Patent ID: 12202247

DETAILED DESCRIPTION

Embodiments can include provisions to facilitate the printing of various designs, patterns, and structures on a surface. In one embodiment, the present disclosure is directed to a method of printing on an article, the method comprising: obtaining data regarding the article using a sensor system, forming a digitized image of the article, where the digitized image comprises a plurality of pixels, and where the plurality of pixels includes a first pixel and the first pixel represents a specific area of the article. Furthermore, the method includes the step of classifying the first pixel as belonging to a first category or a second category; discharging a print material on the article using a printing system if the first pixel belongs to the first category; and preventing the specific area of the article represented by the first pixel from receiving the print material if the first pixel belongs to the second category.

In another embodiment, the present disclosure is directed to a method of printing on an object using a virtual mask, the method comprising: aligning the object within a printing system using a sensor system, obtaining data regarding the object using at least one image capture device, and registering the image to form a virtual representation of the object. Furthermore, the method comprises generating a virtual mask, where the virtual mask classifies different regions of the virtual representation as belonging to either a print area or to an area where printing is prohibited, and then utilizing the virtual mask in conjunction with the printing system to exclude printing upon the different portions of the object represented by regions classified in the area where printing is prohibited.

In another embodiment, the present disclosure is directed to an apparatus for printing on an article, the apparatus comprising a housing, where the housing includes a base disposed along the bottom of the housing, and where the housing is configured to receive the article. The apparatus further comprises a nozzle assembly configured to discharge a print material and a sensor system, where the sensor system includes an image capture device. The apparatus also includes a computing system, where the computing system is configured to classify areas of the article as a print area or an area prohibited from printing. The apparatus is configured to print a print design on the areas of the article classified as a print area, and the apparatus is also configured to exclude printing of the print design on the areas of the article classified as an area that is prohibited from printing.

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. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the embodiments, and be protected by the following claims.

FIG.1is a schematic view of an embodiment of a three-dimensional printing system100, also referred to simply as printing system100hereafter.FIG.1also illustrates several exemplary articles130that may be used with printing system100. Referring toFIG.1, printing system100may further comprise a printing device102, a computing system104, and a network106.

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

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

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

The term “vertical,” as used throughout this detailed description and in the claims, refers to a direction generally perpendicular to both the lateral and longitudinal directions, along a vertical axis. For example, in cases where a component is flat on a ground surface, the vertical direction may extend from the ground surface upward.

In the embodiments shown in the figures, printing system100may be associated with fused filament fabrication (FFF), also referred to as fused deposition modeling. In the embodiment shown inFIG.1, printing device102of printing system100may use fused filament fabrication to produce three-dimensional parts. An example of a printing device using fused filament fabrication (FFF) is disclosed in U.S. Pat. No. 5,121,329 to Crump, issued Jun. 9, 1992, and titled “Apparatus and Method for Creating Three-Dimensional Objects,” which application is herein incorporated by reference 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 device102may include a housing110that supports various systems, devices, components, or other provisions that facilitate the three-dimensional printing of objects (e.g., parts, components, or structures). Although the exemplary embodiment depicts a particular rectangular box-like geometry for housing110, other embodiments could use any housing having any geometry and/or design. The shape and size of housing110could be varied according to factors including a desired footprint for the device, the size and shape of parts that may be formed within printing device102, as well as possibly other factors. It will be understood that housing110could 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 device102may include provisions to retain or hold a printed object (or a component supporting the printed object). In some embodiments, printing device102may 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 applied. In the embodiment ofFIG.1, printing device102includes a tray112. In some embodiments, tray112may be fixed in place and act as a stable base. In other embodiments, however, tray112could move. For example, in some cases, tray112may be configured to translate within housing110in a horizontal direction (e.g., front-back and/or left right with respect to housing110) as well as a vertical direction (e.g., up-down within housing110). Moreover, in some cases, tray112may be configured to rotate and/or tilt about one or more axes associated with tray112. Thus, it is contemplated that in at least some embodiments, tray112may be moved into any desired relative configuration with a nozzle or print head of printing device102. In other embodiments, printing device102may not include a tray112. In some embodiments, tray112may be curved, irregularly shaped, or shaped to provide a customized platform upon which an article or object may be placed or secured. In some embodiments, printing device102may include an open space or cavity formed within tray112.

In some embodiments, printing device102may include one or more systems, devices, assemblies, or components for delivering a printed material (or printed substance) to a target location. Target locations could include the surface of tray112, a surface or portion of a partially printed structure, and/or a surface or portion of a non-printed structure or component, such as a textile or other article. Provisions for delivering printed materials may include, for example, print heads and nozzles. In the embodiment ofFIG.1, printing device102includes a nozzle assembly116.

Nozzle assembly116may comprise one or more nozzles that deliver a printed material to a target location. For purposes of clarity, the exemplary embodiment ofFIG.1depicts a single nozzle118of nozzle assembly116. However, in other embodiments, nozzle assembly116could 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.

Nozzle118may be configured with a nozzle aperture (not shown) that can be opened and/or closed to control the flow of material exiting from nozzle118. Specifically, the nozzle aperture may be in fluid communication with a nozzle channel that receives a supply of material from a material source within printing device102. Some examples of materials that may be received or used are disclosed in U.S. Patent Publication Number 2017/0129176 to Sterman et al., published May 11, 2017 (U.S. patent application Ser. No. 14/935,731, filed Nov. 9, 2015), and titled “Tack and Drag Printing Method,” which application is herein incorporated by reference in its entirety, and is hereinafter referred to as the “Tack and Drag case.” Other examples include aqueous inks, dye-based inks, pigment-based inks, solvent inks, UV-curable inks, dye sublimation inks, and other print materials.

