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.

In one aspect, a method of manufacturing a structure for permanent attachment to a base component includes associating a first nozzle with the base component, the first nozzle having a first aperture size. The method further includes forming an outer shell portion of the structure on the base component by extruding a first material through the first nozzle, where the outer shell portion is formed with at least one opening providing access to an interior of the outer shell portion. The method also includes removing the first nozzle from an area near the outer shell portion. The method also includes associating a second nozzle having a second aperture size with the at least one opening, where the second aperture size is greater than the first aperture size. The method also includes extruding a second material through the second nozzle and into the at least one opening in order to form an inner portion of the structure.

In another aspect, a method of manufacturing a structure for permanent attachment to a base component includes forming an outer shell portion of the structure on a surface of the base component by printing a first material onto the base component using a nozzle, where the outer shell portion is formed with at least one opening and where the outer shell portion is bonded to the base component. The method also includes filling an interior of the outer shell portion by extruding a second material through the nozzle and into the at least one opening in order to form an inner portion of the structure.

In another aspect, a method of manufacturing a structure for permanent attachment to a base component includes aligning a first nozzle with an opening in the base component, the nozzle being located adjacent to a first side of the base component. The method further includes extruding a first material through the opening and into a molding component on a second side of the base component in order to form an anchored portion on the second side. The method also includes extruding the first material from the first nozzle on the first side to form an outer shell portion of the structure, where the outer shell portion is integrally formed with the anchored portion and where the outer shell portion includes an upper opening. The method further includes filling an interior of the outer shell portion by extruding a second material through a second nozzle and into the upper opening of the outer shell portion in order to form an inner portion of the structure.

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>. Referring to <FIG>, printing system <NUM> may further comprise printing device <NUM>, computing system <NUM> and network <NUM>.

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

In the embodiments shown in the figures, printing system <NUM> may be associated with fused filament fabrication (FFF), also referred to as fused deposition modeling. In the embodiment shown in <FIG>, printing device <NUM> of printing system <NUM> uses fused filament fabrication to produce three-dimensional parts. An example of a printing device using fused filament fabrication (FFF) is disclosed in Crump, <CIT> and titled "Apparatus and Method for Creating Three-Dimensional Objects," and 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, 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 the housing of a printing device 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 the printing device as well as possibly other factors. It will be understood that the housing of a printing device 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 tray <NUM>. In some embodiments, tray <NUM> may be fixed in place. 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 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. As used herein, the terms "target location", "target portion" or "target surface" refer to any intended location, portion or surface where a printed material may be applied. 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. Provisions for delivering printed materials include, for example, print heads and nozzles. In the embodiment of <FIG>, printing device <NUM> includes 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. For example, in an embodiment of a printing system discussed below, a printing device could be configured with at least two nozzles that can move in an independent manner from one another.

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, the 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 at least some embodiments, a filament of material (e.g., plastic or wire) is provided as a coil, which may then be unwound and fed through nozzle <NUM> to be deposited at a target location. 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>). 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>.

In some embodiments, nozzle assembly <NUM> is associated with an actuating system <NUM>. Actuating system <NUM> may include various components, devices and systems that facilitate the motion of nozzle assembly <NUM> within housing <NUM>. In particular, actuating system <NUM> may include provisions to move nozzle assembly <NUM> in any horizontal direction and/or vertical direction to facilitate depositing a material so as to form a three-dimensional object. To this end, embodiments of 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. In at least some embodiments, actuating system <NUM> may provide movement for nozzle assembly <NUM> in any of the x-y-z directions defined with respect to printing system <NUM> (e.g., Cartesian directions).

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 actuating system <NUM> and nozzle assembly <NUM>. For example, actuating system <NUM> is shown schematically as including several tracks or rails, but the particular configuration and number of parts comprising actuating system <NUM> may vary from one embodiment to another.

In different embodiments, printing device <NUM> may use a variety of different materials for forming 3D parts, including, but not limited to: thermoplastics (. 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.

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>, 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.

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

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, wristlarm 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, wristlarm 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, 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.

In an exemplary embodiment, printing device <NUM> may be configured to print one or more structures directly onto a portion of one of articles <NUM>. Articles <NUM> comprise exemplary articles that may receive a printed structure directly from printing device <NUM>, including an article of footwear <NUM>, which has a three-dimensional configuration, as well as an upper <NUM>, which has a flattened configuration. Articles <NUM> also include t-shirt <NUM>. Thus it will be understood that printing device <NUM> may be used to apply printed material to articles in three-dimensional configurations and/or flattened configurations.

In order to apply printed materials directly to one or more articles, printing device <NUM> may be capable of printing onto the surfaces of various kinds of materials. Specifically, in some cases, printing device <NUM> may be capable of printing onto the surfaces of various materials such as a textile, a natural fabric, a synthetic fabric, a knit, a woven material, a nonwoven material, a mesh, a leather, a synthetic leather, a polymer, a rubber, and a foam, or any combination 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 an article.

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>. 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 actuating device <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 material as it is deposited.

Although some of the embodiments shown in the figures depict a system using filament fused fabrication printing technologies, it will be understood that still other embodiments could incorporate one or more different 3D printing technologies. Moreover, still other embodiments could incorporate a combination of filament fused fabrication and another type of 3D printing technique to achieve desired results for a particular printed structure or part.

<FIG> illustrates a schematic embodiment of a print control system <NUM>. Referring to <FIG>, print control system <NUM> includes an extrusion control system <NUM>, a sensor system <NUM> and a nozzle actuating system <NUM>. Each of these systems, discussed in further detail below, may operate in cooperation with one another to facilitate the printing of a structure. Specifically, nozzle actuating system <NUM> controls the movement of nozzle <NUM>, while extrusion control system <NUM> controls the flow and properties of material deposited as nozzle <NUM> is moved around. Additionally, sensor system <NUM> includes provisions to provide feedback to both nozzle actuating system <NUM> and extrusion control system <NUM> in real-time, so that printing can be adjusted in real-time to achieve precise geometries and material characteristics for printed structures.

Nozzle actuating system <NUM> allows for the motion of nozzle <NUM> in any direction, including both horizontal and vertical directions within housing <NUM>. In at least some embodiments, nozzle actuating system <NUM> facilitates the motion of nozzle <NUM> along a tool path that is determined from the CAD design of the printed structure.

Extrusion control system <NUM> may include one or more provisions for controlling the flow of material from nozzle <NUM> (or any other nozzles associated with nozzle assembly <NUM>) as well as the behavior of the material after it has been deposited onto a target location. As shown schematically in <FIG>, extrusion control system <NUM> can be associated with one or more "extrusion control parameters" that can be varied to change the flow rate of, and/or other properties of, the extruded material. For example, extrusion control parameters can include a nozzle withdrawal rate <NUM>, an extrusion rate <NUM>, an extrusion temperature <NUM>, a nozzle diameter <NUM>, an extrusion pressure <NUM>, an ambient temperature <NUM> and an ambient pressure <NUM>. It will be understood that these parameters are only intended to be exemplary and other embodiments could include additional extrusion control parameters. Also, in at least some embodiments, some of these extrusion control parameters may be optional. In other words, in some other embodiments, one or more of these parameters may be either fixed or not adjustable.

Nozzle withdrawal rate <NUM> may characterize the rate at which nozzle <NUM> is moved away from (or raised) an underlying surface where extruded material is being deposited. Because newly extruded material is forced from nozzle <NUM> under pressure, changing the rate at which nozzle <NUM> is pulled away from the target location may tend to affect how the extruded material spreads on the target location. Extrusion rate <NUM> may characterize the rate at which material is flowing through aperture <NUM> of nozzle <NUM>. As used herein, the term "extrusion rate", also referred to as the "flow rate", refers to the volumetric flow rate at which material is extruded from (or flows from) the nozzle. Increasing the extrusion rate may tend to create a larger volume of material deposited at a given location over an interval of time, while decreasing the extrusion rate may tend to decrease the volume of material deposited at a given location for the same interval of time.

Extrusion temperature <NUM> may characterize the temperature of the material as it is extruded from nozzle <NUM> and deposited at a target location. In at least some cases, varying the extrusion temperature may change the pliability of the material, which can affect spreading of the material at the target location. Also, the temperature of the extruded material may affect how quickly the material cools and/or cures, which can also affect spreading and the final geometry of a printed structure. Nozzle diameter <NUM> characterizes the size of aperture <NUM> and/or of channel <NUM> of nozzle <NUM>. Varying these diameters can affect the total volume of material deposited at a target location over a given period of same.

Extrusion pressure <NUM> characterizes the force per unit area applied by a portion of extruded material against a portion of material at a target location. The extrusion pressure may affect the rate and degree of spreading. Also, ambient temperature <NUM> and ambient pressure <NUM> may characterize the ambient temperature and ambient pressure, respectively, of the area near nozzle <NUM>. In at least some embodiments, material pliability and curing properties may vary significantly with differences in ambient temperature and/or ambient pressure.

