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.

Structures formed from three-dimensional printing systems can be used with objects formed by other manufacturing techniques. These include textile materials used in various articles of footwear and/or articles of apparel. <CIT> describes a platen planarizing process for an additive manufacturing system. <CIT> describes a decorative material repairing method. <CIT> describes a coating method with a planarizing step. <CIT> describes an article of footwear or an article of apparel with a layer of protruding elements applied by printing.

According to the claimed invention, there is provided a method of printing as defined in appended independent claim <NUM>. A specific embodiments is defined in the appended dependent claim <NUM>.

<FIG> illustrates a schematic view of an exemplary embodiment of components of printing system <NUM>. In some embodiments, printing system <NUM> may include several components for facilitating the printing of objects (e.g., parts, elements, features, or structures, etc.) on substrate <NUM>. In some embodiments, printing system <NUM> includes printing device <NUM>, and computing system <NUM> with network <NUM>. These components will be explained further in detail below. For purposes of illustration, only some components of printing system <NUM> are depicted in <FIG> and described below. It will be understood that in other embodiments, printing system <NUM> may include additional provisions.

Printing system <NUM> may generally utilize various types of printing techniques. These can generally include, toner-based printing, liquid inkjet printing, solid ink printing, dye-sublimation printing, inkless printing (including thermal printing and UV printing), MicroElectroMechanical Systems (MEMS) jet printing technologies as well as any other methods of printing. In some cases, printing system <NUM> may make use of a combination of two or more different printing techniques. The type of printing technique used may vary according to factors including, but not limited to, material of the target article, size, and/or geometry of the target article, desired properties of the printed image (such as durability, color, ink density, etc.) as well as printing speed, printing costs, and maintenance requirements.

In some embodiments, printing system <NUM> includes printing device <NUM>. In some embodiments, printing device <NUM> may include features such as housing component <NUM>, tray <NUM>, printhead <NUM>, and sensing device <NUM>. Housing component <NUM> may be used to support other components, devices, or systems of printing system <NUM>. In some embodiments, housing component <NUM> may include features to move substrate <NUM> during operation. In some embodiments, the shape and size of housing component <NUM> may vary according to factors that include the desired footprint for printing device <NUM>, the size and shape of substrate <NUM> or multiple substrates, the size and shape of features that may be formed on substrate <NUM> as well as possibly other factors.

In some embodiments, printing device <NUM> may include provisions such as a table, platform, tray, or similar component to support, retain, and/or hold substrate <NUM>. In some embodiments, tray <NUM> may be used to position substrate <NUM> while layer materials are being deposited onto substrate <NUM> by a printhead <NUM>. In some embodiments, tray <NUM> may retain a single substrate <NUM>. In some other embodiments, tray <NUM> may be so dimensioned and sized such that it can retain additional substrates <NUM>, as shown.

Some embodiments may include provisions to facilitate forming a selectively printed design feature on substrate <NUM>. In some embodiments, printing device <NUM> may include provisions for depositing a layer material onto substrate <NUM>, such as printhead <NUM>. In some embodiments, printing device <NUM> may include provisions for applying radiant energy, such as an ultraviolet (UV) lamp (not shown). In one embodiment, printing device <NUM> includes printhead <NUM> and a UV lamp to transform a physical property of a layer material and form a selectively printed design feature on substrate <NUM>.

In some embodiments, printhead <NUM> could be used to deposit an ink layer in order to form a selectively printed design feature onto substrate <NUM>. In some embodiments, printhead <NUM> could be configured to move and deposit an ink layer within housing component <NUM> in a horizontal direction (e.g., front-back and/or left-right with respect to housing component <NUM>) onto substrate <NUM>.

In some embodiments, a printing device could include provisions for a sensing device that detects various kinds of information. In some embodiments, a printing device could include provisions for detecting depth information (e.g., the depth of contours in a surface). Such provisions may include, but are not limited to, optical sensing devices as well as other kinds of depth sensing devices that may be known in the art.

In the exemplary embodiment shown in <FIG>, printing system <NUM> includes sensing device <NUM> to detect optical or visual information. Specifically, sensing device <NUM> may be an optical sensing device. As discussed further below, the optical information captured by sensing device <NUM> could be used to determine depth information of a nearby surface.