In some embodiments, a worm-drive may be used to push the filament into nozzle118at a specific rate (which may be varied to achieve a desired volumetric flow rate of material from nozzle118). In other embodiments, a worm-drive is omitted. For example, the material may be pulled from nozzle118using an actuating system. It will be understood that in some cases, the supply of material could be provided at a location near nozzle118(e.g., in a portion of nozzle assembly116), while in other embodiments the supply of material could be located at some other location of printing device102and fed via tubes, conduits, or other provisions, to nozzle assembly116.

For purposes of this description, articles130may encompass a wide variety of objects, components, materials, and/or shapes that are flat or include a three-dimensional geometry. Articles130may have portions that include curves, bumps, gaps, openings, and/or varying thickness, such as shown in articles130ofFIG.1. For example, an article may have regions or portions that are flat, smooth, level, or even, with relatively little thickness. However, the same article may also include uneven portions with surfaces that deviate from being flat for some or all of its length or area. InFIG.1, articles130include an upper134for an article of footwear, a knit structure132, and a woven pattern136. In other embodiments, articles can comprise regular, geometric curves such as those associated with circles, triangles, squares, and other geometric shapes, and/or they may also be irregular, for example in articles shaped to accommodate or include a particular uneven configuration. For example articles130such as woven pattern136can comprise one more tangible portions138and/or one or more apertures142. For purposes of this disclosure, a tangible portion may be a material portion that can receive a print material. Thus, tangible portions138may be distinct from voids, spaces, gaps, etc. (for example, apertures142), which cannot receive a print material. Furthermore, it should be understood that the use of the term “aperture” herein represents any one or more of voids, spaces, gaps, recesses, and/or any other type of intangible portions, etc. In some embodiments, apertures142may be surrounded by or disposed adjacent to one or more tangible portions138of articles130. The relationship between tangible portions138and apertures142will be discussed in further detail below.

As will be described below, printing system100can include provisions for facilitating the alignment of a printed design or graphic onto an article. In some embodiments, it may be useful to provide a user with a way of aligning an article or object with printing system100so as to ensure a graphic is printed in the desired portion of the article. In particular, printing system100may include provisions for programming the orientation of an article with print device102in such a way as to accommodate articles of various types, shapes, curves, and sizes. Thus, in some cases, printing system100may include provisions for pre-aligning the article (for example, with registration markers within the system). In some embodiments, the object may be aligned with tray112and/or nozzle118. In one embodiment, the object may be automatically aligned within printing system100using techniques known in the art.

In some embodiments, nozzle assembly116is associated with an actuating system114. Actuating system114may include various components, devices, and systems that facilitate the motion of nozzle assembly116within housing110. In particular, actuating system114may include provisions to move nozzle assembly116in any horizontal direction (including but not limited to a longitudinal direction124and a lateral direction126) and/or a vertical direction122to facilitate depositing or discharging a material so as to form a three-dimensional object or to print along a three-dimensional or curved surface. To this end, embodiments of actuating system114may include one or more tracks, rails, and/or similar provisions to hold nozzle assembly116at various positions and/or orientations within housing110. Embodiments may also include any kinds of motors, such as a stepper motor or a servo motor, to move nozzle assembly116along a track or rail, and/or to move one or more tracks or rails relative to one another.

In some embodiments, an actuating system can be configured to move a nozzle in one or more directions. In some embodiments, an actuating system could move a nozzle in a single linear direction. In other embodiments, an actuating system could move a nozzle in at least two perpendicular directions. In still other embodiments, an actuating system could move a nozzle in three perpendicular directions. Of course, while the exemplary embodiment depicts an actuating system capable of moving a nozzle through three independent x-y-z or Cartesian directions, other embodiments may be configured to move a nozzle in three independent directions associated with a non-Cartesian coordinate system (e.g., a spherical coordinate system or a cylindrical coordinate system). Still further, in other cases an actuating system could move a nozzle through three different directions that may not be orthogonal (e.g., directions of an oblique coordinate system).

For purposes of this discussion, a print surface may be associated with the surface where a nozzle is printing. For example, in cases where nozzle118prints directly onto tray112, the print surface is associated with a surface of tray112. In the embodiment ofFIG.1, print surface148is illustrated as the side of tray112that faces upward toward nozzle assembly116. However, it should be noted that in other embodiments, print surface148may comprise the surface or side of an article or object that is printed upon by nozzle118, as shown inFIG.2. Print surface148may be generally flat, or it may be substantially curved and include contours. In one embodiment, print surface148may be the side or surface of an object or article that is generally normal to first direction160. Thus, print surface148may refer to the surface of an article that is attached to a printing material such as a composite yarn or other material extruded or otherwise discharged or emitted from nozzle118.

As shown inFIGS.1and2, in different embodiments, printing system100can include a sensor system190. However, it should be understood that in some embodiments, sensor system190may be independent from printing system100. In other words, sensor system190may be a separate system that is used in conjunction with printing system100. Sensor system190may include various components, devices, and systems that facilitate the detection of various features of articles130within housing110. Although the exemplary embodiment depicts a particular camera component representation for sensor system190, other embodiments could use any system having any geometry and/or design. The shape and size of the sensor system could vary according to factors including the type of article being printed on, the size and shape of parts that may be formed within printing device102, the arrangement of housing110, as well as possibly other factors.