Embodiments can include provisions for adjusting one or more of these extrusion control parameters. In some embodiments, for example, nozzle withdrawal rate <NUM> may be controlled using actuating system <NUM>, which controls both the horizontal and vertical motions of nozzle <NUM>. Additionally, some embodiments can include provisions to control a worm-drive or other mechanism that controls the extrusion rate <NUM> and/or extrusion pressure <NUM> at which material is extruded from nozzle <NUM>. In some embodiments, the extrusion temperature <NUM> can be controlled with heating coils <NUM> (see <FIG>) within nozzle <NUM>. Additionally, nozzle diameter <NUM> may be controlled using methods known in the art. Finally, ambient temperature <NUM> and ambient pressure <NUM> may be controlled with various different provisions known in the art for controlling temperature and pressure within a confined space. Of course it will be understood that embodiments are not limited to these exemplary provisions for controlling one or more extrusion control parameters. Other embodiments could utilize any other systems, methods and/or devices to control these various parameters that may be known in the art.

It may be understood that the parameters discussed with respect to extrusion control system <NUM> are only intended to be examples of parameters that may be used to control how material is deposited at a target location such that the material behaves in the desired manner (e.g., spreads at a desired rate and cures at a desired rate). The types of parameters used may depend on manufacturing considerations as well as the specific design of the printing device. In an exemplary embodiment, printing device <NUM> may be designed to allow for the adjustment of at least one the extrusion control parameters discussed here. In other words, in an exemplary embodiment, printing device <NUM> is designed so that various extrusion control parameters may be adjusted in real-time using information provided as part of, or in coordination with, a 3D printing file for printing device <NUM>.

<FIG> illustrates a schematic configuration of various sensors that may comprise part of sensor system <NUM>. Referring to <FIG>, sensor system <NUM> may include an ambient temperature sensor <NUM> and a nozzle temperature sensor <NUM>. In this exemplary configuration, ambient temperature sensor <NUM> may be located near, but not within or on, nozzle <NUM>. It will be understood that ambient temperature sensor <NUM> could be any kind of sensor known in the art for detecting information related to ambient temperature. In the exemplary configuration shown in <FIG>, nozzle temperature sensor <NUM> is disposed within nozzle <NUM>. In some cases, nozzle temperature sensor <NUM> could be in direct contact with material flowing through channel <NUM> of nozzle <NUM>. In other embodiments, however, nozzle temperature sensor <NUM> could be located in any other portion of nozzle <NUM>, as well as possibly being mounted outside of nozzle <NUM>. In at least some embodiments where the temperature of a flowing material is not directly measured, the temperature of one or more parts of nozzle <NUM> may be used as a proxy for the temperature of the material. It will be understood that nozzle temperature sensor <NUM> may generally be any kind of temperature sensor known in the art.

Embodiments may also include provisions for detecting ambient pressure. In some embodiments, sensor system <NUM> may include ambient pressure sensor <NUM>. Generally, ambient pressure sensor <NUM> may be any kind of pressure sensing device known in the art.

Embodiments can include provisions for detecting optical information about a printed structure, including recently extruded material. In some embodiments, sensor system <NUM> includes an optical sensing device <NUM>. Optical sensing device <NUM> may be any kind of device capable of capturing image information. Examples of different optical sensing devices that can 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 printed structure, desired spatial resolution for viewing a printed structure as well as possibly other factors. In at least one embodiment, optical sensing device could be an image sensor having a minimal form factor, for example an optical sensing device with a CMOS image sensor with a footprint on the order of several millimeters or less.

Exemplary image sensing technologies that could be used with optical 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 nozzle <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.

In different embodiments, the location of optical sensing device <NUM> could vary. In some embodiments, for example, optical sensing device <NUM> could be disposed near, or even attached to, nozzle <NUM>. As nozzle <NUM> is moved, optical sensing device <NUM> may therefore travel with nozzle <NUM>. In other embodiments, optical sensing device <NUM> could be disposed away from nozzle <NUM>. In some cases, optical sensing device <NUM> could have a fixed location and/or orientation relative to housing <NUM>. In other cases, optical sensing device <NUM> could have an adjustable location and/or orientation and could be movable independently of nozzle <NUM>.

Optical 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 optical sensing device <NUM>.

Embodiments may include an electronic control unit <NUM>, also referred to as ECU <NUM>, for controlling and/or communicating with various sensors of sensor system <NUM>. For purposes of clarity, only a single ECU is depicted in this embodiment. However, it will be understood that in other embodiments multiple ECU's could be used, each ECU communicating with some or all of the sensors. The ECU's may themselves be further associated with a particular system or device of printing system <NUM>.

ECU <NUM> may include a microprocessor, RAM, ROM, and software all serving to monitor and control various components of sensor system <NUM>, as well as other components or systems of printing system <NUM>. For example, ECU <NUM> is capable of receiving signals from numerous sensors, devices, and systems associated with printing system <NUM>. The output of various devices is sent to ECU <NUM> where the device signals may be stored in an electronic storage, such as RAM. Both current and electronically stored signals may be processed by a central processing unit (CPU) in accordance with software stored in an electronic memory, such as ROM.

ECU <NUM> may include a number of ports that facilitate the input and output of information and power. The term "port" as used throughout this detailed description and in the claims refers to any interface or shared boundary between two conductors. In some cases, ports can facilitate the insertion and removal of conductors. Examples of these types of ports include mechanical connectors. In other cases, ports are interfaces that generally do not provide easy insertion or removal. Examples of these types of ports include soldering or electron traces on circuit boards.

All of the following ports and provisions associated with ECU <NUM> are optional. Some embodiments may include a given port or provision, while others may exclude it. The following description discloses many of the possible ports and provisions that can be used, however, it should be kept in mind that not every port or provision must be used or included in a given embodiment.

As indicated in <FIG>, ECU <NUM> includes port <NUM> for communicating with, and/or powering, ambient pressure sensor <NUM>. ECU <NUM> also includes port <NUM> for communicating with, and/or powering, ambient temperature sensor <NUM>; port <NUM> for communicating with, and/or powering, nozzle temperature sensor <NUM>; and port <NUM> for communicating with, and/or powering, optical sensing device <NUM>.

<FIG> also schematically indicates optional heating coils <NUM> associated with nozzle <NUM> that may be used to heat nozzle <NUM> and/or material flowing through nozzle <NUM>. Heating coils <NUM> may be connected to ECU <NUM>, or a similar control unit. Although the exemplary embodiment depicts heating coils disposed interior to nozzle <NUM>, other embodiments could use heating coils at any other portion nozzle assembly <NUM>, as well as possibly other portions of printing device <NUM> upstream of nozzle assembly <NUM>. It will also be understood that heating coils are only one exemplary type of heating device that could be used. Other embodiments could utilize any other heating devices, systems or mechanisms known in the art for heating nozzles, valves, channels, tubes or other systems associated with the transfer of a flowing material.

Embodiments can include provisions to control the properties of a material that has been recently extruded or deposited from a nozzle. In at least some embodiments, printing device <NUM> may include one or more curing control devices. A curing control device may be any device that allows for the curing of the extruded material to be controlled, or adjusted, after the material has been extruded from a nozzle.

<FIG> is a schematic view of an embodiment of two curing control devices <NUM>. Curing control devices <NUM> includes a cooling device <NUM> and a UV lighting device <NUM>. Cooling device <NUM> may be a device that applies cooled air (i.e., air well below ambient temperature) to a portion of extruded material <NUM>. The application of cooled air may facilitate faster curing of the portion of extruded material <NUM>. Likewise, UV lighting device <NUM> may be a device that applies ultraviolet radiation to a portion of extruded material <NUM>. For materials that may be UV cured, the application of ultraviolet light may facilitate faster curing of the portion of extruded material <NUM>. Although not shown, it is also contemplated that some embodiments could incorporate one or more heating devices that allow portions of extruded material to be heated above the temperature at which they are extruded, in order to temporarily increase pliability and flow, so that the material may more quickly spread over a target location.

Although a single device is shown for each kind of curing control device in the exemplary embodiment of <FIG>, other embodiments could include two or more of each kind of curing control device. Moreover, some embodiments could include single devices that provide coverage (e.g., application of cooled air or UV radiation) through a wide range of angles surrounding the extruded portion of material. Such embodiments could apply cooled air and/or UV radiation to regions ranging from a few degrees to <NUM> degrees around the portion of extruded material.

It is contemplated that curing control devices could be applied locally or globally. For example, in <FIG>, both curing control devices <NUM> are comprised of a relatively narrow probe-like device that applies cooled air and/or UV radiation to a local portion of extruded material. However, other embodiments could include larger devices that apply cooled air and/or UV radiation to a large portion, or even all portions of, extruded material. Still further, some embodiments may use curing control devices <NUM> to provide local curing to predetermined portions of a structure while the structure is printed, and may also use additional curing provisions to provide curing to the entire structure after the printing process has been completed. For example, in another embodiment, following the formation of a printed structure, the entire printed structure could be exposed to cool air and/or UV radiation for curing.

Embodiments that use highly local applications of cooled air and/or UV curing (or possibly heating), may help improve the precision of forming a three-dimensional structure. For example, applying cooled air to some thermoplastic materials may allow the extruded material to be cured very quickly, thereby allowing for improved precision in forming curved and/or overhanging structures in relatively short periods of time. Additionally, because the exemplary embodiments contemplate extruding relatively large volumes of material at a target location in a short period of time compared to some alternative methods, decreasing curing time of the material as it is extruded using curing control devices can help improve the overall quality of the printed structure.