In different embodiments, the location of the sensing device could vary. Sensing device <NUM> could be static or moving. In some embodiments, for example, sensing device <NUM> could be stationary and could be disposed above printing device <NUM>. This position could maximize the ability to capture large sections of substrate <NUM>. In some embodiments, sensing device <NUM> could be located by a separate positioning assembly (not shown). In other embodiments, sensing device <NUM> could be disposed on or within housing component <NUM>. In the exemplary embodiment, sensing device <NUM> could be disposed near, or even attached to printhead <NUM>. As printhead <NUM> is moved, sensing device <NUM> could therefore travel with printhead <NUM>. Sensing device <NUM> could move in the same direction as printhead <NUM> to detect visual and/or optical information of substrate <NUM>. In other embodiments, sensing device <NUM> could be disposed away from printhead <NUM>. In some cases, sensing device <NUM> could have a fixed location and/or orientation relative to housing component <NUM>. In other cases, sensing device <NUM> could have an adjustable location and/or orientation and could be movable independently of printhead <NUM>.

Embodiments can include provisions for detecting optical information about substrate <NUM>, including depth of any irregularities on the surface of substrate <NUM>. The irregularities could be recesses, depressions, cavities, holes, gaps, craters, pits, or any inconsistencies on the surface of the substrate. The substrate could be any article as described in further detail below, or any material that could be used as a base or substrate such as metal, any form of plastics, thermoplastics, or ceramics.

In some embodiments, sensing device <NUM> may be any kind of device or combination of devices capable of capturing image information and detecting the depth of an irregularity on a surface. Examples of different optical sensing devices that could be used include, but are not limited to, still-shot cameras, video cameras, digital cameras, non-digital cameras, web cameras (web cams), as well as other kinds of optical devices known in the art. The type of optical sensing device may be selected according to factors such as desired data transfer speeds, system memory allocation, desired temporal resolution for viewing a substrate, desired spatial resolution for viewing a substrate as well as possibly other factors. In at least one embodiment, sensing device <NUM> could be an image sensor having a minimal form factor, for example, an optical sensing device with a complementary metal-oxide-semiconductor (CMOS) image sensor with a footprint on the order of several millimeters or less.

Exemplary image sensing technologies that could be used with sensing device <NUM> include, but are not limited to, semiconductor charge-coupled devices (CCD), complementary metal-oxide-semiconductor (CMOS) type sensors, N-type metal-oxide-semiconductor (NMOS) type sensors as well as possibly other kinds of sensors. The type of image sensing technology used may vary according to factors including optimizing the sensor type compatible with ambient conditions in printing device <NUM> (and near or within printhead <NUM>), size constraints as well as possibly other factors. In some other embodiments, optical sensing devices that detect non-visible wavelengths (including, for instance, infrared wavelengths) could also be used.

Sensing device <NUM> may convert optical images into information transmitted via electrical signals to one or more systems of printing system <NUM>. Upon receiving these electrical signals, the one or more systems can use this information to determine a variety of information about objects that may be visible to sensing device <NUM>.

In different embodiments, detecting the depth of an irregularity on the surface of a substrate could include using a laser to detect the depth. Different kinds of depth detecting devices or sensors could be utilized. Not just optical sensing devices, but any device designed or configured to detect the depth of an irregularity on a surface. For example, reflected light wavelengths could be increased when an irregularity or cavity is detected on the surface of the substrate. In other embodiments, detecting the depth of an irregularity on the surface of a substrate could include provisions of ultrasonic waves to detect the depth. Ultrasonic waves could be emitted onto the surface of the substrate, and the returning waves could be analyzed. For example, if a defect is present on the surface, the ultrasonic waves could reflect sooner than if there were no defects on the surface. Different provisions could be used to detect the depth of an irregularity by comparing the different reflections on the varying surfaces of the substrate. Another example is a measuring device wherein light is projected upon a substrate being examined and the measurement is made by utilizing interference of light reflected from the substrate to determine the depth of the irregularity. Another example of detecting the depth of an irregularity could be spectral reflection characteristics of the return signal are detected and analyzed to determine the depth of the irregularity. Light is projected onto the substrate and any irregularity is detected based on the variation of the intensity of the reflected light. Another example is irradiating a laser beam to the surface of the article and determining when the reflected beam is interrupted temporarily. Any depth detecting device or sensor could be configured with the printing device to detect the depth of an irregularity on the surface of the substrate.

Some printing systems may include provisions to control and/or receive information from printing device <NUM>. These provisions can include computing system <NUM> and network <NUM>. As used in this detailed description and in the claims, "computing system" and its variants thereof may refer to the computing resources of a single computer, a portion of 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, laptops or tablet) may facilitate interactions with a user (not shown). 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.

As illustrated in <FIG>, computing system <NUM> may comprise central processing device <NUM>, visual 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 design feature and the number of layers required to achieve the structure.

In some embodiments, computing system <NUM> may be in communication with printing device <NUM> through network <NUM>. Network <NUM> may include any wired or wireless provision 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.

