Patent ID: 12226954

DETAILED DESCRIPTION

The figures and descriptions provided herein may have been simplified to illustrate aspects that are relevant for a clear understanding of the herein described apparatuses, systems, and methods, while eliminating, for the purpose of clarity, other aspects that may be found in typical similar devices, systems, and methods. Those of ordinary skill may thus recognize that other elements and/or operations may be desirable and/or necessary to implement the devices, systems, and methods described herein. But because such elements and operations are known in the art, and because they do not facilitate a better understanding of the present disclosure, for the sake of brevity a discussion of such elements and operations may not be provided herein. However, the present disclosure is deemed to nevertheless include all such elements, variations, and modifications to the described aspects that would be known to those of ordinary skill in the art.

Embodiments are provided throughout so that this disclosure is sufficiently thorough and fully conveys the scope of the disclosed embodiments to those who are skilled in the art. Numerous specific details are set forth, such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. Nevertheless, it will be apparent to those skilled in the art that certain specific disclosed details need not be employed, and that embodiments may be embodied in different forms. As such, the embodiments should not be construed to limit the scope of the disclosure. As referenced above, in some embodiments, well-known processes, well-known device structures, and well-known technologies may not be described in detail.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. For example, as used herein, the singular forms “a”, “an” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The steps, processes, and operations described herein are not to be construed as necessarily requiring their respective performance in the particular order discussed or illustrated, unless specifically identified as a preferred or required order of performance. It is also to be understood that additional or alternative steps may be employed, in place of or in conjunction with the disclosed aspects.

When an element or layer is referred to as being “on”, “engaged to”, “connected to” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present, unless clearly indicated otherwise. In contrast, when an element is referred to as being “directly on,” “directly engaged to”, “directly connected to” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). Further, as used herein the term “and/or” includes any and all combinations of one or more of the associated listed items.

Yet further, although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another element, component, region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the embodiments.

The disclosed apparatus, system and method provide materials, and enable the production of additively manufactured parts from those materials, having properties presently unavailable in the known art. Further, embodiments include designs for specification that may match and/or correlate particular print materials, print material fillers, and printed output objects given one or more processes available to produce the printed output object.

Historically, the use of additive manufacturing (AM), such as 3D printing, to produce a three-dimensional foam part has been challenging and required custom machines and materials. The embodiments include materials and processes by which material is produced to more readily be used in existing AM technologies to produce foam parts for various industries.

The embodiments may allow for a part to be printed from the provided print materials, and then selectively cut or crushed to create a final foam part. The three-dimensional foam part produced using AM can be printed very rapidly using existing technologies. Further, the inherent elastomeric properties are more continuous throughout the printed part, and can thus be further tailored during and after the printing, than the known art.

Foam applications provided in the embodiments include, but are not limited to: footwear midsoles, insoles and outsoles; integral skin for vehicle interiors; bedding, such as mattress padding, solid-core mattress cores, and general padding; upholstery foams; furniture, such as cushions, carpet cushion, and structural foams; insulation, such as construction, wall/roof, window/door, and air barrier sealents; packaging; building materials; automotive exterior parts and facia; automotive and aerospace seating, interior trim, structural parts, and electronics; automotive seats, headrests, armrests, roof liners, dashboards and instrument panels; automotive steering wheels, bumpers and fenders; refrigeration and freezer insulation; construction and other moldings; seals and gaskets; foam core doors, walls and panels; bushings; carpet underlay; parts and insulators for electronic instrumentation; surfboards; foam for rigid-hulled boats; sporting goods, such as helmets, bike seats, padding, racquet grips, padding, and filler in rigid sporting goods; headsets; healthcare, such as for physical therapy molds, custom braces and orthopedic cushions; pillows; sound proofing; wheels, such as for wheelchairs, bicycles, carts and toys; and the like.

FIG.1illustrates a typical additive manufacturing (AM) system10. In the illustration, a print material12is fed into a print process14, such as the powder/pulverant-based AM processes discussed throughout, and the print process14outputs a printed 3D part16. In the embodiments, the print material12may have the particular characteristics discussed herein, which may allow for the use of the print material12in any one or more processes14, and which thereby result in any of various types of output parts16such as may have the characteristics discussed herein.

