size, shape and dimensions of third recess <NUM> may be selected to generally correspond at least in part to the size, shape, and dimensions of an element. For example, in <FIG>, third recess <NUM> provides a recess surface <NUM> that generally matches the contours of at least a portion of second shaft <NUM>. In other words, as second shaft <NUM> is moved in the direction of an arrow <NUM>, and is laid along recess surface <NUM>, at least a portion of second shaft <NUM> can fit snugly and securely within the curvature provided by third recess <NUM>. In other embodiments, third recess <NUM> may be substantially larger than second shaft <NUM> or otherwise provide a less secure fit to second shaft <NUM>. For example, in one embodiment, there may be no recess, or curvature of third recess <NUM> may be nearly flat such that second shaft <NUM> rests on a surface that does not include contours for securely holding second shaft <NUM>.

In <FIG>, second shaft <NUM> has been placed along recess surface <NUM> (see <FIG>) of fifth partial structure <NUM>. As printing continues in <FIG>, additional layers have been printed over fifth partial structure <NUM>, as well as over second shaft <NUM>, forming a seventh structure <NUM>. Seventh structure <NUM> includes a fourth tunnel <NUM>, formed in part with the previously formed third recess <NUM>. In the embodiment of <FIG>, substantially the entire length and width of second shaft <NUM> is now covered by or enclosed within fourth tunnel <NUM> of seventh structure <NUM>. Thus, in some embodiments, as shown in <FIG>, a composite printed structure <NUM> can be formed, where an element (such as second shaft <NUM>) is joined, attached, enclosed, or otherwise disposed within the printed structure. Together, a printed structure may be formed in some embodiments that is more resilient, rigid, and/or or includes the properties of both the printed material and the included element.

In the embodiment of <FIG>, composite printed structure <NUM> includes fourth tunnel <NUM> with a first end <NUM> and a second end <NUM>. Second end <NUM> is disposed within the interior of composite printed structure <NUM>. In other words, fourth tunnel <NUM> forms a blind-hole aperture in composite printed structure <NUM>. However, it should be noted that in other embodiments, not according to the claims, an element such as second shaft <NUM> may be placed or incorporated into composite printed structure <NUM> such that both first end <NUM> and second end <NUM> are disposed in the interior of fourth tunnel <NUM>, and no opening is present on either a front side <NUM> or a rear side <NUM>. Thus, as described above, a fully enclosed element located entirely within composite printed structure <NUM> is possible in some embodiments, not according to the claims.

It should be noted that in other embodiments, a composite printed structure may also include portions that permit some portions of the element to be exposed while the element is retained by the structure. For example, a composite printed structure may have various openings along the surface of the composite printed structure that expose or make visible the incorporated element. In one embodiment, a composite printed structure may have windows or gaps that expose one or more portions of the incorporated element.

It should be understood that the embodiments described above with respect to the composite printed structures may also include or incorporate elements that are not fixed in place. In other words, printing system <NUM> may form composite printed structures with operative elements. Operative elements can include portions that are moveable relative to another portion of the operative element. As shown through <FIG>, an element may be disposed within a printed structure (e.g., second lace <NUM> in first tunnel <NUM> of third structure <NUM>, or first shaft <NUM> in second tunnel <NUM> of fourth structure <NUM>). While in some embodiments, an element may be removed (as shown in <FIG>), in other embodiments, the same element may be retained by the printed structure. In addition, in one embodiment, the element that is retained may be configured to move or slide through a tunnel formed in the printed structure.

In some embodiments, for example, composite printed structures may be designed to provide guide tubes or routing components for a lacing system in an article of footwear. Thus, in some cases, a user may be able easily to tighten or loosen the laces (i.e., the elements) disposed within the printed guide tubes.

A variety of elements may be disposed within a printed structure while retaining the ability to slide or translate through the printed structure. In some embodiments, each of the elements described or mentioned herein may be configured such that they are disposed in a printed structure, but are not attached to any portion of the printed structure. In other words, an element may be disposed within a printed structure and also be able to readily move through and/or along the printed structure.