In particular, sensor system190may include provisions to detect, map, or otherwise identify the presence of various surface types, such as the regions associated with apertures142and tangible portions138. Sensor system190may further include an imaging device192, (such as a camera or other image capture device), which may move in any horizontal direction and/or vertical direction122to facilitate the position imaging device192within housing110. The image capture device may record images of the object and/or generates data representing the object in some embodiments.

To this end, embodiments of sensor system190may include one or more tracks, rails, and/or similar provisions to reposition imaging device192at various positions and/or orientations within housing110. In other words, sensor system190may include provisions for aligning articles or objects such that appropriate recordings may be obtained.

Embodiments may also include any kinds of motors, such as a stepper motor or a servo motor that can move objects or imaging device192along a track or rail, and/or to move one or more tracks or rails relative to one another. For purposes of clarity, imaging device192is shown inFIGS.1-2in isolation from any components that could be used to move imaging device192. In some embodiment, imaging device192or other components of sensor system190may not be mobile and may instead be stationary within housing110.

It should be noted that portions of sensor system190may be positioned in various locations within printing system100in order to provide the necessary data capture and feature detection. For example, imaging device192could move from one location to another within printing system100in order to record data sufficient for generating a virtual representation. In different embodiments, there may be multiple image capture devices, which may be used together to synthesize a composite image. In one embodiment, there may be a 2-5 image capture devices; in other embodiments, there may be more than five image capture devices, arranged throughout printing system100. Thus, the data captured and/or generated by the image capture devices may be synthesized into a composite image through an image registration process, where the resulting image can be made up of a first image portion, a second image portion, a third image portion, etc. obtained from multiple sources.

For purposes of this disclosure, image registration is the process of transforming sets of data into one coordinate system. Thus, in one embodiment, image registration is the process of aligning two or more images of the same scene. The images or data may be obtained by one source (e.g., a single camera taking images from various locations), or by multiple sources. In some embodiments, this process involves designating one image as the reference (also called the reference image or the fixed image), and applying geometric transformations to the other images so that they align with the reference. A geometric transformation can map locations in one image to new locations in another image.

In some embodiments, components associated with sensor system190may be specifically adapted to secure articles130in a fixed position or orientation. For example, some embodiments may include various kinds of mounting devices, harnesses, temporary adhesives, or other provisions that may temporarily fix or hold the position of an article relative to housing110. Such provisions may help precisely orient a specific portion of an article towards nozzle118(and correspondingly towards other components of printing device102) or sensor system190. For example, some embodiments could utilize a harness that fixes the orientation and position of an article over tray112so that imaging device can capture or scan data from along any desired portion of an article, such as upper134for an article of footwear. These provisions may also reduce the tendency of an article to move or jostle as the position of tray112is adjusted, or nozzle118extrudes or releases a print material onto articles130.

Thus, in some embodiments, articles130may be scanned or otherwise examined or inspected in housing110before and/or during printing. It should be noted that actuating system114and sensor system190may be operated simultaneously or independently during use of printing system100. In addition, actuating system114and sensor system190may be connected in such a way so as to allow both to operate in conjunction with one another during printing. As discussed above, printing system100can include provisions to control and/or receive information from printing device102. These provisions can include computing system104and network106. 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. Further, it should be understood that in some embodiments, computing system104may be independent from printing system100. In other words, computing system104may be a separate system that is used in conjunction with printing system100.

In some embodiments, computing system104may include one or more servers. In some cases, a print server may be primarily responsible for controlling and/or communicating with printing device102, while a separate computer (e.g., desktop, laptop, or tablet) may facilitate interactions with a user. Computing system104can 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 ofFIG.1, computing system104may comprise a central processing device185, a viewing interface186(e.g., a monitor or screen), input devices187(e.g., keyboard and mouse), and software180. While software180is represented inFIG.1as being stored in computing system104, it should be understood that in other embodiments, software180may be accessed from other locations. In some embodiments, software180may be used for designing a computer-aided design (“CAD”) representation189of a printed structure. In at least some embodiments, the CAD representation189of 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 different embodiments, software180may also be used to facilitate interaction between computing system104and printing device102, including sensor system190. In some embodiments, for example, computing system104may include image edge detection software or another type of classification software, a processor configured with the software to receive an image, and a process of decomposing and/or determining the areas of the image comprising tangible portions138relative to non-tangible portions (e.g., apertures142). For purposes of this description, this operation or process may also be referred to as image discrimination. In one embodiment, printing system100may also generate a virtual mask to identify regions that will be excluded from printing. Virtual masks will be discussed further with respect toFIGS.5-19.

According to one embodiment, imaging device192may provide a real-time video input source, including real-time video feed or other real-time data. Alternatively, imaging device192may provide pre-recorded video data. According to another embodiment, imaging device192may provide heat detection information, including infrared imaging data and/or other heat detection information. One of ordinary skill in the art will readily appreciate that other imaging data may be gathered and processed at various points during the image capture process. Thus, in different embodiments, imaging device192may be utilized to capture information from various objects. According to another embodiment, printing system100may recognize any video source and any resolution that is sufficiently clear to recognize the images. One skilled in the art will readily appreciate that various types of imaging devices may be implemented.