<FIG> is a schematic isometric view of an embodiment of several 3D printed structures <NUM>, also referred to simply as structures throughout this detailed description and in the claims. Structures <NUM> include an exemplary cleat structure <NUM>, hook structure <NUM> and knob-like structure <NUM>. It will be understood that these structures are only intended to be examples of possible 3D printed structures that can be formed using the methods disclosed herein. Moreover, in at least some embodiments, these exemplary structures may be formed using an extrusion type of 3D printing process that can decrease total printing times over some other embodiments of 3D printing methods.

In the embodiment shown in <FIG>, structures <NUM> are bonded to base component <NUM>. Base component <NUM> is shown schematically for purposes of illustration, and could be considered to be a portion of various kinds of articles including both articles of footwear and articles of apparel in some embodiments. As used throughout this detailed description and in the claims, a "base component" may generally comprise any component that to which one or more printed structures have been applied. A base component could be a textile material (including woven textiles, knit textiles, braided textiles and non-woven textiles), a leather (natural or synthetic) a plastic (including a plastic film), rubber, a metal or any other kind of material. Furthermore, in some embodiments 3D printed structures could be printed directly onto the surface of a base component. In such embodiments, the one or more materials forming the 3D printed structure may be bond compatible with at least one material of the base component. In other embodiments, the one or more materials forming the 3D printing structure could be applied to the base component after printing, for example, using an adhesive or a mechanical connection.

<FIG> illustrate schematic views of an embodiment of a process for forming 3D printed structure <NUM> (a knob-like structure) on base component <NUM>. The formed structure <NUM> is shown specifically in <FIG>. For purposes of description, several terms are defined herein to refer to material used in forming a 3D printed structure, including terms indicating various states or configurations of material throughout the forming process. The term "portion of material" is used herein to refer to any volume or part of an extruded material that may or may not be continuous with adjacent volumes or parts of extruded material. A portion of material may be located exterior to a nozzle (once the portion has been extruded or deposited) or may be located interior to the nozzle (or even upstream of the nozzle) prior to extrusion. Still further, a portion of material can be partially disposed within the nozzle and partially exterior to the nozzle. Once extruded and cured (e.g., hardened), portions of material may comprise portions of the final 3D printed structure.

As previously described, a material <NUM> is extruded through and from nozzle <NUM>. The material exiting nozzle <NUM> may be characterized herein as being "extruded", "printed", "ejected" or "deposited". Material <NUM> could comprise any kind of printable and/or extrudable material. Different embodiments could use materials including, but not limited to: an ink, a resin, an acrylic, a polymer, a thermoplastic material, a thermosetting material, a light-curable material, or combinations thereof. Some embodiments could also utilize filler materials incorporated into an extruded or printed material. For example, a filler material incorporated into an extruded material may be a powdered material or dye designed to impart desired color or color patterns or transitions, metallic or plastic particles or shavings, or any other powdered mineral, metal, or plastic. In at least some embodiments, therefore, material <NUM> may thus be a composite material. In one embodiment, material <NUM> may be a thermoplastic material that may be heat cured (i.e., heated above its glass transition temperature for printing and then cooled to form a relatively rigid, or non-pliable, printed structure).

For purposes of consistency and convenience, a first direction <NUM> (shown schematically in <FIG>) is defined relative to nozzle <NUM>. First direction <NUM> is a direction extending along a central axis of nozzle <NUM> and defines an "extruding direction", i.e., a direction along which material is extruded from, or pushed from, nozzle <NUM>. In embodiments where nozzle <NUM> is primarily kept in a fixed orientation and raised vertically away from base component <NUM>, first direction <NUM> may remain approximately perpendicular with an outer surface <NUM> of base component <NUM>, as depicted in the embodiment of <FIG>.

However, in other embodiments where the orientation of nozzle <NUM> may change with respect to a base component, as shown in the embodiment of <FIG>, first direction <NUM> may be characterized as remaining approximately parallel with a central axis of the formed 3D printed structure such that nozzle <NUM> is always extruding material onto the end, or most recently formed, portion of the structure.

A second direction <NUM> is characterized as a direction that is approximately perpendicular to first direction <NUM>. Although shown in the embodiments as oriented in a particular widthwise direction, it should be understood that second direction <NUM> is representative of any direction perpendicular to first direction <NUM>. For example, second direction <NUM> may be characterized as a radial direction with respect to first direction <NUM>. In some cases, first direction <NUM> may be characterized as an axial direction. In embodiments where nozzle <NUM> is primarily kept in fixed orientation with respect to base component <NUM>, as in the embodiment of <FIG>, second direction <NUM> may be approximately parallel with outer surface <NUM> of base component <NUM>. However, in embodiments where the orientation of nozzle <NUM> may change relative to a base component, as shown in <FIG>, second direction <NUM> may still be characterized as being perpendicular to first direction <NUM>, and may generally be approximately parallel with a lateral or widthwise direction of a portion of a structure adjacent to nozzle <NUM>.

The exemplary embodiment contemplates "extruding" (i.e., thrusting or pushing) portions of material through the nozzle, which may generate forces and pressures within the material initially directed along first direction <NUM>. As portions of material exit nozzle <NUM>, however, contact with base component <NUM> and/or portions of material already formed on base component <NUM> may result in a change of flow direction from being primarily along first direction <NUM>, to being primarily along second direction <NUM>. In other words, when pushed against either base component <NUM> or an adjacent portion of material, the recently extruded portions of material may tend to flow, or spread, outwardly along second direction <NUM>. This flow may be alternatively characterized as "outward spreading" as it tends to occur in a direction that is radially outward from the initial stream of material extruded from nozzle <NUM> in first direction <NUM>. In embodiments where a structure is formed with a longitudinal axis oriented in first direction <NUM>, this outward spreading may be oriented along a lateral dimension (or widthwise) dimension of the 3D printed structure.

For purposes of characterizing the dimensions of portions of material oriented in second direction <NUM>, the term "cross-sectional area" is used to refer to the cross-sectional area of a portion of material taken along second direction <NUM>. In particular, the cross-sectional area is generally taken through a plane that is (like second direction <NUM>) perpendicular to first direction <NUM>. In at least some embodiments, the portions of material may spread uniformly outwardly in the second direction <NUM>, so that the cross-sectional area is approximately circular. In such cases, the term "diameter" may also be used to characterize the dimensions of the portion of material oriented along second direction <NUM>. In particular, any approximately circular cross-sectional area for a portion may have a unique corresponding diameter.

As shown in <FIG>, in the exemplary printing process, material <NUM> is extruded from nozzle <NUM> onto base component <NUM>. In <FIG>, a first portion of material <NUM> is extruded directly onto outer surface <NUM> of base portion <NUM>. As nozzle <NUM> is raised from a position in direct contact with base component <NUM> (<FIG>) to a position disposed a distance <NUM> from base component <NUM> (<FIG>), first portion of material <NUM> undergoes spreading in second direction <NUM>. As material <NUM> is continually extruded from nozzle <NUM>, first portion of material <NUM> expands from having a first cross-sectional area <NUM> (<FIG>) to having a second cross-sectional area <NUM> (<FIG>), which is larger than first cross-sectional area <NUM>. In this case, since the approximate distance of nozzle <NUM> to base component <NUM> is unchanged between the configuration of <FIG> and the configuration of <FIG>, first portion of material <NUM> retains an approximately constant height and the outward flow of material can be seen to be partially due to the constriction of first portion of material <NUM> between the end of nozzle <NUM> and base component <NUM>.

Moving next to the configuration shown in <FIG>, first portion of material <NUM> may stop spreading in second direction <NUM> as first portion of material <NUM> is cured (by cooling below a predetermined temperature or another mechanism) and as nozzle <NUM> is raised to a position a second distance <NUM> from base component <NUM>. Here, first portion of material <NUM> has formed a first portion of structure <NUM>, as seen by comparing the geometry of first portion of material <NUM> in <FIG> with a corresponding first portion <NUM> of structure <NUM> shown in <FIG>. As seen in <FIG>, a second portion of material <NUM>, generally continuous with first portion of material <NUM>, is extruded from nozzle <NUM> onto first portion of material <NUM>. Being pushed down against first portion of material <NUM>, and
partially constricted between nozzle <NUM> and first portion of material <NUM>, second portion of material <NUM> spreads outwardly in second direction <NUM>.

In the next configuration of the process shown in <FIG>, second portion of material <NUM> has spread until second portion <NUM> of structure <NUM> has been formed, as seen by comparing <FIG> and <FIG>. Together, first portion <NUM> of structure <NUM> and second portion <NUM> of structure <NUM>, formed by first portion of material <NUM> and second portion of material <NUM>, respectively, comprise a bottom most portion of structure <NUM> with a generally increasing cross-sectional area (and diameter) from first portion <NUM> to second portion <NUM>. Correspondingly, in the configuration indicated in <FIG>, second portion of material <NUM> has a larger cross-sectional area <NUM> than the cross-sectional area <NUM> of first portion of material <NUM>. Here it may be understood that the cross-sectional areas of each portion varies through the height of each portion so that cross-sectional area <NUM> and cross-sectional area <NUM> are only representative cross-sectional areas.