Additionally, computing system1100may execute one or more programs/algorithms1190to control one or more aspects of system10, as referenced throughout. By way of example, program1190may be the AMF referenced herein above, and the AMF1190may independently control at least process14. The AMF may additionally control the selection and/or distribution of print material12, compounds12a, and/or additives and fillers, and may further modify processes14, print materials12, and so on in order to achieve a user-desired print output16, as discussed further herein below.

More particularly, the embodiments include particular TPU-coated print materials12. These materials12may include a TPU polymer coating on a low density particle, such as a microsphere, for example, and may additionally include one or more additives20, such as may further enhance the operating characteristics and operating windows discussed throughout the disclosure, and such as are discussed further herein below.

Alternatively, a TPU polymer may be mixed with a low density particle, such as a microsphere, for example and may additionally include one or more additives20, such as may further enhance the operating characteristics and operating windows discussed throughout the disclosure. Mixing may be accomplished by high shear blending, low shear blending, or a combination of high shear and low shear blending. To disperse particles in a dry solid state, the use of a high shear mixer is employed to break up agglomerates and obtain a fluidized state of mixing. Care should be taken to avoid high temperatures, and mixing tool design and other processing parameters can be optimized for batch time and repeatability. Masterbatches or concentrates of additives with the powdered bulk resin are initially formed. The concentrate or masterbatch is then blended, typically in a low shear blender, to disperse the additive and homogenize the blend.

As referenced, the disclosed print input materials12may be used in powder-based AM processes14, such as those in which the powder120including the material12may be spread, melted in a targeted manner, and allowed to or processed to solidify, thus forming successive layers that result in a three-dimensional output object/part16having the characteristics discussed herein as indicative of both the process14and the input print material12. Processes14may include, but are not limited to: Selective Laser Sintering (SLS), Selective Laser Melting (SLM), Selective Heat Sintering (SHS), High Speed Sintering (HSS), Multi Jet Fusion (MJF), Binder Jetting (BJ), Material Jetting (MJ), Laminated Object Manufacturing (LOM), and other AM technologies referenced herein, and/or AM technologies that utilize thermoplastic powders/pulverants as may be known to the skilled artisan. It will also be understood to the skilled artisan that other AM and similar processes14may be modified to employ the print materials12disclosed herein, including but not limited to injection molding, roto molding, vacuum molding, subtractive manufacturing, and so on.

As referenced above, and referring now specifically toFIG.2A, additives130may be included with material12in forming powder120. Additives130may provide desired characteristics to powder120, may enable or improve aspects of processes14, or may provide desired characteristics to output part16produced by exposure of the input print material12to process14. Moreover, additives130may enable the particular characteristics of input print material12discussed herein. Additives130may include, by way of non-limiting example, glass beads, glass fibers, hollow glass spheres, carbon fibers, carbon black, metal oxides, copper metals, flame retardants, antioxidants, pigments, powder flow aids, inks, and so on. For example, ink additives130may allow for modification of print material12properties, such as may provide for different functional inks for use in multi-jet fusion AM printing or high speed sintering.

By way of example, a powder comprised of both additives130and print materials12, that is, combined particles and/or compound12a, may provide a lightweight, low density output with good rebound. Rather than avoiding porosity, as discussed above, embodiments of either print material12, or combination/compound12amay target higher levels of voids and porosity in the printed output16, such that a foam is produced having a desired, lower density. This “TPU foam” output16may be used in a variety of applications, as it may produce a foam part that possesses gradient properties as desired throughout the single continuous part, while also providing the correct dimensions for the finished part in-process14as the gradient properties are imparted layer-by-layer.

