Method for forming three-dimensional structures with different material portions

Patent metadata

Field	Value
Publication number	US-11214024-B2
Application number	US-201916375804-A
Country	US
Kind code	B2
Filing date	Apr 4, 2019
Priority date	May 9, 2014
Publication date	Jan 4, 2022
Grant date	Jan 4, 2022

Abstract

A system and method for forming 3D printed structures includes printing an outer shell portion and filling an interior of the outer shell portion to form an inner portion. The outer shell portion and inner portion may have differing material properties. The outer shell portion may be anchored to the base component.

First claim

We claim:

1. A method of manufacturing a structure for permanent attachment to a base component, comprising:
aligning a first nozzle with an opening in the base component, the first nozzle being located adjacent to a first side of the base component;
forming an anchored portion on a second side of the base component, including extruding a first material from the first nozzle through the opening and into a molding component on the second side;
extruding the first material from the first nozzle on the first side to form an outer shell portion of the structure, wherein the outer shell portion is integrally formed with the anchored portion and wherein the outer shell portion includes an upper opening; and
forming an inner portion of the structure, including filling an interior of the outer shell portion by extruding a second material through a second nozzle and into the upper opening of the outer shell portion.

2. The method according to claim 1 , wherein the method includes forming a portion of the structure extending outside of the outer shell portion, wherein the portion of the structure is formed from the second material.

3. The method according to claim 1 , wherein the method includes forming more than one anchored portion on the second side of the base component, wherein the outer shell portion is integrally formed with each of the anchored portions.

4. The method according to claim 1 , wherein the outer shell portion helps to keep the inner portion in place on the base component.

5. The method according to claim 1 , wherein the outer shell portion is cured before the second material is extruded into the interior of the outer shell portion.

6. The method according to claim 1 , wherein the first material has a first rigidity when the outer shell portion is cured and wherein the second material has a second rigidity when the inner portion is cured, wherein the second rigidity is greater than the first rigidity.

7. The method according to claim 1 , wherein the first material has a first rigidity when the outer shell portion is cured and wherein the second material has a second rigidity when the inner portion is cured, wherein the second rigidity is less than the first rigidity.

8. The method according to claim 6 , wherein the first material is rubber and the second material is a plastic material.

9. The method according to claim 7 , wherein the first material is a plastic material and the second material is a foam material.

10. The method according to claim 1 , wherein the first material and the second material are the same material.

Assignees

• Nike Inc

Inventors

• Sterman Yoav
• Waatti Todd A

Classifications

• A43B13/26

  projecting beyond the sole surface · CPC title

• A43C19/00

  Attachments for footwear, not provided for in other groups of this subclass · CPC title

• A43C3/00

  Hooks for laces (making from sheet metal B21D53/46); Guards for hooks · CPC title

• A43C15/162

  characterised by the shape · CPC title

• B29C70/745 Primary

  Filling cavities in the preformed part (for joining B29C70/84) · CPC title