As indicated in <FIG>, the contact angle <NUM> with respect to outer surface <NUM> for the portion of structure <NUM> formed by first portion of material <NUM> and second portion of material <NUM> is greater than <NUM> degrees. In an exemplary embodiment, contact angle <NUM> may be in the range between <NUM> and <NUM> degrees. Such large contact angles allow for a wider variety of part geometries, with both convex and concave portions being configurable at the bottom-most layer of the structure to enhance design and in some cases functionality of the structure.

In the configuration shown in <FIG>, a third portion of material <NUM> has been extruded onto second portion of material <NUM>. Furthermore, a fourth portion <NUM> of material <NUM> has been extruded onto third portion of material <NUM>. Here, third portion of material <NUM> has a cross-sectional area <NUM> that is substantially greater than a cross-sectional area <NUM> of fourth portion of material <NUM>.

At this stage, in some embodiments, curing control devices <NUM> may be applied to increase the speed at which third portion of material <NUM> and/or fourth portion of material of material <NUM> are cured. This may help ensure that these portions are stable enough to support additional extruded material on top of fourth portion of material <NUM>, and to ensure these portions are cured before their geometries are distorted due to material flow under gravity. In an embodiment where material <NUM> is a thermoplastic material, curing control devices <NUM> could be cooling devices that supply cooled air below a predetermined temperature (associated with hardening) to local areas of structure <NUM> (i.e., areas corresponding to first portion of material <NUM> and/or second portion of material <NUM>). Once hardened, third portion of material <NUM> and fourth portion of material <NUM> correspond to a third portion <NUM> and a fourth portion <NUM> of structure <NUM>.

In <FIG>, a fifth portion of material <NUM> is extruded onto fourth portion of material <NUM> to form a fifth portion <NUM> of structure <NUM> that comprises the top-most portion of structure <NUM>. As indicated in <FIG>, fifth portion of material <NUM> has a cross-sectional area <NUM> that is substantially greater than the cross-sectional area <NUM> of fourth portion of material <NUM>.

Once completed, nozzle <NUM> stops extruding material and pulls away from the formed structure <NUM> shown in <FIG>. As seen in <FIG>, corresponding to the varying cross-sectional areas of the portions of material used to form structure <NUM>, different portions of structure <NUM> have different cross-sectional areas. For example, a bottom portion of structure <NUM>, which includes first portion <NUM>, second portion <NUM> and third portion <NUM>, has a representative cross-sectional area <NUM>. Fourth portion <NUM>, forming the middle of structure <NUM>, has a representative cross-sectional area <NUM>, which is less than cross-sectional area <NUM>. Finally, a top portion of structure <NUM>, comprised of fifth portion <NUM> of structure <NUM>, has a cross-sectional area <NUM>, which is greater than cross-sectional area <NUM>. Thus, it may be seen that this process allows for the formation of structures that vary in cross-sectional geometry from bottom to top, including structures that go from wide, to narrow to wide again. Moreover, this exemplary process could be used to form printed structured having different portions with any combinations of variable cross-sectional areas.

Generally, the formation of portions having different cross-sectional areas may be achieved by varying one or more extrusion control parameters throughout the formation of a 3D printed structure. As already discussed, the amount of spreading of material in the second direction (also referred to as "outward spreading") is due to various factors including flow rate, temperature (related to material viscosity), constriction forces between the nozzle and an underlying portion of material (or base component), as well as other factors. Therefore, adjusting one or more of these parameters throughout the printing of a 3D structure will result in portions of varying outward spread, and therefore varying cross-sectional areas (or diameters).

In order to illustrate an exemplary method for varying an extrusion parameter in the process shown in <FIG>, a flow rate parameter is indicated schematically in each of <FIG> by an arrow oriented along first direction <NUM>. In particular, the magnitude of the flow rate at various stages in the printing process is depicted by variations in arrow length (with shorter arrows indicating relatively slower flow rates and longer arrows indicating relatively faster flow rates). As seen in <FIG>, the flow rate may generally vary according to the desired cross-sectional area or diameter of a portion. For example, in <FIG>, the flow rate <NUM> of material <NUM> is relatively slow compared to a faster slow rate <NUM> of material <NUM> shown in <FIG>. This increase in flow rate may result in a slightly larger cross-sectional area for second portion of material <NUM> compared to the cross-sectional area of first portion of material <NUM>, as more material is laid down for the same duration of time. As third portion of material <NUM> is extruded, the flow rate of material <NUM> is slower than flow rate <NUM>, to create a smaller cross-sectional area for the corresponding portion of structure <NUM>. As shown in <FIG>, as fourth portion of material <NUM> is extruded, the flow rate <NUM> may obtain a minimum value compared to other flow rates occurring during the process, as fourth portion <NUM> (corresponding to fourth portion <NUM> of structure <NUM>) has the smallest cross-sectional area of all portions of structure <NUM>. Finally, to achieve a gradually increased cross-sectional area for fifth portion of material <NUM>, flow rate <NUM> is increased again relative to flow rate <NUM>.

For purposes of clarity, the embodiments depict changes in the flow rate of material <NUM> as a primary way of controlling the resulting diameter of a formed portion for structure <NUM>. However, it will be understood that any other extrusion control parameters could also be varied, possibly in combination with other extrusion control parameters. For example, another means for controlling the degree of outward spreading of material is the nozzle withdrawal rate, since the constriction of material between the end of the nozzle and underlying material can be a factor in the degree of outward spreading. Thus, for example, forming relatively narrow portions of a structure, such as third portion <NUM> of structure <NUM>, could be accomplished by increasing the nozzle withdrawal rate so that material is built up vertically with less outward spreading. In at least some embodiments, third portion <NUM> could be formed with an increased nozzle withdrawal rate (relative to the nozzle withdrawal rate used for forming other portions) and a reduced flow rate (relative to the flow rates used for forming other portions).

Still other embodiments could use variations in nozzle temperature (a proxy for material temperature), ambient temperature, ambient pressure as well as any other extrusion control parameters to vary the geometry (e.g., cross-sectional area) of different portions and/or other material characteristics of different portions (e.g., density, hardness, etc.).

As seen in <FIG>, this exemplary embodiment may use a fixed nozzle cross-sectional area <NUM> for extruding material <NUM>. Moreover, cross-sectional area <NUM> is seen to be substantially smaller than the cross-sectional areas of various portions of structure <NUM>. For example, cross-sectional area <NUM> is substantially less than cross-sectional area <NUM> of third portion <NUM> of structure <NUM>, which is the narrowest portion of structure <NUM>. In still other embodiments, of course, the cross-sectional area (or diameter) of nozzle <NUM> could be varied to increase (or decrease) the flow rate of material <NUM>.

The exemplary process shown in <FIG> may be useful in improving the speed of forming 3D printed structure <NUM>. Specifically, when compared to methods used in other embodiments, where a structure is formed by moving nozzle <NUM> to form horizontal layers and vertically to build subsequent layers on existing layers, this exemplary process may provide substantially decreased printing times. This may occur since alternative embodiments require a nozzle to move through a path that corresponds to the entire volume of the desired 3D printed part, while the exemplary method may hold the nozzle at a fixed horizontal location and use outward spreading of the material to fill out the intended 3D volume without requiring the nozzle to pass over every horizontal location where material is to be located in the final structure.

<FIG> illustrate another embodiment of a process of forming a 3D printed structure from a material <NUM>. Referring to <FIG>, 3D printed structure <NUM>, comprising a hook or hook-like fastener, is formed using a similar extrusion process described above and shown in <FIG>. However, in contrast to the embodiment of <FIG>, the process of <FIG> includes moving nozzle <NUM> in more than just a single direction (e.g., a vertical direction) away from a base component. In particular, as described herein, nozzle <NUM> may be moved in two approximately perpendicular directions (e.g., a vertical direction and a horizontal direction) to form structure <NUM>.

Starting with <FIG>, nozzle <NUM> extrudes a first portion of material <NUM> to form a base portion of structure <NUM>, which is bonded to base component <NUM>. Next, as shown in <FIG>, nozzle <NUM> is raised in a first direction <NUM>, for example, a vertical direction, as second portion of material <NUM> is extruded. As shown in a subsequent configuration in <FIG>, in order to form a curved portion for structure <NUM>, nozzle <NUM> may be moved in both the first direction <NUM> and a second direction <NUM> (e.g., a horizontal direction), as third portion of material <NUM> is extruded from nozzle <NUM>. Moreover, in at least some embodiments, curing control device <NUM> may be applied to third portion of material <NUM> to decrease curing time so that third portion of material <NUM> maintains a desired curved and overhanging geometry against the force of gravity that may otherwise cause material <NUM> to flow down. In <FIG>, nozzle <NUM> continues to form a curved portion for structure <NUM>, as fourth potion of material <NUM> is extruded while nozzle <NUM> moves in both the first direction <NUM> and the second direction <NUM>.