More particularly, the disclosure includes a TPU foam16or similar AM “printed” object that is printed from a print material12having therein numerous voids or the like, which voids thereby make the printed output less dense than other layer-by-layer AM printed objects. As referenced above with respect toFIG.2A, such a print material may be formed of combined particles12a, wherein interstitial ones12bof the combined particles may be sacrificial or low density such that, when combined with others in a combined particle print powder120, the combined print material12provides a low density AM printed output. Ones of the combined particles12amay also be compounds, such as discussed below with respect toFIG.2B.

Similarly and as referenced throughout,FIG.2Billustrates a compound print particle12a, in which an inner-particle12c, such as a sacrificial inner particle, is “coated” with a polymer12d, such as a TPU coating, as further detailed herein. This coating12dmay be performed using any of the various methods discussed throughout, and results in a compound print particle12afor use in the various AM processes14discussed throughout.

More particularly, and by way of example, a TPU polymer12dmay be placed into solution202to be coated onto a base particle12c. In embodiments, the base particle12cmay be sacrificial in nature, i.e., may be a hollow or low density particle that is sacrificed in foam formation, such as a glass or polymer bead. In other embodiments for the purposes of this disclosure, the base particle12cmay be air or gas, i.e., may constitute the absence of a solid particle, and thereby an introduction of porosity into a TPU-“coating”12d.

The solvent202amay be a liquid or gas that serves as the medium for the coating reaction. The solvent202amay be non-participatory with the reactants in the solution202, wherein the solvent202adoes not participate in the reaction; or participatory, wherein the solvent202amay be, for example an acid (proton), a base (removing protons), or a nucleophile (donating a lone pair of electrons) and may thereby contribute to the coating reaction.

Further, solvents202amay be polar or non-polar, and may further be subjected to inversion as to polarity. Polar solvents have large dipole moments—that is, they contain bonds between atoms with very different electronegativities, such as oxygen and hydrogen. Non-polar solvents contain bonds between atoms with similar electronegativities, such as carbon and hydrogen, which thus lack partial charges, i.e., which thus lack polarity. Polarity inversion may include enhancing solvent properties, such as to produce porous TPU-“coated” particles as discussed throughout.

Any coating material12dsoluble in an organic solvent202a(e.g., water, THF, MEK, cyclohexanone) will precipitate out of the solvent202aupon drying. Thereby, a polymer-based substance with characteristics of common engineering thermoplastics is highly appropriate for use as coating material12din the disclosed embodiments.

For different applications, the soluble coating material12dmay vary in accordance with the application. For example, foam-centric applications may employ an elastomeric coating material12dhaving high elongation, substantial rebound, and adequate compression. By way of non-limiting example, for footwear parts, such elastomeric materials12dmay be particularly common. Applicable elastomeric compounds may include: styrene block copolymers, thermoplastic olefins, elastomeric alloys, thermoplastic polyurethanes, thermoplastic copolyesters, thermoplastic polyamides, ethylene-vinyl acetate, ethylene propylene rubber, ethylene propylene diene rubber, polyurethanes, silicones, polysulfides, elastolefins, high density polyethylene, low density polyethylene, linear low density polyethylene, polypropylene, polyolefin copolymers, polystyrene, polystyrene copolymers, polyacrylates, polymethacrylates, polyesters, polyvinylchloride, fluoropolymers, liquid crystal polymers, polyamides, polyether imides, polyphenylene sulfides, polysulfones, polyacetals, polycarbonates, polyphenylene oxides, polyurethanes, thermoplastic elastomers, epoxies, alkyds, melamines, phenolics, ureas, vinyl esters, liquid crystal polymers and/or combinations thereof.

The goal of the foregoing may be to obtain print particles12aand/or a TPU foam output16having particular characteristics. Among these characteristics may be: hardness of 60±25 Shore A; specific gravity of less than 1.0; compression set of maximum 60%, and more particularly of <40%; rebound/resilience of minimum of 35%, and more particularly of >50%; elongation of minimum of 100%; a target particle size of 10 to 180 microns, more particularly, 30 to 150 microns; tensile strength of a minimum of 2 N/mm2. Additional characteristics may relate to shrinkage, light fastness, flex testing, parallel tear strength, reusability, and flowability, by way of non-limiting example.