According to the claimed invention, printed structures are printed directly to one or more substrates or articles. The term "articles" is intended to include both articles of footwear (e.g., shoes) and articles of apparel (e.g., shirts, pants, etc.). As used throughout this disclosure, the terms "article of footwear" and "footwear" include any footwear and any material associated with footwear, including an upper, and may also be applied to a variety of athletic footwear types, including baseball shoes, basketball shoes, cross-training shoes, cycling shoes, football shoes, tennis shoes, soccer shoes, and hiking boots, for example. As used throughout this disclosure, the terms "article of footwear" and "footwear" also include footwear types that are generally considered to be nonathletic, formal, or decorative, including dress shoes, loafers, sandals, slippers, boat shoes, and work boots.

While the disclosed embodiments are described in the context of footwear, the disclosed embodiments may further be equally applied to any article of clothing, apparel, or equipment that includes 3D printing. For example, the disclosed embodiments may be applied to 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, sports equipment, etc. 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. As used throughout this disclosure, the terms "article of apparel," "apparel," "article of footwear," and "footwear" may also refer to a textile, natural fabric, synthetic fabric, knit, woven material, nonwoven material, mesh, leather, synthetic leather, polymer, rubber, and foam.

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, natural fabric, synthetic fabric, knit, woven material, nonwoven material, mesh, leather, synthetic leather, polymer, rubber, and 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.

Printing system <NUM> may be operated as follows to provide three-dimensional structures that have been formed using a layering process. Computing system <NUM> may be used to design a three-dimensional 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>). The structure could be any shape or geometry and could be produced from a three-dimensional model or electronic data source.

Although the embodiments shown in the figures depict a system using inkjet printing technologies, it will be understood that still other embodiments not covered by the claimed invention could incorporate any kind of printing technology or different kinds of three-dimensional printing technologies. Before printing, an article may be placed onto tray <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 printhead <NUM> to build up layers of a structure using deposited material. Generally, embodiments could apply any kind of print material to a substrate. As used herein, the term "print material" refers to any material that can be printed, and includes inks as well as resins, plastics, or other print materials associated with 2D and/or 3D printing. According to the claimed invention, the materials used in the printing technology could be any aqueous ink, dye-based ink, pigment-based ink, solvent-based ink, dye sublimation ink, thermoplastic material, acrylic resin, polyurethane, thermoplastic polyurethane, silicone, or any other curable substance.

<FIG> illustrates an embodiment of a process for printing on an article having irregularities. Generally, one or more of the steps depicted in <FIG> may be performed by computing system <NUM>, sensing device <NUM>, and/or any other system or component of printing device <NUM>. In other cases, some of the following steps could be performed by any other system or device. In addition, the order of steps could vary in any manner in other embodiments. In some embodiments, the process of <FIG> may include additional steps, while in other embodiments some steps depicted in <FIG> may be optional. For purposes of clarity, the following discussion describes steps in this process as being performed by a control unit. As used herein, the term "control unit" or "electronic control unit" refers to any set of resources (e.g., hardware and/or software) capable of controlling one or more systems or components. A control unit could be a central processing device, such as central processing device <NUM> shown in <FIG>. Alternatively, a control unit could be separate from central processing device <NUM>, and could be integrated with printing device <NUM>, a remote computing system, and/or a server of some kind. The method of the claimed invention is defined in appended independent method claim <NUM>.

In a first step <NUM>, a control unit may receive image information corresponding to a surface of substrate <NUM>. In some embodiments, the image information may be received from one or more sensors, such as sensing device <NUM>. The received image information could include any kind of analog and/or digital signal that include information related to one or more images captured by sensing device <NUM>.

In step <NUM>, the control unit may use the image information to determine if the surface is smooth. For example, in some embodiments, the surface of substrate <NUM> may have no irregularities or have a planar surface. Then, printing device <NUM> proceeds to printing in step <NUM>. If the surface is not smooth, then the control unit, using image information provided by sensing device <NUM>, continues to analyze the image of substrate <NUM> for surface irregularity in step <NUM>.

In step <NUM>, surface contour map information may be created. The contour map information may be used to detect the depth of any irregularity and provide the depth amount of the irregularity on the surface of substrate <NUM>. The depth amount or information may be a distance from the surface to a viewpoint of sensing device <NUM>. In some embodiments, the surface of substrate <NUM> may be the planar or smooth surface portion of substrate <NUM>. In other embodiments, the surface of substrate <NUM> may be the surface of the irregularity of substrate <NUM>. Sensing device <NUM> could detect the depth of the irregularity using any of the technologies mentioned earlier.