In at least some embodiments, nozzle <NUM> may be capable of changing its orientation with respect to another component or part, such as base component <NUM>. As shown in <FIG>, in one embodiment, nozzle <NUM> can be rotated by an angle <NUM> so that nozzle <NUM> is no longer oriented in an approximately perpendicular manner to base component <NUM>. Instead, nozzle <NUM> may be oriented so that extruded material flows from nozzle <NUM> along a direction associated with central axis <NUM> of fifth portion of material <NUM>. With nozzle <NUM> oriented along the direction of central axis <NUM>, material <NUM> extruded from nozzle <NUM> may undergo outward spreading that is in a direction approximately perpendicular to central axis <NUM> of fifth potion of material <NUM>. This perpendicular direction is indicated by lateral axis <NUM>.

By adjusting the orientation of nozzle <NUM> to better align with a central axis of an adjacent portion of a 3D printed structure, extruded material may build up in a direction along the central axis, rather than building up in a vertical direction or other direction that might create an undesired excess of material in various locations as the structure is formed. Although not shown, some embodiments could use supporting structures that may provide support during formation of a structure, but which may be removed after the structure has been completed and is fully cured.

By moving nozzle <NUM> in both the vertical and horizontal direction, in combination with rotating or tilting the orientation of nozzle <NUM>, printing system <NUM> and the processes described above can be used to form parts having a wide variety of geometries and shapes, including portions with various kinds of curved surfaces. Such curved surfaces may be constant in curvature or non-constant in curvature (e.g., compound curves).

Embodiments may include provisions for adjusting one or more extrusion control parameters in response to feedback from sensory information. In some embodiments, an extrusion process can adjust one or more extrusion control parameters in response to optical information.

<FIG> illustrates an embodiment of a process for adjusting one or more extrusion control parameters in response to optical information. Generally, one or more of the steps depicted in <FIG> may be performed by extrusion control system <NUM>, sensor system <NUM> and/or any other system or component of printing device <NUM>. 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 extrusion control system <NUM>.

In a first step <NUM>, extrusion control system <NUM> may receive optical information. In some embodiments, the optical information may be received from one or more sensors, such as optical sensing device <NUM>. The received optical information can include any kinds of analog and/or digitals signals that include information related to one or more images captured by optical sensing device <NUM>.

In step <NUM>, extrusion control system <NUM> may use the optical information to characterize the outward spreading for a particular portion of material. The outward spreading of a portion of material could be characterized in various ways. For example, in some embodiments, the outward spreading could be characterized by the cross-sectional area, diameter, or extension along a particular predetermined direction, of the portion of material at a given instant of time. In other embodiments, the outward spreading could be characterized by an outward spreading rate, which is the rate at which the portion of material is spreading in the outward direction. Depending on the application, it may be more useful to use either the absolute extent of spreading of a portion of material at a particular time or the rate of outward spreading of the portion of material at a particular time. In still other embodiments, other characterizations of outward spreading could be used. For purposes of convenience, the particular characterization of outward spreading used for a portion of material at a particular time is referred to as an outward spreading value.

In different embodiments, a measured or sensed outward spreading value could be determined using optical information. In some embodiments, one or more images captured by optical sensing device <NUM> of a portion of extruded material may analyzed to determine an absolute extent of outward spreading in one or more directions, and/or an outward spreading rate. Any known algorithms for analyzing image data can be used to determine measured or sensed values for absolute outward spreading and/or an outward spreading rate.

In step <NUM>, extrusion control system <NUM> may retrieve a predicted outward spreading value at a given time from memory (e.g., from a database). In contrast to the measured or sensed outward spreading value, the predicted outward spreading value is a value that is predetermined based on assumed values of material flow rate, nozzle withdrawal rate, extrusion temperature, as well as using possibly other factors. Thus, the predicted outward spreading value indicates how spreading is predicted to occur so that the desired part geometry can be achieved. The predicted outward spreading value could vary from the sensed outward spreading value due to various factors, including, but not limited to: printed material imperfections, variations in base component materials and geometries, variations in ambient conditions (e.g., temperature and pressure) as well as possibly other factors.

In step <NUM>, the sensed outward spreading value is compared with the predicted outward spreading value. If the sensed outward spreading value is within a predetermined tolerance of the predicted outward spreading value, the system may continue extruding material without any adjustments. However, if the sensed outward spreading value differs from the predicted outward spreading value by more than a predetermined tolerance, extrusion control system <NUM> may proceed to step <NUM> to make adjustments to one or more extrusion control parameters.

<FIG> illustrates a schematic view of a process in which optical information is used to provide feedback to an extrusion control system. Referring to <FIG>, optical sensing device <NUM> is positioned to capture optical information about a portion of material <NUM> after portion of material <NUM> has been extruded from nozzle <NUM>. This optical information can be used to determine a sensed outward spreading diameter <NUM>, which is a real-time measurement of the approximate diameter of portion of material <NUM> as it spreads outwardly on base component <NUM>. In the schematic view of nozzle <NUM> and portion of material <NUM> of <FIG>, sensed spreading diameter <NUM> of portion of material <NUM> is shown for a particular instant of time.

In the chart of <FIG>, sensed outward spreading diameter <NUM> is plotted as a function of time. Additionally, predicted outward spreading diameter <NUM> is also plotted as a function of time. In this case, predicted outward spreading diameter <NUM> follows an approximately straight line, which indicates a generally constant spread of material in time (e.g., a constant spreading rate). It will be understood that predicted outward spreading diameter <NUM> is only one exemplary type of function, which is used here for clarity, and in other embodiments the behavior of predicted outward spreading diameter <NUM> could be non-linear.

At time T1, predicted outward spreading diameter <NUM> and sensed outward spreading diameter <NUM> may be approximately the same. In other words, at this point, sensed outward spreading diameter <NUM> may be within a predetermined tolerance of predicted outward spreading diameter <NUM>. This indicates that portion of material <NUM> is spreading in the desired manner to form the first portion or layer of the intended 3D printed structure. At a later time T2, however, sensed outward spreading diameter <NUM> falls substantially below predicted outward spreading diameter <NUM>, indicating that portion of material <NUM> is not spreading in the desired manner (e.g., at the desired rate). As extrusion control system <NUM> detects this relative drop in the sensed outward spreading diameter <NUM>, extrusion control system <NUM> may adjust the flow rate or extrusion rate of material <NUM> to induce faster and/or more spreading in portion of material <NUM>. In particular, at time T2, the flow rate is increased from the initial flow rate <NUM> (associated with time T1) to a new increased flow rate <NUM>. Following time T2, sensed outward spreading diameter <NUM> begins to increase and may fall once again with the predetermined tolerance of predicted outward spreading diameter <NUM>.

At a later time T3, sensed outward spreading diameter <NUM> increases above predicted outward spreading diameter <NUM>, thereby indicating that portion of material <NUM> is flowing too -rapidly and possibly extending too far. Therefore, at time T3, the flow rate is adjusted to a new reduced flow rate <NUM>, which is a substantially lower flow rate than both initial flow rate <NUM> (associated with time T1) and flow rate <NUM> (associated with time T2). Following time T3, sensed outward spreading diameter <NUM> begins to decreased and may fall once again with the predetermined tolerance of predicted outward spreading diameter <NUM>. This process may therefore be iterative, providing a means of continuously adjusting the flow rate (or other extrusion control parameter) in response to sensed optical information about how a portion of material is spreading. Moreover, though the exemplary process is shown in <FIG> for a specific portion of material <NUM>, corresponding to the lower layer of material in a printed structure, this process may be used for all portions and layers of material in forming a printed structure.

<FIG> illustrates an embodiment of a process for applying a curing control device to a recently extruded portion of material in response to sensed information about the recently extruded portion of material. In step <NUM>, extrusion control system <NUM> may received sensed information from one or more sensors about the extruded portion and/or ambient conditions. Exemplary sensors that may supply information to extrusion control system <NUM> include temperature sensors, pressure sensors, flow rate sensors, optical sensors as well as possibly other kinds of sensors. In step <NUM>, extrusion control system <NUM> uses the sensed information to determine if the recently extruded portion of material is cured. For example, in some embodiments optical information could be used to determine if an extruded portion is stable or non-moving, and therefore likely cured. If the recently extruded portion is not yet cured and it necessary to set the portion of material before extruding more material, a curing control device may be used to cure the portion of material directly. In this case, extrusion. control system <NUM> moves to step <NUM> to apply cooling and/or UV curing to the extruded portion.

Of course, in some embodiments, direct application of a curing control device to one or more portions of an extruded material to increase the speed of curing can be done automatically, without relying on sensed information. In particular, as already depicted in earlier embodiments, direct curing (e.g., cooling) can be done to increase curing speed as part of the process of forming portions with particular geometries that may require quick curing to remain stable during the printing process.

Embodiments can include provisions for applying three-dimensional printed structures that may be anchored to a base component, such as a textile material. In embodiments using an extrusion process that results in outward spreading of extruded material, it may be possible to induce outward spreading of material on an opposing side of a base component from the side where the nozzle is located. This may allow for the creation of anchoring portions that might not be achievable with alternative processes that require a nozzle to pass above all locations within a volume associated with a printed structure.