In embodiments, to obtain one or more of the foregoing characteristics, the TPU may be suitable coated onto an absence of a particle, a unitary particle type, a compound particle, or a particle blend, acting as the base particle12c, to form the print material12ato be used in an AM creation of TPU foam16through the use of one or more of several AM processes, as discussed throughout. By way of example and as illustrated inFIG.3, particles12cmay be placed in a vessel302and fluidized304, such as using a gas304with controlled flow.

More particularly, a spray nozzle306inside the vessel302may spray306aa solution202containing the selected polymer coating12dand any necessary or desired solvents, dispersants or additives, onto base particles12c. Upon coating, the combined/compound print particles12amay be actively dried, such as after or during the fluidization and/or spraying. This spray process may be repeated, such as until all the print particles12ahave been coated and dried. Once dried, the coated particles12amay be collected, and may be further processed, such as by additional drying, post-process particle treatment, or the like, as and if needed.

Additionally and alternatively, spray drying may be used to coat TPU12donto base particles12c, as illustrated inFIG.4. By way of example, a liquid feed solution402may be made by dissolving a polymer12dinto a suitable solvent(s)202a, and adding thereto any dispersants or other additives. The solution202may be mixed, such as to reach homogeneity. In order to form foam16with the requisite porosity upon AM processing, to the mixture may be added additives130, such as hollow metal oxide and/or polymeric microspheres, for example.

After the addition of the additives130, only low shear forces may be applied so as to not damage the delicate spherical additive particles in solution202. Accordingly, low shear mixing methods may be used. For example, while the solution is being gently agitated, it may be fed into a sprayer/dryer410.

The sprayer dryer410may include an atomizer disc and a nozzle spray head, or other like-technology to atomize to provide a liquid feed. Parameters of interest to provide the liquid feed spray may include, but are not limited to: inlet temperature, exhaust temperature, HEPA pressure, chamber pressure, cyclone pressure, bagfilter pressure, disc rotating speed, liquid volume ml/min, and so on.

The solution spray202may be dried as it is atomized, to thereby form a coating12donto the base particles12c. It may be preferred that only individual spherical base particles12care coated in the embodiments, and thus it may be desirable that agglomeration is kept to a minimum. The dried, powdered print material12amay then be collected using known methodologies. Paddle, belt high shear mixing and screen drying may also be used in the embodiments, wherein, in each such case, the process is similar to that discussed herein with respect to spray drying. A high shear mixer may be used to coat base particles12cwith coating12d. The high shear mixer may be heated. For example, the high shear mixer may be heated from 20° C. to 350° C. Coating12dand base particles12cmay be added simultaneously to the high shear mixer before mixing. Alternatively, base particles12cmay be first loaded into a high shear mixer and the high shear mixer may start to mix in the absence of coating12d. Coating12dmay be added or sprayed into the high shear mixer to coat the previously loaded base particles12c. The high shear mixer may function to dry a coating12donto the base particles12c.

More specifically and by way of example, paddle drying or high shear mixing may use an indirect heat/cool source with a rotating shaft having adjustable paddles/blades to properly mix/crystallize/react the solution. After recovery of the solvent, the coating material12dmay be dried/reacted/precipitated/coated onto base particle microspheres12cover a predetermined length of time, after which time the output product12amay be collected. By way of particular example with respect to belt drying, the coating material12dmay be sprayed onto a continuous belt having thereon base particles12c, which rides into an oven that further dries the combined print material12a. The dried and coated spherical print materials12aare then collected using known methods. For screen drying, the coating material12cmay be sprayed onto a screen or a rigid substrate that includes base particles12c, and the screen or substrate may then be dried and the coated particles12aharvested therefrom.

The TPU-coated print particles12amay also be generated using general conversion. That is, a liquid feed may be used to form a solid product, such as the afore-discussed print powder particles12a. A lubricant or antistatic agent may be used to deagglomerate particles, by way of example. The material used in a general conversion process may typically have a low glass transition temperature, thereby making the material “tacky” and soft at elevated temperatures. The feed may typically comprise a polymer dissolved in a solvent, such as with a dispersant, to allow for the feed to be “sprayed onto” an activated sphere.