Computing system <NUM> could receive information to print an image, graphic, or structure on substrate <NUM>. The image, graphic, or structure to be printed could be any 2D layer showing an image or a 3D structure/object of some kind. In some embodiments, the information may be images or graphic files, grayscale files, or any other kinds of files representing the structure to be printed. Image files may be any kind of file format providing image compression of the structure to be printed. For example, the files could be tagged image file format (tiff), joint photographic experts group (jpeg), graphics interchange format (gif), portable network graphics (png), bitmap file (bmp), photoshop document (psd), portable document format (pdf) file or any other kind of file format providing image compression to reduce the amount of storage space required in computing system <NUM>.

In some embodiments, computing system <NUM> could receive grayscale files representing information of a structure to be printed on substrate <NUM>, or it could convert an image file to a grayscale file. The grayscale file could have any of the file formats previously discussed. The grayscale file contains an image in which the value of each pixel carries intensity information. A grayscale file contains only shades of gray and no color. In some embodiments, the intensity of light could be measured at each pixel to determine the grayscale. The darkest possible shade is black, which is the total absence of transmitted or reflected light or weakest intensity. The lightest possible shade is white, the total transmission or reflection of light or strongest intensity. In other embodiments, the intensity of a pixel could also be expressed in percentages. The percentile notation is used to denote how much ink is employed or deposited onto the substrate. For example, <NUM>% intensity of a pixel is represented by no print material deposited onto the substrate. Further, <NUM>% intensity of a pixel is represented by a maximum amount of print material that could be deposited on the substrate for given settings or physical constraints of a printing system. Computing system <NUM> could receive any type of information or compute any type of files to print an image, graphic, or structure on substrate <NUM>.

In the foregoing discussion, layer files could be any graphic or image file, grayscale file, or any other kind of file containing information of a structure to be printed onto a substrate. The layer files may contain information pertaining to the predetermined thickness for each layer. Printing device <NUM> could print a layer file multiple times to create the desired image, graphic, or structure on the substrate. In step <NUM>, the layer files could be modified to fill the irregularity on the surface of the substrate with a depositing material. The layer files could be modified based on the surface contour map information created in step <NUM>. The control unit may utilize the surface contour map information to modify or adjust the predetermined thickness of a layer file based on the depth amount of the irregularities. The layer file could be modified at the position or location of the irregularity. The other positions or locations of the layer file could maintain their predetermined thickness. In step <NUM>, each layer file could be adjusted or modified in a similar manner or could be modified differently depending on the depth amount of the irregularity.

In some embodiments, the layer file could contain information in which the layer has the same predetermined thickness at all positions or locations. In other embodiments, the layer file could be a grayscale file containing information in which the layer has different or varying predetermined thicknesses depending on the grayscale of the image. For example, the grayscale file could establish a relationship between color and thickness. For lighter regions of an image, the printer could print thinner layers, and for darker regions of the image, the printer could print thicker layers. Printing device <NUM> could print the grayscale file multiple times in layers, thereby a three-dimensional structure could be printed onto the substrate. For example, the grayscale file could have a region of the image being <NUM> thick. That region of the image could reach a height ranging from <NUM> - <NUM> thick. The grayscale file could contain any combination of information depending on the structure to be printed. For example, the grayscale file could have a portion or region of the image with <NUM>% intensity of a pixel. Then that region of the layer could be <NUM> thick. Printing device <NUM> could be programmed to print <NUM> layers, then that region of the image could be <NUM> thick after printing the same file <NUM> times. Another region could show <NUM>% intensity of a pixel, and then this portion of the layer could be <NUM> thick. Printing device <NUM> could be programmed to print <NUM> layers, and then this region of the image could be <NUM> thick after printing the same file <NUM> times. Printing device <NUM> prints the entire grayscale file containing different amounts of information for each region, such as <NUM>% intensity in a region and <NUM>% intensity in another region. In one embodiment, a three-dimensional structure could be printed onto the substrate from one single image file, grayscale file, or other file containing image information. Computing system <NUM> could send information to print a predetermined number of layers to achieve the three-dimensional structure. Computing system <NUM> could program the thickness of each region to a predetermined thickness depending on the shape of the three-dimensional structure. The grayscale file could be modified to print onto the substrate and fill the irregularity to make the substrate substantially planar or smooth. The grayscale files could be dynamically modified or adjusted depending on any detection of irregularities of the surface. Examples of grayscale files representing images or structures are disclosed in <CIT>.

