System and method for forming three-dimensional structures with different material portions

Patent metadata

Field	Value
Publication number	US-2017239902-A1
Application number	US-201715590966-A
Country	US
Kind code	A1
Filing date	May 9, 2017
Priority date	May 9, 2014
Publication date	Aug 24, 2017
Grant date	—

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

What is claimed is:

1 . A method of manufacturing a structure for permanent attachment to a base component, comprising:
associating a first nozzle with the base component, the first nozzle having a first aperture size; forming an outer shell portion of the structure on the base component by extruding a first material through the first nozzle, wherein the outer shell portion is formed with at least one opening providing access to an interior of the outer shell portion; removing the first nozzle from an area near the outer shell portion; associating a second nozzle having a second aperture size with the at least one opening, wherein the second aperture size is greater than the first aperture size; and extruding a second material through the second nozzle and into the at least one opening, thereby forming an inner portion of the structure.

2 . 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.

3 . 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.

4 . The method according to claim 3 , wherein the second rigidity is greater than the first rigidity.

5 . The method according to claim 4 , wherein the first material is rubber and the second material is a plastic material.

6 . The method according to claim 3 , wherein the second rigidity is less than the first rigidity.

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

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

9 . The method according to claim 1 , wherein the structure is a cleat member and the base component is a sole structure of an article of footwear.

10 . The method according to claim 1 , wherein the first nozzle can be moved independently of the second nozzle.

11 . The method according to claim 1 , wherein the outer shell portion is formed using a filament fused fabrication printing process.

12 . 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 nozzle being located adjacent to a first side of the base component; extruding a first material through the opening and into a molding component on a second side of the base component, thereby forming an anchored portion 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 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, thereby forming an inner portion of the structure.

13 . The method according to claim 12 , 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.

14 . The method according to claim 12 , wherein the method includes forming several anchored portions on the second side of the base component, wherein the outer shell portion is integrally formed with each of the several anchored portions.

15 . The method according to claim 12 , wherein the outer shell portion helps to keep the inner portion in place on the base component.

Assignees

• Nike Inc

Inventors

• Sterman Yoav
• Waati Todd A

Classifications

• B29C64/118 Primary

  using filamentary material being melted, e.g. fused deposition modelling [FDM] · CPC title

• A43C3/00

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

• A43C19/00

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

• A43B13/26

  projecting beyond the sole surface · CPC title

• A43C15/162

  characterised by the shape · CPC title