The coated print particles12athus created may additionally comprise flow agents, lubricants (such as silica gel), carbon black, or other additives needed to make the particles more “printable” in the selected AM technology. Yet further, coated print particles12amay be packaged so as to retain the desired properties, such as being packaged to prevent overheating, to prevent any contact with chemicals, and/or to prevent accidental crushing.

Once the coated print particles12aare created, they may be printed using an AM process14, as illustrated inFIG.5. The AM printing process14may use a laser504, and thus may be, for example, a dry blend SLS print. In such an embodiment, the TPU-coated particles12amay be dry blended with hollow glass microspheres130, and the blended powder120may then be printed to a form16, layer-by-layer, using an SLS printer as discussed above. Hollow glass microspheres130may be made of, by way of example, soda-lime-borosilicate, perlite, sodium borosilicate, clay and the like. Additionally, various other hollow microspheres130bcan also be used. For example, hollow microspheres130bmay be made from ceramic hollow microspheres such as alumino-silicate microspheres (Cenospheres) and the like. Similarly, various plastic microspheres such as those based on phenolic and amino polymers or made of a copolymer such as vinylidene chloride, acrylo-nitrile or methyl methacrylate that encapsulate a hydrocarbon blowing agent, such as isobutene or isopentane. Additional coating and functionalization of the microspheres is possible through the addition of a coating of a metal such as aluminum, silver, copper, stainless steel, platinum, zinc or gold. In another example, hollow microspheres may also be utilized.

In another embodiment, carbon spheres may be used, which may be comprised of carbon nanotubes bonded to the surface of spheres made from graphitization or pyrolysis of polymer spheres. The syntactic foam part that results of the additive manufacturing process may contain any of the above, in any combination. Typical microsphere sizes range from 1 to 200 μM.

Alternatively, base particles12cmay be dry blended with hollow glass microspheres130or another light weight filler and the blended powder may then be printed to form an output part16. The light weight filler may comprise an acrylic copolymer that encapsulates a blowing agent. The blowing agent may comprise isobutane. Alternatively, the light weight filler may comprise phenolic microspheres comprising phenol formaldehyde resin. Alternatively, the light weight filler may comprise cenospheres, which may comprise alumino-silicate microspheres. The combination of polymer matrix and microsphere produces syntactic foams, where previously this technology has not been utilized in powder bed additive manufacturing. Crush strength can be tuned by defining the wall thickness and particle size distribution of the light weighting filler used. Table 1 illustrates the ranges of particle size and density values of several low density microspheres. Table 1.

TABLE 1Ranges of particle size and densityvalues of low density microspheres.Typical TrueTypical average particleMicropshereDensity (g/cc)size, Volume D50 (μm)Phenolic0.1 to 0.45 to 150Acrylic copolymer0.02 to 0.215 to 95Hollow Glass0.12 to 0.61 to 200Carbon0.04 to 0.35 to 150

Similarly, wherein the AM printing process is a powder bed fusion process, a single thin layer, such as an approximately 0.1 mm thick layer, of compound print material12ain powder120, such as may be created using the methodologies discussed above, may be spread over a build platform. The laser504may then fuse the first layer, or first cross section, of the model. Thereafter, a new layer of the compound print material12ain powder120is spread across the previous layer, such as using a roller. Further layers or cross sections may then be added until the entire model is created. Loose, unfused powder print material may remain in position throughout, but may be removed during post processing, by way of non-limiting example.

Also in a manner similar to that ofFIG.5, binder jetting may use a “binder”, rather than or in addition to a laser504. In such an embodiment, the powder print material12amay be spread over the build platform, such as using a roller. A print head may then deposit a binder adhesive on top of the powder where required. The build platform may then be lowered by the model's layer thickness. Another layer of powder may then be spread over the previous layer, and the object is formed where the powder is bound to the liquid, layer-by-layer.