Then in step <NUM>, printing device <NUM> may print each modified layer file. The control unit may provide the information of the modified layer files to printing device <NUM> via network <NUM>. In some embodiments, printing device <NUM> may print a first modified layer file directly onto substrate <NUM>. The modified layer files could be printed repeatedly until the surface of the substrate is substantially smooth.

<FIG> illustrates a schematic view of an article having irregularities on the surface. In some embodiments, the article may be used as an upper of a shoe. The upper material may be of any type of material, such as synthetic leather, leather, textile, or knit. In the exemplary embodiment, synthetic leather article <NUM>, hereinafter referred to as article <NUM>, may have an irregularity shown as a deep groove <NUM>. Also, article <NUM> may have an irregularity shown as a shallow groove <NUM>. Throughout article <NUM>, there could be multiple grooves of varying depth. The position of shallow groove <NUM> may be designated by X and Y coordinates. Similarly, the position of deep groove <NUM> and other grooves may be designated by X and Y coordinates.

As shown in <FIG> and <FIG>, article <NUM> has a deep groove <NUM>. <FIG> illustrates an enlarged view <NUM> of deep groove <NUM>. <FIG> shows a cross-section of deep groove <NUM>. Sensing device <NUM> may detect the depth of deep groove <NUM> by providing optical information to the control unit. In some embodiments, article <NUM> could have a size of <NUM> x <NUM> (<NUM> x <NUM> inches). The control unit and sensing device <NUM> could convert the article size to an image size representing the image in pixels. It will be understood that the size of each pixel can be varied in different embodiments. Therefore, an article size of <NUM> x <NUM> inches could have an image size of <NUM> x <NUM> pixels. <FIG> shows pixels at the X coordinate of <NUM>. X=<NUM> represents the <NUM>th pixel from the reference point of an edge of the article. For purposes of clarity, the Y coordinate will be discussed at the first <NUM> pixel locations. As shown in <FIG>, since deep groove <NUM> has a similar depth throughout the X plane, only a few pixel locations will be discussed.

<FIG> shows the coordinate locations of deep groove <NUM> at the X coordinate of <NUM>. At pixel location <NUM>, the X coordinate is equal to <NUM>, and the Y coordinate is equal to <NUM>. At this pixel location, the depth of the irregularity is <NUM> units deep. At pixel location <NUM>, the X coordinate is equal to <NUM>, and the Y coordinate is equal to <NUM>. At this pixel location, the depth of the irregularity is <NUM> units deep. At pixel location <NUM>, the X coordinate is equal to <NUM>, and the Y coordinate is equal to <NUM>. At this pixel location, the depth of the irregularity is <NUM> units deep. At pixel location <NUM>, the X coordinate is equal to <NUM>, and the Y coordinate is equal to <NUM>. At this pixel location, the depth of the irregularity is <NUM> units deep. At pixel location <NUM>, the X coordinate is equal to <NUM>, and the Y coordinate is equal to <NUM>. At this pixel location, the depth of the irregularity is <NUM> units deep. The unit of depth of each pixel may correspond to a linear dimension of a pixel. In some cases, each unit of depth may be equal in magnitude to the width of a pixel. In other cases, a unit of depth could be less than or greater than the width of a pixel. This surface image information could be generated by using sensing device <NUM> and computing system <NUM> to determine the depth of deep groove <NUM>.

Referring to <FIG>, in step <NUM>, the surface image information could be analyzed by the control unit. Throughout this detailed description and claims, the control unit may utilize the sensing device <NUM>, computing system <NUM>, printing device <NUM>, and/or a combination of them to analyze the surface image information. In step <NUM>, surface contour map information may be created, as shown in <FIG>. The article size could be converted to the image size represented by pixels. The location of the irregularity or cavity could be defined by the pixel coordinates. For example, <FIG> shows the deep groove <NUM> at pixel location <NUM> having coordinates of X=<NUM> and Y=<NUM>. The control unit could detect the depth of the irregularity or cavity at each pixel location using any of the depth detecting technologies previously discussed. For example, <FIG> and <FIG> show the depth of the irregularity as <NUM> units deep at each of the pixel locations. The depth could be a distance from the top of the surface of article <NUM> to the bottom of the irregularity or cavity.

In step <NUM>, the predetermined thickness of a layer file may be adjusted or modified to compensate for any irregularities on the surface of article <NUM>. The control unit may dynamically modify a predetermined thickness of a layer file to be printed on article <NUM> based on the depth of the cavity of deep groove <NUM>. In an exemplary embodiment, the control unit may correct for the surface being moderately non-planar by printing the modified layer to fill in the irregularity or cavity. The control unit could modify a certain number of layer files as needed to fill in the irregularity or cavity to make the article smooth so that printing device <NUM> could print an unmodified layer file on a smooth surface.