In other embodiments, computing system104can also include provisions for determining the edges of an object such as articles130. In one embodiment, an edge194is a portion of articles130where there is a change in the brightness of the image. For example, images taken by imaging device192may be processed such that tangible portions138are separated or distinguished from the background in real-time analysis. In another embodiment, the processing may occur after the image is captured. Therefore, various edge detection or other technologies for identifying different aspects of the image can be utilized. Some embodiments may make use of the features described in U.S. Patent Publication Number 2009/0192874 to Powles et al., published Jul. 30, 2009 and titled “Systems and methods for targeted advertising,” the disclosure of which is herein incorporated by reference in its entirety. Other embodiments may make use of the features described in U.S. Pat. No. 8,538,163 to Moesle et al., filed Sep. 29, 2010, and titled “Method and system for detecting edges within an image,” the disclosure of which is herein incorporated by reference in its entirety.

In some embodiments, computing system104may be in direct contact with printing device102via network106. Network106may include any wired or wireless provisions that facilitate the exchange of information between computing system104and printing device102. In some embodiments, network106may further include various components such as network interface controllers, repeaters, hubs, bridges, switches, routers, modems and firewalls. In some cases, network106may be a wireless network that facilitates wireless communication between two or more systems, devices, and/or components of printing system100. 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 802.11 WLAN standards), wireless mesh networks, and mobile device networks, as well as other kinds of wireless networks. In other cases, network106could be a wired network including networks whose signals are facilitated by twisted pair wires, coaxial cables, and optical fibers. In still other cases, a combination of wired and wireless networks and/or connections could be used.

It will be understood that for purposes of illustration, the components, devices and systems of printing system100are shown schematically inFIG.1. 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 system114, sensor system190, computing system104, network106, and nozzle assembly116. For example, actuating system114is shown schematically as including several tracks or rails, but the particular configuration and number of parts comprising actuating system114may vary from one embodiment to another.

Printing system100may be operated as follows to form one or more printed images using a two-dimensional (2D) printing process in some embodiments. For purposes of this disclosure, 2D printing refers to the rendering of 2D images on a substrate or other surface. In other embodiments, printed structures may be formed using a three-dimensional (3D) printing, or additive, process.

Although some of the 3D printing embodiments shown in the figures depict a system using filament fused fabrication printing technologies, it will be understood that still other embodiments could incorporate one or more different 3D printing technologies. For example, printing system100may use a tack and drag print method, as described in the Tag and Drag case. Moreover, still other embodiments could incorporate a combination of filament fused fabrication and another type of 2D or 3D printing technique to achieve desired results for a particular printed structure or part. It should be understood that the techniques described herein may also utilize 2D printer systems (e.g., inkjets, etc.) and/or 3D (e.g., additive manufacturing) and processes.

In different embodiments, printing device102may use a variety of different materials for forming 2D images and/or 3D parts, including, but not limited to: inks, thermoplastics (e.g., polyactic acid and acrylonitrile butadiene styrene), high density polyethylene, eutectic metals, rubber, clays (including metal clays), Room Temperature Vulcanizing silicone (RTV silicone), and porcelain, as well as possibly other kinds of materials known in the art. In embodiments where two or more different printed or extruded materials are used to form a part, any two or more of the materials disclosed above could be used.

In some cases, computing system104may be used to design a print pattern or 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 device102(or a related print server in communication with printing device102). In some cases, the design may be converted to a 3D printable file, such as a stereolithography file (STL file).

As discussed above, in some embodiments, printed structures may be printed directly to one or more articles130. The term “articles” is intended to include both articles of footwear (e.g., shoes) and articles of apparel (e.g., shirts and pants), as well as various other objects. While the disclosed embodiments are described in the context of textiles, the disclosed embodiments may further be equally applied to any article of apparel, clothing equipment, or other objects. For example, the disclosed embodiments may be applied to hats, caps, shirts, jerseys, jackets, socks, shorts, pants, undergarments, athletic support garments, gloves, wrist/arm bands, sleeves, headbands, any knit material, any woven material, any nonwoven material, sports equipment, etc. Thus, as used throughout this disclosure, the term “article of apparel” may refer to any apparel or clothing, including any article of footwear, as well as hats, caps, shirts, jerseys, jackets, socks, shorts, pants, undergarments, athletic support garments, gloves, wrist/arm bands, sleeves, headbands, any knit material, any woven material, any nonwoven material, etc. As used throughout this disclosure, the terms “article of apparel,” “apparel,” “article of footwear,” and “footwear” may also refer to a textile, 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.

Furthermore, objects made of other non-textile materials may also provide print surface148in printing system100. For example, articles130may also include an article of footwear, a helmet, a glove, or other articles. Specifically, in some cases, printing device102may be capable of printing onto the surfaces of various materials such as a textile, a natural fabric, a synthetic fabric, a knit, a woven material, a nonwoven material, a mesh, a leather, a synthetic leather, a polymer, a rubber, and a foam, or any combination thereof. For example, the disclosed methods may include printing a resin, acrylic, thermoplastic material, or ink material onto a fabric, for example, a knit material, where the material is adhered or bonded to the fabric and where the material does not generally delaminate when flexed, rolled, worked, or subjected to additional assembly processes or steps. As used throughout this disclosure, the term “fabric” may be used to refer generally to materials chosen from any textile, natural fabric, synthetic fabric, knit, woven material, nonwoven material, mesh, leather, synthetic leather, polymers, rubbers, foam, and combinations thereof.

In some embodiments, the horizontal or vertical position of articles130may be adjusted using sensor system190. Sensor system190may operate in conjunction with computing system104to provide greater automation to printing system100.