An ink jet based methodology, such as multijet fusion or high speed sintering may operate in a manner similar to the powder bed fusion, but may employ heat lamps or similar technologies, rather than a laser. Likewise, in a directed energy deposition AM method, an axis arm with a nozzle may move around a fixed object, and the print material12amay be deposited from the nozzle onto existing surfaces of the object. The material may be provided, by way of example, in wire/filament or powder form, and may be melted for dispersal from the nozzle using a laser, electron beam or plasma arc.

Various other methodologies may provide a suitable format for the combined/compound print particles12ato enable or improve printing using AM technologies. For example, a sheet may be made from the combined/compound powder print materials, or a filament may be provided. Moreover, additives may be provided in the print material to enable or improve printing and/or foam formation. Additive materials may include, but are not limited to, hollow metal oxide beads or hollow polymeric spheres, solid glass bead, glass fibers, talc, nonoclay, carbon fibers, carbon black, metal oxides, copper metals, flame retardants, antioxidants, pigments, crosslinking agents, chain extenders, thermoplastic polymer powders and flow aids. Such beads or spheres may provide varied crushing behavior in void-forming for foam formation. Yet further, certain additives may be used in particular for certain foam types, such as blow-molded foams.

In each such embodiment, parameters of interest for the combined/compound print material12amay include parameters such as moisture level, heat of build chamber, heater power and temperature emitted, time of heat exposure, time between layers, recoating rate/thickness, feed rate, feed temperature, pressure and vacuum, gas flow rate, and the like. In short, the TPU coating12don the inner-particle12cmelts, such as upon exposure to a laser, and thus fuses to nearby particles during an AM process. As such, the print material12ashould melt during the selected AM print process14past its respective TPU-coating melting point, and should be subjected to a lowered modulus sufficient for the TPU-coating to flow. Under such circumstances, the respective polymer chains may suitably bond with those of the particle next to each particle, to form output16. The selected AM print process14may allow that bond to cool, and thus the cooled particle chains form a solid layer in output16. Of course, each print material12may also be subjected to additives130as discussed throughout, such as may aid with melting or flow during melting, with impact resistance, or with heat stabilization, by way of example, dependent upon the AM process selected. Where a dry mixture of TPU and a light weight filler are used in an AM process, the TPU will melt and fuse to nearby particles upon exposure to electromagnetic energy while the light weight filler will not melt.

In a specific exemplary embodiment of the foregoing, and as illustrated inFIG.6, an end-to-end AM process, such as a shoe sole making process, may include preparation of the print material, which may include drying, cleaning, etching, dissolving the polymer, and the addition of additives such as dispersing agents, anti-static agents, surfactants, viscosity modifiers, and flow agents, at step1202. Thereafter, the print material may be subjected to a liquid-solid conversion to form coated particles at step1204. Additional processing, such as drying, infusing additives, and so on may be performed at step1206.

The print material, once formed, may be packaged for printing at step1208. This packaging at step1208may be tailored to the specific AM print process to be employed. The print material may be fed into an AM printer at step1210, and a part printed therefrom at step1212. The AM printer feed1210may include an AMF, as discussed above, which may include the desired layer-by-layer gradients for the final part, a shape and a size of the final part, and so on. The part may be post processed, cut, and/or crushed to form the final part at step1214.

More specifically, step1214may comprise a shoe sole making process. The process1214may include crushing using a roller, wherein the roller may have a built in mold, and wherein a continuous feed of printed parts may be fed into roller. Similarly, a CNC 3 axis or 5 axis machine may apply a crushing force over a particular area of the printed part.

A hot isostatic compaction may also be employed. Hammering or stamping may be used as well, such as to simply crush the areas of the printed parts that are needed. Stamping or hammering may provide the desired contours and gradient properties, such as for attachment to a shoe.

In short, step1214may include changing the mechanical integrity of the part. After the change in mechanical integrity, step1214may further comprise additional cleaning or finishing steps, such as annealing, coating, curing, treating, washing the part, or any other process which would prepare the part, such as a shoe sole, for bonding.