As shown in <FIG> and <FIG>, article <NUM> has an irregularity shown as shallow groove <NUM>. <FIG> illustrates an enlarged view <NUM> of shallow groove <NUM>. <FIG> shows a cross-section of shallow groove <NUM>. Sensing device <NUM> may detect the depth of shallow groove <NUM> by providing optical information to the control unit. In some embodiments, article <NUM> could have a size of <NUM> x <NUM> (<NUM> x <NUM> inches). The control unit and sensing device <NUM> could convert the article size to an image size represented by pixels. Therefore, an article size of <NUM> x <NUM> (<NUM> x <NUM> inches). could have an image size of <NUM> x <NUM> pixels. <FIG> shows pixels at the X coordinate of <NUM>. X=<NUM> represents the <NUM>th pixel from the reference point of an edge of the article. For purposes of clarity, the Y coordinate will be discussed showing the varying depths of shallow groove <NUM>.

<FIG> shows the coordinate locations of shallow groove <NUM> at the X coordinate of <NUM>. At pixel location <NUM>, the X coordinate is equal to <NUM>, and the Y coordinate is equal to <NUM>. At this pixel location, the depth of the irregularity is <NUM> unit deep. At pixel location <NUM>, the X coordinate is equal to <NUM>, and the Y coordinate is equal to <NUM>. At this pixel location, the depth of the irregularity is <NUM> unit deep. At pixel location <NUM>, the X coordinate is equal to <NUM>, and the Y coordinate is equal to <NUM>. At this pixel location, the depth of the irregularity is <NUM> units deep. At pixel location <NUM>, the X coordinate is equal to <NUM>, and the Y coordinate is equal to <NUM>. At this pixel location, the depth of the irregularity is <NUM> units deep. At pixel location <NUM>, the X coordinate is equal to <NUM>, and the Y coordinate is equal to <NUM>. At this pixel location, the depth of the irregularity is <NUM> units deep. At pixel location <NUM>, the X coordinate is equal to <NUM>, and the Y coordinate is equal to <NUM>. At this pixel location, the depth of the irregularity is <NUM> units deep. At pixel location <NUM>, the X coordinate is equal to <NUM>, and the Y coordinate is equal to <NUM>. At this pixel location, the depth of the irregularity is <NUM> units deep. At pixel location <NUM>, the X coordinate is equal to <NUM>, and the Y coordinate is equal to <NUM>. At this pixel location, the depth of the irregularity is <NUM> units deep. The unit of depth of each pixel may correspond to a linear dimension of a pixel. In some cases, each unit of depth may have the same width of a pixel. This surface image information could be generated by using sensing device <NUM> and computing system <NUM> to determine the depth of shallow groove <NUM>.

Referring to <FIG>, in step <NUM>, the surface image information could be analyzed by the control unit. In step <NUM>, surface contour map information may be created, as shown in <FIG>. The article size could be converted to the image size represented by pixels. The location of the irregularity or cavity could be defined by the pixel coordinates. For example, <FIG> shows shallow groove <NUM> at pixel location <NUM> having coordinates of X=<NUM> and Y=<NUM>. The control unit could detect the depth of the irregularity or cavity at each pixel location using any of the depth detecting technologies previously discussed. For example, <FIG> and <FIG> show the depth of the irregularity having varying depths at each of the pixel locations. At pixel location <NUM>, the depth of the irregularity is <NUM> unit deep. Shallow groove <NUM> also shows at pixel location <NUM>, the depth of the irregularity as <NUM> units deep. The depth could be a distance from the top of the surface of article <NUM> to the bottom of the irregularity or cavity. The control unit could determine the depth of a cavity even if the cavity has varying depths.

In step <NUM>, the predetermined thickness of a layer file may be adjusted or modified to compensate for any irregularities on the surface of article <NUM>. The control unit may dynamically modify a predetermined thickness of a layer file to be printed on article <NUM> based on the depth of the cavity of shallow groove <NUM>. In an exemplary embodiment, the control unit may correct for the surface being slightly non-planar by printing the modified layer to fill in the cavity. The control unit could modify a certain number of layer files as needed to fill in the irregularity or cavity to make the article smooth so that printing device <NUM> could print an unmodified layer file on a smooth surface.