<FIG> illustrate schematic views of an embodiment of a process for printing a 3D anchoring structure <NUM> that is anchored directly to base component <NUM> as it is formed. As seen in <FIG>, the exemplary process may utilize nozzle <NUM>, base component <NUM> and a molding component <NUM>. Nozzle <NUM> may be disposed on a first side <NUM> of base component <NUM>, while molding component <NUM> may be disposed on a second side <NUM> of base component <NUM>. Moreover, to provide fluid communication between first side <NUM> and second side <NUM>, base component <NUM> includes an opening <NUM>.

As seen in <FIG>, material <NUM> is extruded from nozzle <NUM> and flows through opening <NUM>. With molding component <NUM> in place against second side <NUM> of base component <NUM>, first portion of material <NUM> flows into cavity <NUM> of molding component <NUM>. In <FIG>, first portion of material <NUM> fills the entirety of cavity <NUM>. Because opening <NUM> of cavity <NUM> has a diameter <NUM> (see <FIG>), first portion of material <NUM> obtains a diameter <NUM> directly adjacent to second side <NUM> of base component <NUM>. Moreover, since diameter <NUM> of first portion of material <NUM> is greater than diameter <NUM> of opening <NUM>, first portion of material <NUM> is prevented from passing through opening <NUM>.

In <FIG>, a second portion of material <NUM> is extruded from nozzle <NUM> and begins to spread laterally on first side <NUM> of base component <NUM>. In the <FIG>, second portion of material <NUM> is seen to obtain a diameter <NUM> that is substantially larger than diameter <NUM> of opening <NUM>. Thus, the anchoring structure <NUM> is formed in a manner such that anchoring structure <NUM> cannot be separated from base component <NUM> without irreversibly damaging either base component <NUM> or anchoring structure <NUM>.

With anchoring structure <NUM> formed as in the process depicted in <FIG>, additional extruded material can be added to form various 3D structures extending away from first side <NUM> of base component <NUM>. These structures could include any of the 3D printed structures already discussed, such as cleats, hooks, knob-like fasteners as well as other structures.

Anchoring of a structure may be achieved using a single aperture, or could be accomplished using two or more apertures. The number of apertures used could vary according to the type of base component used as well as the geometry of the formed 3D structure.

In different embodiments, the type of molding component used could vary. For example, molding components could vary in size, cavity shape, material construction as well as in other properties. Any kinds of molds known in the art could be used. The type of mold used could be selected according to the desired geometry of the final structure (especially the geometry of the part on second side <NUM> of base component <NUM>), required part sizes, temperature tolerances of the mold material, as well as possibly other factors.

As one example of variations in a molding component, <FIG> illustrates two alternative designs. Referring to <FIG>, a first molding component <NUM> has a cavity <NUM> with a generally rectangular geometry, as opposed to the approximately rounded (or dome-like) geometry of cavity <NUM> of molding component <NUM> in <FIG>. Also, second molding component <NUM> has a cavity <NUM> with a generally irregular geometry. These variations in cavity geometry may result in corresponding variations in the geometry of the formed 3D structures (for the portions of the structures on the side of the base component where the mold is placed).

In some other embodiments, anchoring structures could be created by pushing extruded material through a material, such as a knit, mesh or braided fabric, which may not include distinct apertures. Such an embodiment is depicted in <FIG>. Here, anchored structure <NUM> includes a first portion <NUM> on first side <NUM> of base component <NUM>, and a second portion <NUM> on a second side <NUM> of base component <NUM>. First portion <NUM> and second portion <NUM> are connected by extruded material portions <NUM>, which have been pushed through the open spaces in base component <NUM>.

<FIG> illustrates an exemplary embodiment of a printing device <NUM> along with two different methods for holding or supporting articles that may receive printed structures. As seen in <FIG>, in some embodiments, a flat upper portion <NUM> may be placed on a tray <NUM> that is housed within printing device <NUM>. In other embodiments, an assembled article of footwear <NUM> may be associated with a footwear holding device <NUM>, which may be inserted into printing device <NUM>. In some embodiments, footwear holding device <NUM> may be configured to present an approximately flattened portion of article of footwear <NUM> to a nozzle for printing. An exemplary footwear holding device that could be used is disclosed in Miller, <CIT> (now <CIT>) and titled "Holding Assembly for Articles".

General systems and methods for printing 3D structures directly onto portions of articles, including articles comprised of textiles are disclosed in Jones et al. , <CIT> (now <CIT>), and entitled "Footwear Assembly Method with 3D Printing," and hereafter referred to as the "3D Printing" application. In particular, the 3D printing application includes systems and methods for printing onto textiles or ibase components that may not have hydrophobic or non-wetting surfaces. The 3D printing application also teaches systems and methods for printing onto irregular surfaces such as those encountered in woven, knit, braided or other kinds of fabrics or textile materials.

<FIG> is an isometric view of an embodiment of an article of footwear <NUM>. As seen in <FIG>, article of footwear <NUM> includes a plurality of 3D printed structures in the form of fasteners that may be engaged by a lace or other fastening provision. Specifically, article of footwear <NUM> includes a set of knob-like fasteners <NUM> that have been formed using a 3D printing process as previously discussed and shown in <FIG>. Additionally, article of footwear <NUM> includes a set of hook fasteners <NUM> that have been formed using a 3D printing process as previously discussed and shown in <FIG>. Thus, it may be seen that the exemplary printing (specifically, extrusion) process discussed in these embodiments can be used to form functional structures, such as fasteners, for articles of footwear and as well as other kinds of articles.

Embodiments can include further provisions to improve the speed of forming 3D printed structures. In some embodiments, a 3D printed structure can be formed using two different printing processes to form at least two different portions of the 3D printed structure. In some cases, for example, a first portion of a 3D printed structure may be formed using a first 3D printing process, while a second portion of the 3D printed structure may be formed using a second 3D printing process that is distinct from the first 3D printing process.

<FIG> illustrates a schematic view of an embodiment of a 3D printed structure <NUM>, or simply structure <NUM>, which is attached to base component <NUM>. In the embodiment of <FIG>, structure <NUM> has the form of a cleat for use with an article of footwear. However, in other embodiments similar printed structures could be formed in a variety of different shapes and for different purposes. In other words, the principles discussed for structure <NUM> are not intended to be limited to making cleats or similar parts.

In the embodiment depicted in <FIG>, structure <NUM> is comprised of two different portions. In particular, structure <NUM> includes an outer shell portion <NUM> and an inner portion <NUM>. As discussed in further detail below, outer shell portion <NUM> and inner portion <NUM> may differ in one or more characteristics, including size, volume, shape, material, color, as well as possibly other characteristics.

In different embodiments, the geometry of outer shell portion <NUM> can vary. In some embodiments, outer shell portion <NUM> may have a generally rounded geometry. In some cases, for example, outer shell portion <NUM> could have a dome-like geometry. In other embodiments, outer shell portion <NUM> could have a generally conical geometry. In some cases, for example, outer shell portion <NUM> could have a truncated conical geometry.

In at least some embodiments, outer shell portion <NUM> may include one or more openings. In some embodiments, outer shell portion <NUM> could include a single opening. In other embodiments, outer shell portion <NUM> could include two openings. In still other embodiments, outer shell portion <NUM> could include three or more openings. In the embodiment depicted in <FIG>, outer shell portion <NUM> includes a single opening <NUM>.

In different embodiments, the location of one or more openings in outer shell portion <NUM> could vary. In some embodiments, one or more openings could be disposed on a portion of outer shell portion <NUM> located adjacent to base component <NUM>. In other embodiments, one or more openings could be disposed on a portion of outer shell portion <NUM> disposed furthest from base component <NUM>. In the embodiment depicted in <FIG>, opening <NUM> of outer shell portion <NUM> is disposed at tip portion <NUM> of outer shell portion <NUM>.

In some embodiments, outer shell portion <NUM> may comprise a generally thin portion of material. In some embodiments, the thickness <NUM> of outer shell portion <NUM> may be substantially less than a diameter <NUM> of outer shell portion <NUM>. Further, in some embodiments, the thickness <NUM> of outer shell portion <NUM> may be substantially less than a height <NUM> (as measured from base component <NUM>) of outer shell portion <NUM>. In an exemplary embodiment, thickness <NUM> of outer shell portion <NUM> may have a value approximately in the range between <NUM> millimeters and <NUM> millimeters. In still other embodiments, thickness <NUM> could be greater than <NUM> millimeters.

Inner portion <NUM> may generally fill the interior region bounded by outer shell portion <NUM>. Therefore, the geometry of inner portion <NUM> may generally correspond to the geometry of outer shell portion <NUM>. In embodiments where outer shell portion <NUM> has an approximately dome-like geometry, inner portion <NUM> may also have a dome-like geometry. In embodiments where outer shell portion <NUM> has a conical (including truncated conical) geometry, inner portion <NUM> may have a similar conical geometry. In other embodiments, however, it is contemplated that the interior region bounded by outer shell portion <NUM> does not have a geometry corresponding to the geometry of the exterior side of outer shell portion <NUM>. In such cases, the geometry of inner portion <NUM> may generally correspond to the geometry induced by the shape of the interior side of outer shell portion <NUM>.