Thus, in some embodiments, second lace <NUM> in third structure <NUM> may be moved in a generally horizontal direction <NUM>. In one embodiment second lace <NUM> may be able to slide or be moved translationally (back and forth) through first tunnel <NUM>. This may provide the printed structure with the ability to act as a support, guide, router, covering, protection, sleeve, tube, anchor, or other such component for a portion of the element, while the element itself remains capable of movement through the printed structure. A further example may be seen in <FIG>, where first shaft <NUM> is shown as it slides or moves through second tunnel <NUM> of fourth structure <NUM>. In <FIG>, first shaft <NUM> is removed from fourth structure <NUM>. However, in other cases, it should be understood that first shaft <NUM> may remain within fourth structure <NUM>. In one case, first shaft <NUM> can be configured to slide through second tunnel <NUM> if so desired. It should also be understood that in some cases, an element may be removed from a printed structure, and a different element may be inserted within the same printed structure. Thus, although first shaft <NUM> is removed from fourth structure <NUM> in <FIG>, a lace or another shaft, or a different element altogether, may be placed, incorporated into or used with second tunnel <NUM>.

Printing system <NUM> may provide for the translation of elements in the printed structures in a variety of ways. In some embodiments, the materials comprising the printed structures may be different from the material comprising the elements. In some cases, the materials of either or both of the printed material and elements may be resistant to adhesion. In different cases, the use of dissimilar or incompatible materials that do not readily bind or adhere to one another, or, in one case, materials that repel binding, may be used in each of the printed structure and/or the element. Thus, in some embodiments, the element may comprise a material that resists adhesion to the printed material. In one embodiment, the element could comprise one or more materials that include lower friction coefficients, such as materials with friction coefficients in the range of <NUM> and <NUM>. In other embodiments, the printed material may comprise a material that resists adhesion to the element. In one embodiment, the printed material could comprise a material with a lower friction coefficients, such as material with a friction coefficient in the range of <NUM> and <NUM>.

Furthermore, in other cases, various portions of the elements or the interior of the tunnels (the printed material) may be coated with or otherwise include a non-stick material or a low friction material. Some examples of low friction materials include but are not limited to polymer coatings, fluorocarbons, polytetrafluoroethylene (PTFE) (e.g., Teflon), fluorinated ethylene propylene (FEP), perfluoroalkoxy (PFA), Delrin, paints and elastomeric coatings, anodized aluminium, phenolics, acetals, polyimides, polysulfone, polyphenylene sulfide, plastics, metallic materials, ceramics, silicone, enameled cast iron, seasoned cast iron, nylon, and/or other materials. In some instances, the coatings or material included in the elements or printed material can comprise thermoplastics or thermoplastic polymers. In other cases, the materials used may comprise thermosets.

As discussed above, elements may vary in shape, size, and other features in different embodiments. <FIG> present a few examples of elements that may be placed on, utilized, incorporated or otherwise joined to a printed structure. In <FIG>, a cylindrical shaped third shaft <NUM> is illustrated. Third shaft <NUM> has a first end <NUM> that is generally circular, and a second end <NUM> that is also circular. In the embodiment of <FIG>, third shaft <NUM> is generally uniform along its length, and first end <NUM> and second end <NUM> are substantially similar. In <FIG>, a rectangular cylinder type fourth shaft <NUM> is depicted. Fourth shaft <NUM> includes sharper edges at a first end <NUM> and second end <NUM> relative to third shaft <NUM>. Similar to third shaft <NUM>, fourth shaft <NUM> is generally uniform along its length, and first end <NUM> and second end <NUM> are substantially similar.

As seen in the Figures, different elements may be used to form varying shapes in the printed structures. Thus, in some embodiments, elements may be used which include additional edges, shapes, portions, or other features. For example, in <FIG>, two elements are depicted which may be contrasted with those previously presented in <FIG> illustrates a fifth shaft <NUM> and <FIG> a sixth shaft <NUM> that are substantially rectangular. However, fifth shaft <NUM> includes a first vane <NUM> and a second vane <NUM> disposed along a first end <NUM>. Similarly, sixth shaft <NUM> includes a first vane <NUM> and a second vane <NUM> disposed along first end <NUM>. For purposes of this description, a vane is a bump, irregularity, or additional component or piece that is part of an element or disposed along the length of the element. Furthermore, in the embodiments of <FIG>, the vanes are tapered, whereby the width of each vane decreases as it approaches first end <NUM> of fifth shaft <NUM> and first end <NUM> of sixth shaft <NUM> respectively. The tapering can provide a shaft with a smoother removal from a printed structure.

Vanes and other additional features of elements may provide printed structures with different designs, and allow insertion of variously shaped components. In some embodiments, vanes can enhance the aesthetic of a printed structure. In another embodiment, vanes may help form sections in the tunnels that are necessary for the utilization of the printed structure.