<FIG> illustrates a schematic view of an article having different irregularities. Article <NUM> could have an irregularity with shallow cavity <NUM>, moderate cavity <NUM> and deep cavity <NUM>. As discussed above, the depth of the irregularity could be represented by units of depth that may correspond to a linear dimension of a pixel. Shallow cavity <NUM> has shallow depth <NUM> with a depth of one unit. Moderate cavity <NUM> has moderate depth <NUM> with a depth of <NUM> units. Deep cavity <NUM> has deep depth <NUM> with a depth of <NUM> units. In some embodiments, sensing device <NUM> and computing system <NUM> could detect the depth of a cavity on the surface of article <NUM>. The control unit may adjust a predetermined thickness of a layer file to be printed on article <NUM> based on the depth of the cavities on the surface.

<FIG> illustrate a schematic view of multiple layers printed on article <NUM>. In one embodiment, the layer files to create an image, graphic, or structure has predetermined thickness <NUM>. Some of the layers are printed from layer files having predetermined thickness <NUM>. Other layers are printed from modified layer files that include adjusted predetermined thicknesses or modified thicknesses to compensate for the different irregularities on the surface of article <NUM>. Printing device <NUM> could print any number of layers from layer files or modified layer files or a combination of layer files and modified layer files to create a desired image, graphic, or structure on article <NUM>.

<FIG> illustrates a schematic view of first layer <NUM> printed on article <NUM>. As used herein and throughout this description, each layer could have an upper surface or top surface which corresponds to the exposed portion of the layer. The exposed portion could be covered by another layer or remain exposed. Also, each layer could have a lower surface or bottom surface, opposite the upper surface, which corresponds to the portion of the layer adjacent the substrate or the exposed portion of a layer which has already been printed. A base layer could be adjacent the substrate by printing the base layer directly onto the substrate. Any subsequent layer could be adjacent a previously printed layer by printing the subsequent layer directly onto the previously printed layer.

First layer <NUM> is printed from a modified layer file that has predetermined thickness <NUM> and multiple modified thicknesses. First portion <NUM> of first layer <NUM> has shallow modified thickness <NUM> to fill shallow cavity <NUM>. Further, second portion <NUM> of first layer <NUM> has moderate modified thickness <NUM> to fill moderate cavity <NUM>. To partially fill deep cavity <NUM>, third portion <NUM> of first layer <NUM> has deep modified thickness <NUM>. Deep cavity <NUM> is partially filled thereby forming another cavity with thickness <NUM> which extends from a top surface of first layer <NUM> to a top surface of deep modified thickness <NUM>. Since first layer <NUM> may not completely fill deep cavity <NUM>, another layer representing information from a modified layer file could be printed on the top surface of first layer <NUM>.

After first layer <NUM> has been printed, portions of first layer <NUM> could be continuous or flat. First portion <NUM> shows shallow cavity <NUM> completely filled with first layer <NUM> which has upper surface <NUM>. Fourth portion <NUM> shows a non-adjusted portion of first layer <NUM> which has predetermined thickness <NUM> with predetermined thickness upper surface <NUM>. Since shallow cavity <NUM> is completely filled, upper surface <NUM> is flush with predetermined thickness upper surface <NUM> to provide a smooth and continuous surface from first portion <NUM> to fourth portion <NUM>.

Upper surface <NUM> and predetermined thickness upper surface <NUM> are in the same plane providing a smooth flat surface without any cavities or irregularities. A subsequent layer printed onto first layer <NUM> could have a portion of the layer adjacent to first portion <NUM> and fourth portion <NUM> having the predetermined thickness. Fifth portion <NUM> shown in <FIG>, shows second layer <NUM> with predetermined thickness <NUM>. Since there were no cavities or irregularities detected at fifth portion <NUM>, that portion of the layer file was not modified and printing device <NUM> could print that portion of second layer <NUM> directly onto the smooth portion of the top surface of first layer <NUM>.

<FIG> illustrates a schematic view of second layer <NUM> printed onto the top surface of first layer <NUM>. Second layer <NUM> is printed from a modified layer file that has predetermined thickness <NUM> and modified thickness <NUM>. Second layer <NUM> has predetermined thickness <NUM> on the smooth surface portions of first layer <NUM>. Portion <NUM> of second layer <NUM> has modified thickness <NUM> to fill the remaining portion of deep cavity <NUM>. Since first layer <NUM> may be substantially smooth at portions around shallow cavity <NUM> and moderate cavity <NUM>, second layer <NUM> may print predetermined thickness <NUM> directly onto the surface of first layer <NUM>. Each layer file could be modified or adjusted to compensate for irregularities found on the surface of the article. A modified layer file could have an adjusted predetermined thickness at the location or position of the irregularity.