In some embodiments, an outer shell portion may comprise a relatively small percentage of the total volume of a 3D printed structure while an inner portion can comprise a large percentage (at least a majority) of the total volume of the 3D printed structure. For example, in the embodiment of <FIG>, outer shell portion <NUM> is seen to have a first volume comprising a first percentage of the total volume of structure <NUM>. Also, inner-portion <NUM> is seen to have a second volume comprising a second percentage of the total volume of structure <NUM>. In an exemplary embodiment, the second percentage is substantially greater than the first percentage, so that outer shell portion <NUM> only comprises a small percentage of the total volume of structure <NUM>, while inner portion <NUM> comprises a large percentage of the total volume of structure <NUM>.

Values of the first percentage and the second percentage can vary from one embodiment to another. In some embodiments, the first percentage may have a value approximately in the range between <NUM> percent and <NUM> percent. Correspondingly, in such embodiments, the second percentage may have a value approximately in the range between <NUM> percent and <NUM> percent. Here it is to be understood that the total of the first percentage and the second percentage should equal <NUM> percent in embodiments where structure <NUM> consists of only outer shell portion <NUM> and inner portion <NUM>.

In some embodiments, outer shell portion <NUM> may be formed using a first 3D printing process, while inner portion <NUM> may be formed using a second 3D process that is distinct from the first 3D printing process. Using different printing processes for each portion may allow for improvements in efficiency and/or manufacturing speed. For example, the following embodiments illustrate printing methods where outer shell portion <NUM> is formed using a relatively slow printing process, while inner portion <NUM> is formed using a relatively faster printing process. Because inner portion <NUM> comprises a majority of the volume of structure <NUM>, such printing methods may allow structure <NUM> to be formed in a significantly shorter period of time than if the volume of structure <NUM> were printed using the relatively slow printing process.

As shown in <FIG>, in at least some embodiments, outer shell portion <NUM> and inner portion <NUM> may be formed using different nozzles and/or print heads. In one embodiment, outer shell portion <NUM> may be formed using a first nozzle <NUM> while inner portion <NUM> may be formed using a second nozzle <NUM>. In some embodiments, first nozzle <NUM> has a first aperture <NUM> while second nozzle <NUM> has a second aperture <NUM>. In one embodiment, first aperture <NUM> may have a substantially smaller diameter than second aperture <NUM>. With this configuration, a greater total volume of material may flow through second aperture <NUM> than through first aperture <NUM> for a given interval of time.

Although some embodiments may use different nozzles to form outer shell portion <NUM> and inner portion <NUM>, other embodiments may use a single nozzle to form both outer shell portion <NUM> and inner potion <NUM>. Such an alternative embodiment is described below and shown in <FIG>.

In different embodiments, the materials comprising outer shell portion <NUM> and inner potion <NUM> could vary. In some embodiments, outer shell portion <NUM> may be comprised of a first material and inner portion <NUM> may be comprised of a second material. In some cases, the first material may be substantially identical to the second material. In other cases, the first material may be substantially different from the second material.

In different embodiments, the rigidities of the first material and the second material could vary. For example, when cured, the first material forming the outer shell portion may have a first rigidity, while the second material forming the inner portion may have a second rigidity when cured. In some embodiments, the second rigidity may be greater than the first rigidity. As an example, in some embodiments for a cleat structure, the first material could be a rubber to provide traction and give to the outer shell portion, while the inner portion may be a harder plastic to provide structure and support to the cleat structure. In other embodiments, the second rigidity could be less than the first rigidity. As an example, in some embodiments of a cleat structure, the first material could be hard rubber or plastic to provide strength and/or traction for the outer shell portion, while the second material could be a foam material for support and cushioning.

Of course in other embodiments still other combinations of materials could be used. In particular, the first material and the second material could be selected to achieve various combinations of materials that differ in properties including, but not limited to: weight, strength, cushioning, bonding compatibility with a base component as well as other material properties.

<FIG> illustrate schematic views of an embodiment of a process for forming structure <NUM>. As seen in <FIG>, outer shell portion <NUM> may be formed first using first nozzle <NUM>. As indicated schematically, outer shell portion <NUM> may be formed using a first 3D printing process. Specifically, the first 3D printing process includes moving first nozzle <NUM> horizontally over base component <NUM> so as to form a horizontal layer of outer shell portion <NUM> using extruded material <NUM>. Unlike the embodiments discussed previously and shown, for example, in <FIG>, the first 3D printing process does not involve substantial outward spreading of the printed (or extruded) material. Once a horizontal layer has been formed, for example printed layer <NUM> shown in <FIG>, first nozzle <NUM> may be raised an incremental amount in the vertical direction. At this point, as shown in <FIG>, first nozzle <NUM> may again move in a horizontal manner to form a subsequent layer of printed material <NUM> on top of printed layer <NUM>.

In at least some embodiments, once outer shell portion <NUM> has been fully formed, outer shell portion <NUM> could be cured prior to forming inner portion <NUM>. In some cases, the curing could be accomplished as outer shell portion <NUM> is formed. In other cases, the curing could be accomplished after outer shell <NUM> has been formed, but before inner portion <NUM> has been formed. In still other embodiments, however, outer shell portion <NUM> could be fully (or partially) cured after inner portion <NUM> is formed.

Once outer shell portion <NUM> has been formed by the first 3D printing process, first nozzle <NUM> may be moved away from outer shell portion <NUM>. As seen in <FIG>, second nozzle <NUM> may be moved to a position above opening <NUM>. At this point, a second 3D printing process may be used to fill interior void <NUM> of outer shell portion <NUM> with second material <NUM>. As shown in <FIG>, the second 3D printing process may involve maintaining second nozzle <NUM> in a substantially fixed position above opening <NUM> as second material <NUM> is extruded or otherwise deposited into interior void <NUM>. The second 3D printing process may continue until second material <NUM> fills the entirety of interior void <NUM>, thereby forming inner portion <NUM> of structure <NUM>.

The first 3D printing process used to form outer shell portion <NUM> and the second 3D printing process used to form inner portion <NUM> may be differ in one or more attributes. As already mentioned, the first 3D printing process comprises moving first nozzle <NUM> through a sequence of positions disposed in a horizontal plane to form a horizontal layer of material. Upon the formation of a horizontal layer, first nozzle <NUM> may be briefly raised in the vertical direction to form a subsequent horizontal layer. In contrast, the second 3D printing process comprises maintaining second nozzle <NUM> at an approximately fixed vertical and horizontal position, and extruding second material <NUM> through opening <NUM> of outer shell portion <NUM>. Unlike outer shell portion <NUM>, therefore, inner portion <NUM> is not formed via a process of printing a series of stacked horizontal layers, but is instead formed by forcing second material <NUM> into interior void <NUM>. It can therefore be seen that the resulting geometry of outer shell portion <NUM> is defined by the tooling path taken by first nozzle <NUM> during the first 3D printing process, while the resulting geometry of inner portion <NUM> is induced by the interior geometry of interior void <NUM>, and requires little to no movement of second nozzle <NUM>.

The first 3D printing process and the second 3D printing process may also be distinguished by the degree of outward spreading. The first 3D printing process may deposit material in very fine layers, which result in little to no outward spreading. In particular, the degree of outward spreading for material deposited using the first 3D printing process may be less than <NUM>% of the diameter of aperture <NUM> of first nozzle <NUM> (see <FIG>). In other words, material printed by first nozzle <NUM> may not spread to a size more than twice the diameter of first nozzle <NUM>. In contrast, the second 3D printing process relies on substantial outward spreading to fill interior void <NUM> of outer shell portion <NUM>. Thus, outward spreading of material extruded from second nozzle <NUM> may be many times larger than the diameter of aperture <NUM> of second nozzle <NUM> (see <FIG>). For example, in some embodiments, portions of material may spread to diameters of at least <NUM>% of the diameter of aperture <NUM>.

The exemplary process for forming structure <NUM> may allow for improvements in printing speed while maintaining precision for the geometry of printed structures. This is accomplished by printing a relatively thin outer shell portion having any desired geometry using a precisely controlled printing process and then filling in the interior of the outer shell portion by quickly extruding or otherwise depositing printed material into the interior. By forming only a thin outer shell for the structure using the first 3D printing process and forming a bulk of the volume using the second 3D printing process, the printing time of structure <NUM> may be decreased, as the second 3D printing process is generally a quicker than the first 3D printing process.

It will be understood that the process for forming outer shell portion <NUM> is only intended to be exemplary. In other embodiments, outer shell portion <NUM> could be formed using any known 3D printing process. Some exemplary printing processes include any of those previously mentioned.

<FIG> illustrate an alternative process for forming a 3D printed structure <NUM>. Generally, the process shown in <FIG> may be similar in at least some respects to the process shown for <FIG>. In particular, the process of <FIG> includes using a first 3D printing process and a second 3D printing process that may be different. However, in contrast to the embodiment shown in <FIG>, the embodiment depicted in <FIG> uses a single nozzle <NUM> to form both outer shell portion <NUM> and inner portion <NUM> of structure <NUM>. Although nozzle <NUM> may be used in both the first 3D printing process and the second 3D printing process, in at least some cases, the size of aperture <NUM> may be variable. Moreover, in some embodiments, other extrusion control parameters could be adjustable. By varying the size of aperture <NUM> and/or additional extrusion control parameters, nozzle <NUM> may be configured to extrude printing material <NUM> at a substantially higher flow rate during the second 3D printing process.