As previously mentioned, nozzle118is configured to extrude or discharge various materials. For example, as shown, nozzle118may extrude a print material202such as a substantially elongated continuous composite yarn, or nozzle118may extrude multiple elongated continuous composite yarn segments. For example, in some embodiments, print material202may include a melt resistant material and/or a heat moldable material, or another type of ink. As used herein, heat moldable material includes thermoplastic. In some embodiments, a composite yarn is at least partially formed of thermoplastic.

However, it should be noted that in other embodiments, print material202may be discharged or otherwise emitted via nozzle118in the form of droplets. In some cases, droplets may comprise the print materials (e.g., inks) described earlier. One of ordinary skill in the art will recognize that the form of the droplets may vary depending on the actual material ejected or otherwise emitted from nozzle118. In some embodiments, the droplets may thus be any viscosity liquid material, or even a semi-solid material. Consistent with an embodiment, the droplets may be any desired material or phase of material suitable for use in printing system100.

The methods illustrated may be implemented on various devices, may utilize various materials, and use different types of print surfaces. Accordingly, the exemplary methods illustrated inFIGS.1-19are for illustrative purposes only. In some embodiments, the printing can occur over articles130that have been previously manufactured or fabricated, or partially manufactured, and printing can occur post-manufacture. This can allow customization of articles130to be processed more quickly, as well as more cost-efficiently. Furthermore, printing system100can allow formation of designs that encompass multiple surfaces and curves of article130, including surfaces comprising varying materials, and can provide more seamless design appearance.

As a general introduction to some of the embodiments described herein, a flow diagram is provided inFIG.3. Before printing, an article may be placed onto tray or may be otherwise secured in the housing in a first step310. The object may then be scanned or otherwise have data gathered regarding the object by the sensor system in a second step320. In a third step330, the data may be used by the computing system to examine the object and determine areas to exclude from printing. In a fourth step340, a virtual mask (described in further detail below) may be generated by the computing system. Once the printing process is initiated (by a user, for example), the printing device may begin depositing material onto the article. The printing system may employ the virtual mask to limit printing to areas that have not been excluded by the virtual mask in a fifth step350. In a sixth step360, printing is completed on the object.

Further detail on this process is provided below, with respect toFIGS.4-19. For purposes of convenience some components of printing system100are not shown in the following figures. Thus, it should be understood thatFIGS.4-5, and7-17are for purposes of illustration only, and the components described above with respect toFIGS.1and2may be included or referred to in the following description while not illustrated in the figures.

InFIG.4, one embodiment of the image capture process400is depicted. In some embodiments, an initial image capture489of at least a portion of an article or object may be recorded by imaging device192of sensor system190. As shown inFIG.4, initial image capture489represents a portion of an article (not shown), where the article includes apertures142and tangible portions138. Processing may be performed using computing system104in some embodiments, as depicted by CAD representation189shown on viewing interface186. In one embodiment, initial image capture489may include obtaining data regarding the object and forming a virtual representation of the article.

In one embodiment, computing system104may perform various edge detection and discrimination processes, as described above. For example, computing system104may receive the image or data, apply an edge detection process, and decompose the image or virtual representation of the object into one or more regions. In one embodiment, the multiple regions each represent different portions of the object.

The computing system104may generate a processed image410or virtual representation, which in some embodiments may be used to generate a virtual mask (discussed further with reference toFIGS.5and6). The regions may be classified as either “print areas”438or “no-print areas”442in one embodiment. For purposes of this description, print areas438may represent portions of the object upon which printing is to be permitted (i.e., a printable area), and no-print areas442represent portions of the object upon which printing is to be excluded. In other words, no-print areas are areas prohibited from printing. It should be understood that in some cases, there may not be any print areas438identified, and in other cases, there may not be any no-print areas442identified. As illustrated inFIG.4, each of no-print areas438in processed image410can correspond to each of apertures142in initial image capture489in some embodiments. In other embodiments, each of print areas438can correspond to each of tangible portions138. In other words, the printing system as described herein may include provisions for detecting areas where printing may occur, and areas where printing should not occur, and adjust the output of nozzle118(not shown) accordingly.

It should be understood that the areas designated as no-print may be manually entered by a user, or may be programmed or otherwise provided to computing system104such that the designation may occur in an automated fashion. Furthermore, the discrimination process and/or the generation of a virtual mask may occur in real-time (i.e., during printing or after print material has been discharged) or it may be generated prior to printing.

FIGS.5and6depict one embodiment of the operation of the image discrimination process. InFIG.5, sensor system190(not shown) has captured a digitized image550of a portion of article500. For purposes of this disclosure, digitization may refer to the process of converting an image into a digital form that can be processed by a computing system. Thus, in some embodiments, sensor system190can capture an image of article500and divide the total picture area into rows and columns comprising a large number of relatively tiny subareas. In the embodiment ofFIGS.5and6, this digital organization of numeric data will be referred to as pixels520. Pixels520can contain the digital numeric red-green-blue (RGB) color data (numbers) of one portion of the image's surface area. In other words, a row and column array of pixels may be created by computing system104in some embodiments. As each pixel is generally stored as a color sampled from the frame area, pixels can be utilized by printing system100during the image discrimination process. It should be understood that RGB color identification is only an example of one means of digitally processing and/or storing the image data, and other processes may be used as known by persons skilled in the art.