<FIG> illustrates a schematic view of third layer <NUM> printed onto the top surface of second layer <NUM>. Third layer <NUM> is printed from a layer file having predetermined thickness <NUM>. Since second layer <NUM> may be substantially smooth or flat, the layer file was not modified and printing device <NUM> could print third layer <NUM> directly onto the top surface of second layer <NUM> without adjusting a predetermined thickness.

<FIG> illustrates a schematic view of performance ribs <NUM> printed on article <NUM>. In some embodiments, since third layer <NUM> may be substantially smooth, printing device <NUM> may print performance ribs <NUM> directly onto third layer <NUM> without adjusting a predetermined thickness of the layer file for performance ribs <NUM>. In other embodiments, other layers may be printed from layer files onto third layer <NUM> to create an image, graphic, or structure.

<FIG> illustrates another embodiment of a process for printing on an article having irregularities. Process for printing <NUM> shows that after every layer is printed, the resulting surface could be analyzed again to determine the depth of any irregularity on the surface and modify the next layer file to compensate for any irregularity. In step <NUM>, printing device <NUM> may print a selected layer (e.g., an Nth layer of the layer file). The selected layer could be substrate <NUM> placed on tray <NUM>. Also, the selected layer could be any intervening layer in forming the desired image, graphic, or structure. In step <NUM>, a control unit may receive image information corresponding to a surface of the selected layer. In some embodiments, the image information may be received from one or more sensors, such as sensing device <NUM>. The received image information could include any kind of analog and/or digital signal that include information related to one or more images captured by sensing device <NUM>.

In step <NUM>, surface contour map information of the selected layer may be created. The contour map information may be used to detect the depth of any irregularity and provide the depth amount of irregularities on the surface of substrate <NUM>. The depth amount or information may be a distance from the surface to a viewpoint of sensing device <NUM>. In some embodiments, the surface of substrate <NUM> may be the planar or smooth surface portion of substrate <NUM>. In other embodiments, the surface of substrate <NUM> may be the surface of the irregularity of substrate <NUM>. Sensing device <NUM> could detect the depth of the irregularity using any of the technologies mentioned earlier.

In step <NUM>, the control unit could modify the next layer file using the contour map information. In some embodiments, the layer files could be image files, grayscale files, or any other kind of information files, as previously discussed, of the structure to be printed. The next layer file could be modified to fill the irregularity on the surface of the substrate with a depositing material. The layer files could contain information pertaining to the predetermined thickness for each layer. The next layer file could be modified based on the surface contour map information created in step <NUM>. The control unit may utilize the surface contour map information to modify or adjust the predetermined thickness of the next layer file based on the depth amount of the irregularities. The next layer file could be modified at the position or location of the irregularity. The other positions or locations of the next layer file could maintain their predetermined thickness. In step <NUM>, the next layer file could be adjusted or modified in a similar manner as the previous layer file or could be modified differently depending on the depth amount of the irregularity. The modified layer could be printed onto the selected layer and fill the cavity or irregularity to make the substrate substantially smooth.

The control unit could contain information pertaining to the number of layers to be printed to achieve the three-dimensional structure. Each layer file could be printed a predetermined number of times depending on the desired structure. In some embodiments, each layer file will be the same. In other embodiments, some layer files could be modified to correct for any irregularity on the surface of the substrate. In step <NUM>, printing device <NUM> could print the modified layer having a modified predetermined thickness onto the substrate.

Claim 1:
A method of printing onto a base which is an article of footwear (<NUM>, <NUM>) or an article of apparel (<NUM>, <NUM>), the method comprising:
receiving the base on a platform;
detecting a first depth of a first cavity on the base with a sensing device (<NUM>), which optionally is an optical sensing device;
receiving an image file of a structure to be formed on the base;
wherein the image file includes a predetermined thickness of a layer;
generating a modified image file using the first depth, wherein the modified image file includes a first adjusted thickness for a portion of the layer corresponding to the first cavity; and
inkjet printing a base layer directly onto the base using the modified image file, wherein a print material for printing the base layer is ink, a thermoplastic material, an acrylic resin, a polyurethane, a thermoplastic polyurethane, silicone or any other curable substance,
wherein the base layer includes a first adjusted portion printed within the first cavity, wherein the first adjusted portion has the first adjusted thickness and the base layer includes a non-adjusted portion printed onto the base, wherein the non-adjusted portion has the predetermined thickness,
wherein the first adjusted portion fills the first cavity and an upper surface of the first adjusted portion is flush to an upper surface of the non-adjusted portion, and
wherein the method further comprises printing a three-dimensional object which is a performance rib (<NUM>) directly onto the smooth surface without adjusting a predetermined thickness of the layer file for the performance rib (<NUM>).