Although <FIG> illustrate an embodiment using a single material to form inner and outer portions of a printed structure, other embodiments could use different materials. For example, in some embodiments, following the formation of outer shell portion <NUM> by extruding a first material through nozzle <NUM>, a second material could be extruded through nozzle <NUM> to form inner portion <NUM>.

To ensure that an extruded material can completely fill the interior void of an outer shell portion, some embodiments can include outer shell portions with two or more openings. <FIG> is a schematic view of an embodiment of a 3D printing structure <NUM>, which may be formed using the first 3D printing process and second 3D printing process described above and shown in <FIG>. In the embodiment of <FIG>, printed structure <NUM> may include at least two openings: a first opening <NUM> and a second opening <NUM> in outer shell portion <NUM>. In this configuration, nozzle <NUM> may initially fill first opening <NUM>, then move to a position over second opening <NUM> and fill interior void <NUM> through second opening <NUM>. The use of multiple openings may facilitate the filling of the interior void, especially for larger outer shell portions and/or outer shell portions having complex geometries.

<FIG> illustrate a variety of different embodiments of 3D printed structures, as well as methods for forming 3D printed structures. In the embodiment shown in <FIG>, 3D printed structure <NUM> may comprise an outer shell portion <NUM> and an inner portion <NUM>. In this embodiment, outer shell portion <NUM> may be include multiple anchored portions <NUM>. In some embodiments, outer shell portion <NUM> includes seven anchored portions that are secured within base component <NUM>. However, in other embodiments, any other number of anchored portions could be used.

Anchored portions <NUM> can be formed in any manner. In at least some embodiments, anchored portions <NUM> can be formed using the printing process described above and shown in <FIG>. Specifically, in some cases, anchored portions <NUM> may be formed by extruding material <NUM> through an opening <NUM> in base component <NUM>, which is then received into a molding component <NUM> on an opposing side of base component <NUM>. In some cases, this process can be used to form each of the anchored portions <NUM> of structure <NUM>. In some cases, with anchored portions <NUM> formed, the remaining portions of outer shell portion <NUM> may be formed using the printing process described above and shown in <FIG>, i.e., by building up horizontal layers of outer shell portion <NUM>. In some embodiments, inner portion <NUM> may be formed using the printing process shown in <FIG>, i.e., by extruding material into an interior of outer shell portion <NUM>.

The configuration shown in <FIG> provides a structure <NUM> in which outer shell portion <NUM> is anchored to base component <NUM>, while inner portion <NUM> is not anchored to base component <NUM>. Thus, in at least some embodiments, outer shell portion <NUM> may act to retain inner portion <NUM>. In embodiments where inner portion <NUM> is comprised of a very soft filler material that might not be suitable for creating anchored portions (e.g., if inner portion <NUM> is comprised of a very soft foam), outer shell portion <NUM> may ensure that inner portion <NUM> stays attached to base component <NUM> and within outer shell portion <NUM>.

Of course in other embodiments, inner portion <NUM> could also be configured with one or more anchored portions. Using anchored portions with outer shell portion <NUM> and/or inner portion <NUM> may reduce the tendency of structure <NUM> to pull away or separate form base component <NUM>, which may be especially useful for materials that are not suitably bond compatible with base component <NUM> and/or for configurations where structure <NUM> may encounter large forces (e.g., with a ground or other surface) that might tend to stress material bonds between structure <NUM> and base component <NUM>.

<FIG> illustrate an embodiment of a process for forming a structure <NUM> with an outer shell portion <NUM> and an inner portion <NUM>. In the embodiment of <FIG>, inner portion <NUM> extends through opening <NUM> of outer shell portion <NUM> and includes an outwardly directed anchoring portion <NUM>. Outwardly directed anchoring portion <NUM> may be configured to attach to other components including fasteners (such as laces, cords, etc.). As with previous embodiments, outer shell portion <NUM> may be formed from a first 3D printing process that provides the necessary precision for achieving a desired geometry for structure <NUM>, while inner portion <NUM> may be formed using a second 3D process that can quickly fill the interior of outer shell portion <NUM> and form outwardly directed anchoring portion <NUM> via outward spreading of material.

<FIG> illustrate an embodiment of a process for forming a cleat structure <NUM>. In contrast to previous embodiments, the embodiment of <FIG> may not use an outer shell portion and an associated inner portion. Instead, as seen in <FIG>, a base portion <NUM> of cleat structure <NUM> may be formed by extruding a first material <NUM> onto base component <NUM>. Moreover, an outwardly extending anchoring portion <NUM> may be formed on top of base portion <NUM>. Next, a second material <NUM> may be extruded over outwardly extending anchoring portion <NUM> in order to form a tip portion <NUM> for cleat structure <NUM>. In at least one embodiment, second material <NUM> is a substantially softer material than first material <NUM> comprising base portion <NUM>, thereby providing improved flexibility for gripping surfaces at tip portion <NUM>. In some embodiments, an optional molding member <NUM> may be used to help define the geometry of tip portion <NUM> as second material <NUM> is extruded or otherwise disposed over base portion <NUM>.

In at least some embodiments, rather than forming tip portion <NUM> via 3D printing, tip portion <NUM> could be formed by another process and later assembled over extending anchoring portion <NUM>. For example, tip portion <NUM> could be a pre-formed cap that is manually placed over (e.g., assembled with) extending anchoring portion <NUM>. This manual assembly could be achieved if tip portion <NUM> is substantially flexible (e.g., made of rubber).

<FIG> illustrates a schematic bottom isometric view of an embodiment of an article of footwear <NUM>, including an upper <NUM> and a sole structure <NUM>. Referring to <FIG>, article <NUM> includes a plurality of cleat structures, including cleat structure <NUM> and cleat structure <NUM>.

<FIG> is a schematic view of an embodiment of a nozzle control system <NUM>, which may be used to operate a first nozzle <NUM> and a second nozzle <NUM> in an independent manner. Specifically, in at least some embodiments, first nozzle <NUM> and second nozzle <NUM> may be actuated to move independently of one another. In embodiments where two distinct printing materials are used, or where it is desirable to have nozzles of different aperture diameters, first nozzle <NUM> and second nozzle <NUM> may be used to form different portions of a structure. For example, in some embodiments, first nozzle <NUM> could be used to form the outer shell portion of a structure, while second nozzle <NUM> could be used to form an inner portion of a structure. Likewise, in some other embodiments, first nozzle <NUM> could be used to form a base portion of a structure, while second nozzle <NUM> could be used to form a top portion of the structure.

<FIG> is a schematic view of an embodiment of a process for controlling at least two nozzles that may move and print material independently of one another. In some embodiments, one or more of the following steps could be accomplished by nozzle control system <NUM>. In other embodiments, however, one or more other systems could perform one or more of the steps. Still further, in other embodiments some of these steps could be optional.

In step <NUM>, nozzle control system <NUM> may control first nozzle <NUM> to print a first portion of a structure. In some cases, the printing could be done by extruding the first material. Next, in a step <NUM>, nozzle control system <NUM> may align second nozzle <NUM> with the first portion of the structure formed using first nozzle <NUM>. In step <NUM>, nozzle control system <NUM> may control second nozzle <NUM> to print a second portion of the structure. In some cases, the printing could be done by extruding the second material.

It is contemplated that embodiments could use various methods for aligning, or registering, second nozzle <NUM> with a formed first portion of material. Due to slight variations in the formed first portion due to tolerances in the precision of many kinds of 3D printing processes; openings or other features in the first portion to which second nozzle <NUM> must be aligned, could vary slightly in their locations and/or geometries. In at least some embodiments, therefore, sensors could be used to locate the first portion and/or particular features of the first portion for alignment with second nozzle <NUM>. For example, in one embodiment, an optical sensing device associated with second nozzle <NUM> can be used to determine the location of an opening or other feature on a formed first portion, using algorithms known in the art for detecting visual features in image information. Thus, second nozzle <NUM> may be aligned using feedback from the optical sensing device. In other embodiments, any other alignment and/or registration provisions or features could be used to ensure that second nozzle <NUM> is properly aligned with first portion before the second portion is printed with second nozzle <NUM>.

Claim 1:
An article of apparel comprising:
a base component (<NUM>) having an outward-facing side and an inward-facing side; and
a 3D-printed material (<NUM>) that comprises a first portion (<NUM>) on the outward-facing side of the base component (<NUM>), a first anchoring portion (<NUM>) on the inward-facing side of the base component (<NUM>), and a first connecting portion extending between the outward-facing side and the inward-facing side, the first connecting portion connecting the first portion (<NUM>) to the first anchoring portion (<NUM>), the first connecting portion extending through a first opening (<NUM>) in the base component (<NUM>),
wherein the first portion (<NUM>) is in contact with a first surface on the outward-facing side of the base component (<NUM>) and the first anchoring portion (<NUM>) is in contact with a second surface on the inward-facing side of the base component (<NUM>) to restrict movement of the first portion (<NUM>) and the first anchoring portion (<NUM>) relative to the base component (<NUM>), and
wherein the first portion (<NUM>), the first anchoring portion (<NUM>), and the first connecting portion are integrally formed from the first 3D-printed material (<NUM>).