Of course, step1214may also comprise in situ part formation, such as combined outsole and insole, using the native AM processes. As such, in addition to the foregoing, adhesives, heat, coloring, finishing, coating (including, e.g., antimicrobial) may be added along the process (i.e., the cutting or crushing) path at step1214to create and/or attach the final part. As such, the embodiments may eliminate the historical need for adhering together different aspects of a shoe.

Yet further, post processing may include the cleaning of residual powder from the “part cake,” which cleaning may include: brushing, blowing, grit blasting, tumbling, shaking, spraying, bathing, or other methods of cleaning the part, by way of non-limiting example.

In the aforementioned exemplary embodiment of a shoe sole, the disclosed processes eliminate at least: excess rubber trim-off; the need for mixing of rubber/molding compound; the fusing of insole and outsole; human labor in the molding process, and thus human error in molding process; disclosure of the release-agent chemistries for most of shoe sole; the need for adhesives or bonding agents between layers of the shoe; and the like. The may also provide several advantages, including: allowing for quick iterations on design of footwear, thereby reducing design time and costs; allowing for multiple footwear designs, each with multiple properties, to be produced in the same build, thereby reducing production costs and time.

As such, an output part16processed as described herein may provide correlated characteristics that are indicative of, and/or correlated to, the input material12a, and which occur pursuant to application of AM process14, as described herein throughout. Such correlated characteristics may be measured, by way of non-limiting example, by heat-flowing a sample of the input12aand/or the output16, and then measuring thermal characteristics of the heat-flowed sample, such as Tm, Tg, Tcryst, heat of fusion, and the like. Likewise, infrared microscopy may allow for identification of the wavelengths of the corresponding chemical structures of the input material and/or the output object layers. Yet further, a thermogravimetric or similar analysis may be performed on a sample of the input material12aor printed output16, and this analysis may further include measurement of the composition of decomposition gases as the sample degrades, by way of example.

Of course, in view of the aforementioned prospective correlation of characteristics between an input print material12aand a printed output object16, the correlated characteristics of output object16may vary dependently not only in accordance with the input material12a, but additionally based upon the process14employed to print the print material12ainto the output object16. Accordingly, one or more computing programs/algorithms1190, such as may comprise one or more AMF files; one or more input material12aand/or additive130choices; one or more process14choices and/or one or more process characteristics choices; and/or one or more output16shape, size, and/or characteristic choices, may be executed by a computing system1100. This execution may occur, for example, pursuant to an instruction to a GUI, such as to provide a particular correlation as between a TPU-coated input material12aand/or additives130and a specific output object characteristic, and/or to use a particular available input material12, using an available process14, to target the ultimate production of a particular output object16. This is illustrated with particularity inFIG.7.

More particularly,FIG.7depicts an exemplary computing system1100for use in association with the herein described systems and methods. Computing system1100is capable of executing software, such as an operating system (OS) and/or one or more computing applications/algorithms1190, such as applications applying the correlation algorithms discussed herein, and may execute such applications1190using data, such as materials and process-related data, which may be stored1115locally or remotely.

That is, the application(s)1190may access, from a local or remote storage locations1115, different TPU powders, fillers and compounds; powder-centric processes; and output object characteristics. The application1190may then allow a user, such as using a GUI, to select, for example, an input material, and, such as based on user selection of a process and/or process characteristics to which the input material was to be subjected, to provide the user with a variety of characteristics of the output object characteristics. Of course, likewise, a user may select desired output characteristics, and may be able to select one or more processes and/or process characteristics, and may be provided with an input material (including compound and/or fillers) that may be needed to obtain he desired selected output using the selected process.

More particularly, the operation of an exemplary computing system1100is controlled primarily by computer readable instructions, such as instructions stored in a computer readable storage medium, such as hard disk drive (HDD)1115, optical disk (not shown) such as a CD or DVD, solid state drive (not shown) such as a USB “thumb drive,” or the like. Such instructions may be executed within central processing unit (CPU)1110to cause computing system1100to perform the operations discussed throughout. In many known computer servers, workstations, personal computers, and the like, CPU1110is implemented in an integrated circuit called a processor.