Therefore, in some embodiments, an image file can be created by computing system104, including three color values for every RGB pixel, or location, in the image grid of rows and columns. The data is also organized in the file in rows and columns. File formats may vary in different embodiments. Some examples include BMP, JPEG, GIF, PNG, TIFF, PICT, and other image file formats. The viewing software can then depict each location along one of the rows and along one of the columns in the grid of rows and columns. It should be understood that in some embodiments, the use of pixels implies the virtual construction of a “grid” of pixels that compose or comprise an image.

InFIG.5, for purposes of illustration, an embodiment of a portion of a row of pixels520is identified, including a first pixel502, a second pixel504, a third pixel506, a fourth pixel508, and a fifth pixel510. First pixel502, second pixel504, and third pixel506are associated with tangible portions138. Fourth pixel508and fifth pixel510are associated with apertures142. In some embodiment, each pixel corresponds to or represents a unique or specific location, area, or portion of article500. Thus, in one embodiment, first pixel502can represent a first area on article500, and second pixel504can represent a second area on article500, such that the first area and the second area are different.

InFIG.6, a matrix is illustrated, listing the pixels identified inFIG.5, each pixel's location in the digitized image, the color value assigned to the pixel, as well as the resulting classification of the pixel to either a print area (yes) or a no-print area (no). It should be understood that the matrix including the pixel number, values of the location of each pixel, the color value, and the classification to a print area or no-print area is provided as an example only, and that values other than those included inFIG.6may be listed in the matrix.

As shown inFIG.6, first pixel502, second pixel504, and third pixel506have been designated or classified as print areas, and fourth pixel508and fifth pixel510have been designated or classified as no-print areas. As a result of this classification, a virtual mask may be generated by computing system104. In one embodiment, the virtual mask may be superimposed on the processed or digitized image or be otherwise applied to the original data regarding the object. For purposes of this disclosure, a virtual mask may be a simulated or digital mask, and may not physically exist. The virtual mask can substantially “block” portions of an image in some embodiments. In one embodiment, the virtual mask can include a shape or outline that substantially corresponds to the shape of the digitized image, while any regions identified and classified to the no-print areas are filled with a type of limiting content, such as a uniform pre-selected color or other graphics. In some embodiments, the virtual mask may be automatically generated during the image discrimination process. However, in other embodiments, the virtual mask may be superimposed on the digitized image by a user.

For example, the virtual mask may fill or otherwise superimpose on the region of the no-print areas in the processed image a color or pattern that will be light absorbing color (e.g., black), or any other specialized pattern, such that the printing system interprets or otherwise is instructed to avoid printing in the no-print area, regardless of the print design. In one embodiment, the use of virtual masks can avoid printing on regions of tray112(not shown) or other surfaces that do not require printing. Printing resources can thus be conserved, printing may be more efficient, clean-up of print areas may be minimized, print bleeding can be decreased, and/or image or print results can be optimized in some embodiments.

FIGS.7-10illustrate an embodiment of the printing process that includes a virtual mask during 2D printing. InFIG.7, an example of a print design700is shown. Print design700can be programmed, selected, uploaded, or otherwise inputted into printing system100during the printing process. As shown, print design700is a repeating pattern of round dots702. In other embodiments, print design700may include any design, including 2D and 3D designs.

In some embodiments, the image capture process as discussed may produce a processed image710of a portion of an article720. Processed image710includes print areas438and aperture regions442. Thus, in one embodiment, processed image710may be used to form a virtual mask, which can be utilized by printing system100during printing to identify areas on which to avoid printing. As shown inFIG.7, nozzle118has begun to deposit print material202along print surface148. Article720includes apertures142, and tangible portions138. Printing system100may overlay or otherwise make reference to the virtual mask generated from processed image710. In one embodiment, print surface148may be a surface of the substrate or material portions of article720.

InFIG.8, nozzle118has moved along one side of article720, in a generally longitudinal direction124, depositing dots702. As shown inFIG.8, dots702are only deposited on print surface148that have been characterized as a print area (i.e., tangible portions138). In other words, despite the inclusion of print design700shown inFIG.7, which includes a continuous pattern of dots702, printing of print design700is limited to the areas identified by printing system100as a print surface148or print area. This is further depicted inFIGS.9and10. InFIG.9, printing has occurred in both longitudinal direction124and lateral direction126, across a majority of article720. Printing on article720is being completed inFIG.10. It can be seen that in bothFIGS.9and10, printing has been limited to regions identified as print areas (i.e., associated with tangible portions138). Thus, in one embodiment, the areas of tray112associated with each of apertures142remain unprinted upon.

FIGS.11-15depict another possible embodiment of the printing process as described herein.FIG.11is an embodiment of a textile1100. Textile1100includes six apertures1142that are surrounded or bounded by tangible portions1138. Apertures1142include a first aperture1102, a second aperture1104, a third aperture1106, a fourth aperture1108, a fifth aperture1110, and a sixth aperture1112. As shown inFIG.11, each aperture may have a different shape and/or size. For example, first aperture1102is generally starburst shaped, second aperture1104is generally pentagonal shaped, third aperture1106is generally lightening shaped, fourth aperture1108is generally star shaped, fifth aperture1110is generally heart shaped, and sixth aperture1112is generally circular shaped. Thus, apertures1142may include sharp edges and/or curves, and a variety of geometries. In other embodiments, apertures1142may be larger or smaller than those depicted, and include other regular or irregular shapes.