A second end <NUM> of fifth shaft <NUM> does not include a vane, nor does a second end <NUM> of sixth shaft include a vane. In other embodiments, fifth shaft <NUM> and/or sixth shaft <NUM> may include different types or numbers of vanes, as well as vanes of different sizes and shapes. For example, fifth shaft <NUM> in <FIG> has a first vane <NUM> with a sharp edge, whereas sixth shaft in <FIG> has a first vane <NUM> with a rounded edge relative to fifth shaft <NUM>. Thus, different types of shafts may be designed to provide a variety of different openings and tunnels or composites to a printed structure. It should be noted that in some embodiments, third shaft <NUM>, fourth shaft <NUM>, fifth shaft <NUM> and/or sixth shaft <NUM> may be reusable. Thus, the shape of an element, including any vanes, should allow it to be removed readily from the printed structure in which it was incorporated.

The printed structures of the present embodiments may provide enhanced support. In some cases, one or more printed structures may be attached to an underlying component such as a fabric layer of an upper or other article, and may act to enhance support over a portion of the component. This may occur in situations where the printed structure is more rigid than an underlying material (e.g., fabric, leather, etc.).

In some embodiments, as mentioned with respect to <FIG>, printed structures may be included on an upper. <FIG> depict an embodiment of an upper <NUM> that includes an example of the printed structures described herein. Printed structures may be formed to provide eyelets or other lacing components in some embodiments. In <FIG>, upper <NUM> includes a plurality of partial structures <NUM> that have been formed on print surface <NUM>, which is a surface of upper <NUM>. Partial structures <NUM> include a first partial structure <NUM> and a second partial structure <NUM> disposed along lateral side <NUM>. Other partial structures <NUM> are disposed along medial side <NUM>. In <FIG>, a plurality of lace elements <NUM> have been introduced to upper <NUM>. Lace elements <NUM> include a third lace <NUM>, a fourth lace <NUM>, a fifth lace <NUM>, and a sixth lace <NUM>. In <FIG>, third lace <NUM> and fourth lace <NUM> are disposed along medial side <NUM>, and fifth lace <NUM> and sixth lace <NUM> are disposed along lateral side <NUM>. Lace elements <NUM> have been disposed along upper <NUM> such that each partial structure printed on upper <NUM> is in contact with a lace element. For example, first partial structure <NUM> is in contact with sixth lace <NUM>, and second partial structure <NUM> is in contact with fifth lace <NUM>. In some embodiments, a lace end <NUM> or another lace component may also be included with lace elements <NUM>. In other embodiments, there may be no additional components attached to lace elements <NUM>.

In <FIG>, additional printed material has been added to each of partial structures <NUM> of <FIG> and <FIG>. Upper <NUM> includes a plurality of structures <NUM>. Plurality of structures <NUM> have incorporated plurality of lace elements <NUM> within each structure. For example a seventh structure <NUM> has incorporated a portion of sixth lace <NUM> and an eighth structure <NUM> has incorporated a portion of fifth lace <NUM>. In some embodiments, structures <NUM> may comprise a series of eyelets for lace elements <NUM>. In other embodiments, structures <NUM> may comprise any other component or part of upper <NUM>.

<FIG> provides an illustration of an embodiment of flattened upper <NUM> of <FIG> that has been assembled as a three-dimensional upper <NUM>. Upper <NUM>, along with a sole structure <NUM> and laces <NUM>, comprise a third article <NUM>. Third article <NUM> is an article of footwear <NUM> that includes printed structures <NUM> with lace elements <NUM>. In different embodiments, a variety of designs, patterns, components, elements, structures, and other features may be included in an article using the techniques described herein.

Claim 1:
An article of apparel (<NUM>), comprising:
a first structure (<NUM>) formed of a printed material (<NUM>) extruded, discharged, ejected, or otherwise emitted via a nozzle (<NUM>), the first structure (<NUM>) comprising a first layer (<NUM>) and a second layer (<NUM>);
an element (<NUM>, <NUM>), wherein the element (<NUM>, <NUM>) is in contact with the first structure (<NUM>); and
a portion of the element (<NUM>, <NUM>) being partially enclosed within the first structure (<NUM>),
wherein the element (<NUM>, <NUM>) is movable within the first structure (<NUM>), and
wherein the element is a lacing element (<NUM>), a cord, wire, cylinder, tube, reusable shaft (<NUM>), or a reusable shaft (<NUM>, <NUM>) that includes at least one vane (<NUM>, <NUM>, <NUM>, <NUM>).