It is appreciated that, although exemplary computing system1100is shown to comprise a single CPU1110, such description is merely illustrative, as computing system1100may comprise a plurality of CPUs1110. Additionally, computing system1100may exploit the resources of remote CPUs (not shown), for example, through communications network1170or some other data communications means.

In operation, CPU1110fetches, decodes, and executes instructions from a computer readable storage medium, such as HDD1115. Such instructions may be included in software, such as an operating system (OS), executable programs such as the aforementioned correlation applications, and the like. Information, such as computer instructions and other computer readable data, is transferred between components of computing system1100via the system's main data-transfer path. The main data-transfer path may use a system bus architecture1105, although other computer architectures (not shown) can be used, such as architectures using serializers and deserializers and crossbar switches to communicate data between devices over serial communication paths. System bus1105may include data lines for sending data, address lines for sending addresses, and control lines for sending interrupts and for operating the system bus. Some busses provide bus arbitration that regulates access to the bus by extension cards, controllers, and CPU1110.

Memory devices coupled to system bus1105may include random access memory (RAM)1125and/or read only memory (ROM)1130. Such memories include circuitry that allows information to be stored and retrieved. ROMs1130generally contain stored data that cannot be modified. Data stored in RAM1125can be read or changed by CPU1110or other hardware devices. Access to RAM1125and/or ROM1130may be controlled by memory controller1120. Memory controller1120may provide an address translation function that translates virtual addresses into physical addresses as instructions are executed. Memory controller1120may also provide a memory protection function that isolates processes within the system and isolates system processes from user processes. Thus, a program running in user mode may normally access only memory mapped by its own process virtual address space; in such instances, the program cannot access memory within another process' virtual address space unless memory sharing between the processes has been set up.

In addition, computing system1100may contain peripheral communications bus1135, which is responsible for communicating instructions from CPU1110to, and/or receiving data from, peripherals, such as peripherals1140,1145, and1150, which may include printers, keyboards, and/or the sensors discussed herein throughout. An example of a peripheral bus is the Peripheral Component Interconnect (PCI) bus.

Display1160, which is controlled by display controller1155, may be used to display visual output and/or other presentations generated by or at the request of computing system1100, such as in the form of a GUI, responsive to operation of the aforementioned computing program(s). Such visual output may include text, graphics, animated graphics, and/or video, for example. Display1160may be implemented with a CRT-based video display, an LCD or LED-based display, a gas plasma-based flat-panel display, a touch-panel display, or the like. Display controller1155includes electronic components required to generate a video signal that is sent to display1160.

Further, computing system1100may contain network adapter1165which may be used to couple computing system1100to external communication network1170, which may include or provide access to the Internet, an intranet, an extranet, or the like. Communications network1170may provide user access for computing system1100with means of communicating and transferring software and information electronically. Additionally, communications network1170may provide for distributed processing, which involves several computers and the sharing of workloads or cooperative efforts in performing a task. It is appreciated that the network connections shown are exemplary and other means of establishing communications links between computing system1100and remote users may be used.

Network adaptor1165may communicate to and from network1170using any available wired or wireless technologies. Such technologies may include, by way of non-limiting example, cellular, Wi-Fi, Bluetooth, infrared, or the like.

It is appreciated that exemplary computing system1100is merely illustrative of a computing environment in which the herein described systems and methods may operate, and does not limit the implementation of the herein described systems and methods in computing environments having differing components and configurations. That is to say, the inventive concepts described herein may be implemented in various computing environments using various components and configurations.

In the foregoing detailed description, it may be that various features are grouped together in individual embodiments for the purpose of brevity in the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that any subsequently claimed embodiments require more features than are expressly recited.

Further, the descriptions of the disclosure are provided to enable any person skilled in the art to make or use the disclosed embodiments. Various modifications to the disclosure will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other variations without departing from the spirit or scope of the disclosure. Thus, the disclosure is not intended to be limited to the examples and designs described herein, but rather is to be accorded the widest scope consistent with the principles and novel features disclosed herein.