FIG.12is an embodiment of a processed image1200representing textile1100inFIG.11. InFIG.12, aperture regions1242and tangible regions1238are shown. Aperture regions1242include a first aperture region1202, a second aperture region1204, a third aperture region1206, a fourth aperture region1208, a fifth aperture region1210, and a sixth aperture region1212. As shown inFIGS.11and12, first aperture1102in textile1100corresponds to first aperture region1202in processed image1200. Similarly, second aperture1104corresponds to second aperture region1204, third aperture1106corresponds to third aperture region1206, fourth aperture1108corresponds to fourth aperture region1208, fifth aperture1110corresponds to fifth aperture region1210, and sixth aperture1112corresponds to sixth aperture region1212. Thus, processed image1200may be a digital representation of specified areas of textile1100in some embodiments demarcating between print areas (associated with tangible regions1238) and no-print areas (associated with aperture regions1242).

In other words, when a print design is processed by printing system100, the virtual mask generated (e.g., using processed image1200) may be used to indicate or otherwise inform printing system which areas will not be printed upon. Thus, using this process, regardless of the actual print design employed, only the areas identified and targeted by the printing system as print areas will receive the print material.

For example, inFIG.13, a print design1300is shown. Print design1300includes a series of unbroken or continuous curves1310extending across the image. Print design1300includes curves1310of varying sizes, and curves1310that extend across various portions of the design area. In the embodiment ofFIG.13, curves1310include a first curve1302.

To provide a comparison, in one example of a printing system that does not employ a virtual mask as described, print design1300ofFIG.13may be printed on a surface without regard for the type of surface or for whether there is substrate actually present in the targeted print area. For example, inFIG.14, an embodiment of a first printed textile1400is illustrated. Print design1300has been deposited on print surface148. Print surface148includes the entire region bordered by the edges of first printed textile1400, including the areas associated with both tangible portions1138and apertures1142. Thus, in the example ofFIG.14, tray112may be a target for print material202.

However, in embodiments that utilize a virtual mask, print design1300ofFIG.13may be deposited such that tray112is no longer classified as a print surface. For example, inFIG.15(showing print design1300as modified by the virtual mask), as the information from the virtual mask is included in the printing process, specified areas have been blocked from printing. In other words, in some embodiments, apertures1142of a second printed textile1500are avoided or excluded, while tangible portions1138are printed upon. Thus, areas of tray112associated with the no-print zones (e.g., apertures1142) remain clear of print material202, while tangible portions1138, representing print surface148, include print material202generally matching the corresponding sections of print design1300(shown inFIG.13).

The use of the virtual mask may allow or otherwise permit printing to occur more efficiently and decrease the overall cost (e.g., ink, clean-up, post-processing) of the printing process. Furthermore, the techniques described herein can permit the application of a variety of designs on a wide variety of articles, including articles with uneven surfaces, gaps, or other irregularities. For example, a desired print design need not be altered or adjusted to accommodate the type of print surface prior to printing, because only the surfaces classified as print zones will receive the print material. Additionally, post-manufacture customization of articles may be easier, as well as quicker.

The embodiments described herein can also be directed to 3D printing.FIGS.16and17illustrate an embodiment of the printing process that includes a virtual mask during 3D printing. InFIG.16, an example of a print design1600is shown. Print design1600can be programmed, uploaded, or otherwise inputted into the printing system during the printing process. As shown, print design1600is a repeating pattern of cloud ornaments1602. In other embodiments, print design1600may include any design, including 2D and 3D designs.

In some embodiments, the image capture process as discussed may produce a processed image1610of a portion of an article1620. Processed image1610includes print areas438and aperture regions442. Thus, in one embodiment, processed image1610may be used as a virtual mask, which can be utilized by printing system100during printing to identify areas on which to avoid printing. As shown inFIG.16, nozzle118has begun to deposit three-dimensional print material202along print surface148. In one embodiment, print surface148may comprise of the substrate of article1620. Article1620includes apertures142, and tangible portions138. Printing system100may overlay or otherwise make reference to the virtual mask generated from processed image1610.

InFIG.17, nozzle118has moved along multiple sides of article1620, depositing cloud ornaments1602. Printing has occurred in both longitudinal direction124and lateral direction126, across a majority of article1620. As shown inFIG.17, cloud ornaments1602are only deposited on tangible portions138that have been characterized as a print area. In other words, despite application of print design1600shown inFIG.16, which includes a continuous pattern of cloud ornaments1602, printing of the structures of print design1600is limited to the areas identified by printing system100as a print surface148. It can be seen that in bothFIGS.16and17, printing has been limited to regions identified as print zones (i.e., associated with tangible portions138). Thus, in one embodiment, the areas of tray112associated with each of apertures142remain unprinted upon.

Referring back to the various printing embodiments depicted inFIGS.7-17, in some embodiments, it should be understood that print designs may be utilized by printing system100in different ways. In one embodiment, the print designs may be “mapped” to facilitate the virtual masking process. For purposes of this disclosure, mapping refers to an operation or process that associates each of the elements of a given set with one or more elements of a second set.

In some embodiments, selected print design700, print design1300, and/or print design1600may be stored or represented by a plurality or region of pixels (e.g., similar to the representation of digitized image550by pixels520inFIG.5above). To provide one example of a mapping process, the selected print design may include a first section represented by a first set of pixels, and a second section represented by a second set of pixels. Similarly, the digitized image can also include two sets of pixels, for example, a third set of pixels and a fourth set of pixels.

In some embodiments, each pixel in the first set of pixels from the print design can be mapped (associated) with each pixel in the third set of pixels from the digitized image. Furthermore, each pixel in the second set of pixels from the print design can be mapped (associated) with each pixel in the fourth set of pixels from the digitized image. Thus, in one embodiment, the pixels representing the print design can be linked or correlated to the pixels representing the digitized image. In some cases, this linkage can occur by determining the mapping relationship between each of the sets of pixels, such that the grid of pixels representing the digitized image and the grid of pixels representing the print design are matched and/or spatially correlated.

To determine the mapping between the digitized image and the print design, a bitmap or pixmap of the print design and/or digitized image may be generated. For purpose of this disclosure, a bitmap or pixmap is a type of memory organization or image file format used to store digital images, and may refer to the concept of a spatially mapped array of pixels. The mapping process may also utilize raster images, whether synthetic or photographic, in files or memory.

In one case, utilizing the masking methods described herein, the first section of the print design may then be printed onto the article when the third set of pixels are all classified in the “print areas” category, and the second section of the print design can be prevented from being printed onto the article (or areas associated with the article) when the fourth set of pixels are classified in the “no-print areas” category. In another case, the first section of the print design may be prevented from being printed onto the article (or areas associated with the article) when the third set of pixels are all classified in the “no-print areas” category, and the second section of the print design can be printed onto the article when the fourth set of pixels are classified in the “print areas” category.

One embodiment of the printing process as described herein is outlined in the flow chart ofFIG.18. An object or article located within the housing may be scanned or data regarding the article may be otherwise obtained (for example, using the sensor system described above) in a first step1810. In a second step1820, the scanned information may be used by the computing system to generate a digital (pixelated) image. In some embodiments, each pixel may represent a specific area of the article. In a third step1825, a pixel is selected for examination. In a fourth step1830, one pixel is examined and assigned or classified as either a print area or print zone in a fifth step1840, or as a no-print area or print zone in a sixth step1850. In other words, the pixel may be classified in one of at least two categories, where the first category is associated with allowing printing to occur, and where the second category is associated with the exclusion of any printing. Sixth step1850may occur in conjunction with the software (e.g., edge detection or classification) of the computing system in some embodiments. In a seventh step1860, the printing system determines if any pixels remain unexamined. If there is at least one additional pixel remaining, the process returns to third step1825. If no pixels remain, a virtual mask is generated in an eighth step1870. In a ninth step1880, printing is initiated which utilizes the virtual mask generated in eighth step1870. The virtual mask may be superimposed on the digital image originally generated in second step1820in some embodiments. The print job is completed in a tenth step1890, where the virtual mask can be used to exclude some areas of the article from receiving printed material.

As mentioned above, the processes described herein may occur in real-time in some embodiments. For purposes of this description, a real-time virtual mask process may occur when one or more of the pixels representing the object are classified after printing has begun (i.e., some of the print material has been discharged before all pixels have been classified). A general outline of an embodiment of a real-time virtual mask printing process is provided in the flow diagram ofFIG.19. It should be understood that there may be additional steps in other embodiments, or the steps may differ from those listed inFIG.19in some embodiments.

Before printing, a print design may be selected in a first step1910. An object or article located within the housing may then be scanned or data regarding the article may be otherwise obtained (for example, using the sensor system described above) in a second step1920. In a third step1930, the data may be used by the computing system to generate or render a digital (pixelated) image. In some embodiments, each pixel may represent a specific area of the article. In a fourth step1935, a pixel is selected for examination. It should be understood that in some embodiments, the pixel selected is identified with an area of the object that will be printed on, allowing the system to perform and apply a virtual mask in substantially real-time. In a fifth step1940, one pixel is examined and assigned or classified as either a print area or print zone in a sixth step1950, or as a no-print area or no-print zone in a seventh step1960. In other words, the pixel may be classified in one of at least two categories, where the first category is associated with allowing printing to occur, and where the second category is associated with the exclusion of any printing. Seventh step1960may occur in conjunction with the software (e.g., edge detection or classification) of the computing system in some embodiments. If the pixel is designated as a print area, print material may be deposited on the region of the article associated with the pixel in an eighth step1970. Thus, printing may occur in real-time in some embodiments, as the pixels that are classified for printing receive the print material soon after the designation. Furthermore, if the pixel is designated as a no-print area, printing will be excluded from the region of the article associated with the pixel in a ninth step1980. In a tenth step1990, printing system determines if any pixels remain to be examined. If there is an additional pixel, the process returns to fourth step1935. If no pixels remain, the print job is completed in an eleventh step1992.

It should be understood that in other embodiments, the generation of a virtual mask may be based on data other than pixels. For example, the software used may designate the various aspects or features of an object using other samples, representations, and/or data collected of the object. It should further be understood that the steps listed in the flow charts ofFIGS.3,18, and19are not intended to be comprehensive and are provided as possible embodiments of the printing process. In other words, the process may also incorporate any of the other techniques described herein, as well as others practiced by those skilled in the art.

While various embodiments have been described, the description is intended to be exemplary, rather than limiting and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the embodiments. Although many possible combinations of features are shown in the accompanying figures and discussed in this detailed description, many other combinations of the disclosed features are possible. Any feature of any embodiment may be used in combination with or substituted for any other feature or element in any other embodiment unless specifically restricted. Therefore, it will be understood that any of the features shown and/or discussed in the present disclosure may be implemented together in any suitable combination. Accordingly, the embodiments are not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims.