阅读说明：本技术 纱线结构的选择性附接 (Selective attachment of yarn structures ) 是由 托得·A·瓦提 约阿夫·斯特曼 于 2016-09-21 设计创作，主要内容包括：本申请涉及纱线结构的选择性附接。公开了方法和系统。一种打印到基底(144)上的方法,基底具有上表面(148),上表面以基底厚度(204)与下表面(150)间隔开,该方法包括：从打印系统的喷嘴(118)分配纱线(151)以及将纱线选择性地附接到第一附接区(152)。分配纱线的步骤包括分配可热塑材料(156)和耐熔融材料(158)。将纱线选择性地附接到第一附接区的步骤包括使喷嘴移动到第一附接区中。使喷嘴移动到第一附接区中的步骤使基底厚度减小刺入距离(206)。可热塑材料结合到第一附接区。(The present application relates to selective attachment of yarn structures. Methods and systems are disclosed. A method of printing onto a substrate (144), the substrate having an upper surface (148) spaced apart from a lower surface (150) by a substrate thickness (204), the method comprising: a yarn (151) is dispensed from a nozzle (118) of the printing system and selectively attached to a first attachment region (152). The step of dispensing the yarn includes dispensing a heat-moldable material (156) and a melt-resistant material (158). The step of selectively attaching the yarn to the first attachment region includes moving the nozzle into the first attachment region. The step of moving the nozzle into the first attachment region reduces the substrate thickness by a piercing distance (206). The thermoplastic material is bonded to the first attachment zone.)

1. An article of apparel, comprising:

a yarn printed on the upper surface of the article of apparel, the yarn comprising a thermo-plastic material and a melt-resistant material;

a plurality of attachment areas in which the yarn is bonded to the upper surface of the article of apparel, the plurality of attachment areas including at least a first attachment area and a second attachment area; and

at least one non-attachment region in which the yarns are not bonded to the upper surface, the at least one non-attachment region including at least a first non-attachment region located between the first attachment region and the second attachment region.

2. The article of apparel recited in claim 1, wherein the yarn is bonded to the upper surface of the article of apparel at the plurality of attachment zones by contacting the upper surface of the article of apparel with the thermo-moldable material during transition of the thermo-moldable material from a liquid state to a solid state.

3. The article of apparel recited in claim 2, wherein the at least one non-attachment region is a plurality of non-attachment regions at which the thermoplasticity material of the yarn is spaced from the upper surface of the article of apparel.

4. The article of apparel recited in claim 3, wherein the thermo-moldable material is attached to the melt-resistant material in the plurality of unattached regions.

5. The article of apparel recited in claim 3, wherein the yarn is bonded to the attachment areas along a first length, and adjoining attachment areas of the plurality of attachment areas are spaced apart at a spacing length that is greater than the first length.

6. The article of apparel recited in claim 3, wherein adjoining attachment areas of the plurality of attachment areas are spaced apart at intervals that vary along a length of the yarn.

7. The article of apparel recited in claim 1, further including structures extending from the upper surface of the article of apparel,

wherein the yarns extend at least partially around the structure.

8. The article of apparel recited in claim 7, wherein the structures are pillars.

9. The article of apparel recited in claim 1, wherein the melt-resistant material includes a textile.

10. The article of apparel recited in claim 1, wherein the melt-resistant material includes a plant material.

11. The article of apparel recited in claim 1, wherein the melt-resistant material includes an animal material.

12. The article of apparel recited in claim 1, wherein the article of apparel is an article of apparel.

13. The article of apparel recited in claim 1, wherein the article of apparel is an article of footwear.

14. An article of apparel, comprising:

a yarn printed on the upper surface of the article of apparel, the yarn comprising a thermo-plastic material and a melt-resistant material;

a plurality of attachment areas in which the yarn is bonded to the upper surface of the article of apparel, the plurality of attachment areas including at least a first attachment area and a second attachment area; and

a plurality of unattached regions in which the yarns are not bonded to the upper surface,

wherein the plurality of non-attachment regions are configured to allow the yarn to freely move away from the upper surface of the article of apparel.

15. The article of apparel recited in claim 14, further including a fastener,

wherein at least a portion of the yarn in the non-attachment zone is movable from a first position in which the yarn is attached to the fastener to a second position in which the yarn is not attached to the fastener.

16. The article of apparel recited in claim 15, wherein the yarn is bonded to the upper surface of the article of apparel at the plurality of attachment zones by contacting the upper surface of the article of apparel with the thermo-moldable material during transition of the thermo-moldable material from a liquid state to a solid state.

17. The article of apparel recited in claim 14, wherein the thermo-moldable material is attached to the melt-resistant material in the plurality of unattached regions.

18. The article of apparel recited in claim 17, wherein the yarn is incorporated into the attachment areas at a first length, and adjoining attachment areas of the plurality of attachment areas are spaced apart at a spacing length that is greater than the first length.

19. The article of apparel recited in claim 15, wherein the fastener includes a post that extends from the upper surface of the article of apparel.

20. The article of apparel recited in claim 14, wherein the melt-resistant material includes a textile.

21. The article of apparel recited in claim 14, wherein the melt-resistant material includes a plant material.

22. The article of apparel recited in claim 14, wherein the melt-resistant material includes an animal material.

23. The article of apparel recited in claim 14, wherein the article of apparel is an article of apparel.

24. The article of apparel recited in claim 14, wherein the article of apparel is an article of footwear.

Technical Field

The present embodiments generally relate to three-dimensional printing systems and methods.

Background

Three-dimensional printing systems and methods may be associated with various technologies including Fused Deposition Modeling (FDM), electron beam free form fabrication (EBF), Selective Laser Sintering (SLS), and other kinds of three-dimensional printing techniques.

Structures formed by three-dimensional printing systems may be used with objects formed by other fabrication techniques. These objects include textile materials used in various articles of footwear and/or articles of apparel.

Disclosure of Invention

The present application relates generally to, but is not limited to, the following:

1) a method of printing a yarn onto a substrate, the method comprising:

dispensing the yarn from a nozzle of a printing system, the yarn comprising a thermoplastic material and a melt-resistant material;

wherein the step of dispensing the yarn comprises dispensing the thermo-moldable material in a liquid state, and wherein the step of dispensing the yarn comprises dispensing the melt-resistant material in a solid state;

selectively attaching the yarn to an attachment region of the substrate by moving the nozzle along a first axis into the attachment region;

wherein the first axis is approximately orthogonal to the upper surface;

wherein the substrate has the upper surface spaced from a lower surface by a substrate thickness;

wherein the step of moving the nozzle into the attachment zone along the first axis reduces the substrate thickness by a penetration distance; and is

Wherein the thermoplastic material bonds to the attachment zone during a transition of the thermoplastic material from a liquid state to a solid state of the thermoplastic material.

2) The method of 1), wherein the thermoplastic material bonds to the melt-resistant material during the transition of the thermoplastic material from a liquid state to a solid state.

3) The method of any of 1) to 2), wherein the penetration distance is less than half of the substrate thickness.

4) The method of any of 1) to 3), wherein the yarn has a yarn thickness; and is

Wherein the penetration distance is less than twice the thickness of the yarn.

5) The method of any of 1) through 4), further comprising:

after selectively attaching the yarn, moving the nozzle away from the attachment zone along the first axis; and is

Wherein, after the step of moving the nozzle away from the attachment region along the first axis, the attachment region is spaced from the lower surface by the substrate thickness.

6) The method of any of 1) to 5), further comprising:

after selectively attaching the yarn, moving the nozzle along a second axis toward a non-attachment zone;

wherein the second axis is approximately parallel to the upper surface of the substrate; and is

Wherein, after moving the nozzle along the second axis toward the non-attachment region, a continuous section of the yarn extends from the attachment region to the non-attachment region.

7) The method of any of 1) to 6), wherein the nozzle has a tip area; and is

Wherein the attachment region has a surface area approximately equal to the tip area.

8) A method of printing onto a substrate, the method comprising:

positioning a nozzle of a printing system over an upper surface of the substrate;

dispensing a yarn from the nozzle;

wherein the upper surface comprises at least a first attachment area and a second attachment area for bonding the yarn to the substrate;

wherein the yarn comprises a thermoplastic material and a melt-resistant material;

wherein the step of dispensing the yarn comprises dispensing the thermo-plastic material of the yarn in a liquid state, and wherein the step of dispensing the yarn comprises dispensing the melt resistant material of the yarn in a solid state;

selectively attaching the yarn to the first attachment region by lowering the nozzle toward and into direct contact with the first attachment region;

wherein after the yarn contacts the first attachment zone, a first portion of the thermo-moldable material of the yarn transitions from a liquid state to a solid state of the thermo-moldable material, thereby bonding the yarn to the first attachment zone;

selectively attaching the yarn to the second attachment region by lowering the nozzle toward and into direct contact with the second attachment region; and is

Wherein after the yarn contacts the second attachment zone, a second portion of the thermo-moldable material of the yarn transitions from a liquid state to a solid state of the thermo-moldable material, thereby bonding the yarn to the second attachment zone.

9) The method of 8), wherein lowering the nozzle toward the first attachment region includes moving the nozzle only along an axis normal to the upper surface of the substrate.

10) The method of claim 9), further comprising the step of raising the nozzle away from the upper surface of the base after selectively attaching the yarn to the first attachment zone.

11) The method of claim 10), further comprising moving the nozzle toward the second attachment region along an axis parallel to the upper surface of the substrate.

12) The method of 11), wherein lowering the nozzle toward the second attachment region comprises moving the nozzle only along the axis normal to the upper surface of the substrate.

13) The method of claim 12), wherein the continuous segment of yarn extends from the first attachment area to the second attachment area.

14) The method of any of claims 8) to 13), wherein the first portion of the thermo-moldable material is bonded to the melt-resistant material at the first attachment region, and wherein the second portion of the thermo-moldable material is bonded to the melt-resistant material at the second attachment region.

15) A system for printing onto a substrate, the system for printing onto a substrate comprising:

a yarn comprising a thermoplastically processable material and a melt resistant material;

a heating system configured to heat the yarn;

wherein the heating system heats the yarn such that the thermo-moldable material is in a liquid state and the melt resistant material is in a solid state;

a nozzle assembly configured to dispense the yarn onto the substrate, the substrate having an upper surface and a lower surface;

wherein the nozzle assembly dispenses the thermoplastic material of the yarn in a liquid state and the melt-resistant material of the yarn in a solid state;

an actuation system configured to lower the nozzle assembly into direct contact with a first attachment region of the upper surface and configured to raise the nozzle assembly away from the first attachment region of the upper surface;

wherein the actuation system is further configured to move the nozzle assembly along at least one axis parallel to the upper surface of the substrate;

wherein a first portion of the thermo-moldable material of the yarn is configured to transition from a liquid state to a solid state of the thermo-moldable material upon direct contact with the first attachment region such that the first portion is bonded to the first attachment region; and is

Wherein the melt-resistant material of the yarn is configured to remain as a continuous segment extending from the nozzle assembly to the first attachment zone during transition of the first portion of the thermo-moldable material from a liquid state to a solid state of the thermo-moldable material.

16) The system for printing onto a substrate of claim 15), wherein the upper surface comprises a first non-attachment region;

wherein the actuation system is configured to provide the yarn over the first non-attachment region by moving the nozzle assembly along the axis parallel to the upper surface in a direction away from the first attachment region; and is

Wherein the melt resistant material of the yarn is configured to remain as the continuous segment extending from the nozzle assembly to the first non-attachment region after moving the nozzle assembly away from the first attachment region.

17) The system for printing onto a substrate of claim 16), wherein the first non-attachment region is disposed adjacent to the first attachment region.

18) The system for printing onto a substrate of any of claims 16) to 17), wherein the upper surface comprises a second attachment region;

wherein the actuation system is configured to lower the nozzle assembly into direct contact with the second attachment region of the upper surface, thereby placing the yarn in direct contact with the second attachment region;

wherein a second portion of the thermo-moldable material of the yarn is configured to transition from a liquid state to a solid state of the thermo-moldable material upon direct contact with the second attachment zone such that the yarn is bonded to the second attachment zone; and is

Wherein the melt-resistant material of the yarn is configured to remain as the continuous segment extending from the nozzle assembly to the second attachment zone during transition of the second portion of the thermo-moldable material from a liquid state to a solid state of the thermo-moldable material.

19) The system for printing onto a substrate of claim 18), wherein the substrate comprises a post for shaping the yarn; and is

Wherein the actuation system is further configured to move the nozzle assembly from the first attachment region of the upper surface to the second attachment region of the upper surface such that the yarn is in direct contact with the post.

20) The system for printing onto a substrate of any of claims 18) to 19), wherein the upper surface comprises a third attachment zone;

wherein the actuation system is configured to lower the nozzle assembly into direct contact with the third attachment area of the upper surface, thereby placing the yarn in direct contact with the third attachment area;

wherein a third portion of the thermo-moldable material of the yarn is configured to transition from a liquid state to a solid state of the thermo-moldable material upon direct contact with the third attachment zone such that the yarn bonds to the third attachment zone; and is

Wherein the melt-resistant material of the yarn is configured to remain as the continuous segment extending from the nozzle assembly to the third attachment zone during transition of the third portion of the thermo-moldable material from a liquid state to a solid state of the thermo-moldable material.

21) The system of 20) for printing onto a substrate, wherein the first attachment area is spaced further from the second attachment area than the second attachment area is spaced from the third attachment area.

22) The system for printing onto a substrate as claimed in any one of claims 18) to 21),

wherein the actuation system lowers the nozzle assembly a first separation distance into direct contact with the first attachment region of the upper surface;

wherein the actuation system lowers the nozzle assembly a second separation distance into direct contact with the second attachment region of the upper surface; and is

Wherein the first separation distance and the second separation distance are different.

23) The system for printing onto a substrate of any of claims 15) to 22), wherein the continuous segment extending from the nozzle assembly to the first attachment region is spaced apart from the lower surface of the substrate.

24) The system for printing onto a substrate of any of claims 15) to 23), wherein the first portion of the thermoplasticity material of the yarn bonds to the melt-resistant material of the yarn during the transition of the first portion of the thermoplasticity material from a liquid state to a solid state of the thermoplasticity material.

Brief Description of Drawings

Embodiments may be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the embodiments. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views.

FIG. 1 is a schematic diagram of components of a three-dimensional printing system and several embodiments of articles that may be used with the three-dimensional printing system;

FIG. 2 is a schematic diagram of an embodiment of a printing apparatus and a substrate (base);

FIG. 3 is a schematic illustration of an attachment zone according to an exemplary embodiment;

FIG. 4 is a schematic illustration of a non-attachment region according to an exemplary embodiment;

FIG. 5 is a schematic diagram of an embodiment of a printing device;

FIG. 6 is a schematic view of a process of positioning a nozzle over an upper surface of a substrate according to an exemplary embodiment;

FIG. 7 is a schematic diagram of a process of moving a nozzle along an upper surface of a substrate according to an exemplary embodiment;

FIG. 8 is a schematic illustration of a process of lowering a nozzle into an attachment zone of an upper surface of a substrate according to an exemplary embodiment;

FIG. 9 is a schematic illustration of a process of lowering a nozzle into the attachment region of FIG. 8 to reduce a substrate thickness of a substrate according to an exemplary embodiment;

FIG. 10 is a schematic illustration of a process of raising a nozzle from the attachment region of FIG. 8, according to an exemplary embodiment;

fig. 11 is a schematic illustration of a process of moving a nozzle along an upper surface of a substrate and away from an attachment zone of fig. 8, according to an exemplary embodiment;

FIG. 12 is a schematic illustration of flexibly moving a yarn away from a non-attachment area while maintaining attachment at the attachment area of FIG. 8, according to an exemplary embodiment;

FIG. 13 is a schematic illustration of a process of moving a nozzle along an upper surface of a substrate and toward an attachment region, according to an exemplary embodiment;

FIG. 14 is a schematic illustration of a process of lowering a nozzle into the attachment region of FIG. 13, according to an exemplary embodiment;

FIG. 15 is a schematic illustration of a process of lowering a nozzle into the attachment region of FIG. 13 to reduce a substrate thickness of a substrate, according to an exemplary embodiment;

FIG. 16 is a schematic illustration of a process of raising a nozzle from the attachment region of FIG. 13, according to an exemplary embodiment;

FIG. 17 is a schematic illustration of flexibly moving a yarn away from a non-attachment area while maintaining attachment at the attachment area of FIG. 8 and while maintaining attachment at the attachment area of FIG. 13, according to an exemplary embodiment;

FIG. 18 is a schematic diagram of a process of moving a nozzle relative to a substrate using a first separation distance (separation distance) and a first distance between attachment regions, according to an exemplary embodiment;

fig. 19 is a schematic illustration of attaching a yarn to a substrate using the process of fig. 18, according to an exemplary embodiment;

FIG. 20 is a schematic view of a process for moving a nozzle relative to a substrate using a second separation distance and a second distance between attachment zones, according to an exemplary embodiment;

fig. 21 is a schematic illustration of attaching a yarn to a substrate using the process of fig. 20, according to an exemplary embodiment;

FIG. 22 is a schematic diagram of a process of moving a nozzle relative to a substrate using a third separation distance and a third distance between attachment zones, according to an exemplary embodiment;

fig. 23 is a schematic illustration of attaching a yarn to a substrate using the process of fig. 22, according to an exemplary embodiment;

fig. 24 is an isometric view of attaching a yarn to a substrate according to an exemplary embodiment;

fig. 25 is an isometric view of a yarn attached to a base using a post according to an exemplary embodiment;

FIG. 26 is a schematic illustration of a yarn structure in an attached state according to an exemplary embodiment; and

fig. 27 is a schematic illustration of the yarn structure of fig. 26 in a separated state according to an exemplary embodiment.

Detailed Description

In one aspect, a method of printing onto a substrate includes receiving a substrate and dispensing a yarn from a nozzle of a printing system. The substrate has an upper surface spaced from a lower surface by a substrate thickness. The upper surface includes a plurality of attachment zones for bonding the yarns to the substrate. The plurality of attachment regions includes a first attachment region. The yarns include a heat moldable material and a melt resistant material. The step of dispensing the yarn includes dispensing the thermoplastic material in a liquid state. The step of dispensing the yarn includes dispensing a melt-resistant material in a solid state. The upper surface includes a plurality of attachment zones for bonding the yarns to the substrate. The method includes selectively attaching the yarn to an attachment zone of the plurality of attachment zones by moving the nozzle along the first axis into the attachment zone. The first axis is approximately orthogonal to the upper surface. The step of moving the nozzle into the first attachment region along the first axis reduces the substrate thickness by a puncturing distance (mounting distance). During the transition of the thermoplastic material from the liquid state to the solid state, the thermoplastic material bonds to the first attachment zone.

In another aspect, a method of printing onto a substrate includes positioning a nozzle of a printing system above an upper surface of the substrate and dispensing a yarn from the nozzle. The upper surface includes at least a first attachment area and a second attachment area for bonding the yarn to the substrate. The yarn includes a thermoplastic material and a melt-resistant material. The step of dispensing the yarn includes dispensing the thermoplastic material of the yarn in a liquid state. The step of dispensing the yarn includes dispensing the yarn of a melt-resistant material in a solid state. The method also includes selectively attaching the yarn to a first attachment zone of the plurality of attachment zones by lowering the nozzle into direct contact with the first attachment zone, thereby placing the yarn in direct contact with the first attachment zone. The step of lowering the nozzle into direct contact with the first attachment zone comprises transforming a first portion of the thermo-plastic material of the yarn from a liquid state to a solid state. The first portion of the thermoplastic material is bonded to the first attachment zone during the transformation of the first portion of the thermoplastic material. The method also includes selectively attaching the yarn to the second attachment region by moving the nozzle toward the second attachment region and by moving the nozzle into direct contact with the second attachment region, thereby placing the yarn in direct contact with the second attachment region. The step of moving the nozzle into direct contact with the second attachment zone comprises transforming a second portion of the thermo-plastic material of the yarn from a liquid state to a solid state. The second portion of the thermoplastic material is bonded to the second attachment zone during the transformation of the second portion of the thermoplastic material.

In another aspect, a system for printing onto a substrate includes a yarn, a heating system, a nozzle assembly, and an actuation system. The yarn includes a thermoplastic material and a melt-resistant material. The heating system is configured to heat the yarn. The heating system heats the yarn so that the thermo-moldable material is in a liquid state and the melt resistant material is in a solid state. The nozzle assembly is configured to dispense the yarn onto the substrate. The substrate has an upper surface and a lower surface. The nozzle assembly dispenses the thermoplastic material of the yarn in a liquid state and the melt resistant material of the yarn in a solid state. The actuation system is configured to lower the nozzle assembly into direct contact with the first attachment region of the upper surface. The actuation system is also configured to raise the nozzle assembly away from the first attachment region of the upper surface. The actuation system is also configured to move the nozzle assembly along the upper surface of the substrate. The first portion of the thermo-moldable material of the yarn is configured to transition from a liquid state to a solid state upon direct contact with the first attachment zone. The first portion of the thermoplastic material is bonded to the first attachment zone during the transformation of the first portion of the thermoplastic material. The melt-resistant material of the yarn is configured to remain as a continuous segment extending from the nozzle assembly to the first attachment zone during transition of the first portion of the thermoplastic material from the liquid state to the solid state.

Other systems, methods, features and advantages of the embodiments will be or will become apparent to one with 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. 1 is a schematic diagram of an embodiment of a three-dimensional printing system 100 (hereinafter also referred to simply as printing system 100). Fig. 1 also shows several exemplary articles 130 that may be used with printing system 100. Referring to fig. 1, printing system 100 may also include a printing device 102, a computing system 104, and a network 106.

Embodiments may use various types of three-dimensional printing (or additive manufacturing) techniques. Three-dimensional printing or "3D printing" includes various techniques for forming three-dimensional objects by depositing successive layers of material on top of each other. Exemplary 3D printing techniques that may be used include, but are not limited to: fused Filament Fabrication (FFF), electron beam free form fabrication (EBF), Direct Metal Laser Sintering (DMLS), electron beam melting (EMB), Selective Laser Melting (SLM), Selective Heat Sintering (SHS), Selective Laser Sintering (SLS), gypsum-based 3D printing (PP), layered object fabrication (LOM), Stereolithography (SLA), Digital Light Processing (DLP), and various other 3D printing or additive manufacturing techniques known in the art.

In the embodiment shown in the figures, the printing system 100 may be associated with Fused Filament Fabrication (FFF), also known as fused deposition modeling. In the embodiment shown in fig. 1, the printing device 102 of the printing system 100 uses fused wire manufacturing to produce three-dimensional parts. An example of a printing Apparatus using melt wire fabrication (FFF) is disclosed in U.S. Pat. No. 5,121,329 entitled "Apparatus and Method for Creating Three-Dimensional Objects" filed by Crump at 30/10 1989, which is hereby incorporated by reference and is referred to hereinafter as the "3D object" application. Embodiments of the present disclosure may utilize any of the systems, components, devices, and methods disclosed in the 3D object application.

Printing device 102 may include a housing 110, housing 110 supporting various systems, devices, components, or other arrangements that facilitate three-dimensional printing of objects. Although the exemplary embodiment depicts a particular rectangular box-like geometry for housing 110, other embodiments may use any housing having any geometry and/or design. The shape and size of the housing of the printing device may vary depending on factors including the desired footprint (footprint) for the device, the size and shape of the components that may be formed within the printing device, and possibly other factors. It should be understood that the housing of the printing device may be open or closed. For example, the printing device may be open to provide a frame with a large opening. In another example, the printing device may be enclosed with a sheet of glass or solid material and a door.

In some embodiments, the printing device 102 may include provisions to hold or support a print object (or a component that supports a print object). In some embodiments, printing device 102 may include a table, platform, tray, or similar component to support, hold, and/or hold the object being printed or onto which the printing material is being applied. In the embodiment of fig. 1, printing device 102 includes a tray 112. In some embodiments, the tray 112 may be fixed in place. However, in other embodiments, the tray 112 may be movable. For example, in some cases, the tray 112 may be configured to translate within the housing 110 in one or more horizontal directions (e.g., directions along a horizontal axis) and in one or more vertical directions (e.g., directions along a vertical axis). As used herein, a horizontal axis may refer to an axis that extends fore-aft and/or side-to-side with respect to housing 110. As used herein, a vertical axis may refer to an axis that extends up and down within the housing 110. Further, in some cases, the tray 112 may be configured to rotate and/or tilt about one or more axes associated with the tray 112. Thus, it is contemplated that in at least some embodiments, the tray 112 may be moved with the nozzles or printheads of the printing device 102 into any desired relative configuration.

In some embodiments, printing device 102 may include one or more systems, devices, assemblies, or components for delivering printing material (or printing substance) to a target location. The target location may include a surface of the tray 112, a surface or portion of a partially printed structure, and/or a surface or portion of a non-printed structure or component. Arrangements for conveying the printing material include, for example, a print head and nozzles. In the embodiment of fig. 1, printing device 102 includes a nozzle assembly 116.

Nozzle assembly 116 may include one or more nozzles that deliver printing material to a target location. For clarity, the exemplary embodiment of FIG. 1 depicts a single nozzle 118 of the nozzle assembly 116. However, in other embodiments, the nozzle assembly 116 may be configured with any number of nozzles, which may be arranged in an array or in any particular configuration. In embodiments including two or more nozzles, the nozzles can be configured to move together and/or independently. For example, in the embodiments of the printing system discussed below, the printing device may be configured with at least two nozzles that may be moved independently of each other.

Nozzle 118 may be configured with a nozzle orifice 119, and nozzle orifice 119 may be opened and/or closed to control the flow of material exiting nozzle 118. Specifically, nozzle aperture 119 may be in fluid communication with a nozzle channel 121, which nozzle channel 121 receives a supply of material from a material source (not shown) within printing device 102. For example, the material supply may be a yarn construction component. In other examples, the supply of material is a thermoplastic material. In at least some embodiments, the wire of material is provided as a coil, which may then be unwound and fed through nozzle 118 for deposition at the target location. In some embodiments, a worm drive may be used to push the filaments into the nozzle 118 at a particular rate (which may be varied to achieve a desired volumetric flow rate of material out of the nozzle 118). In other embodiments, the worm drive is omitted. For example, in another embodiment, the material is pulled from the nozzle using an actuation system. It should be understood that in some cases, the supply of material may be provided at a location near the nozzle 118, while in other embodiments the supply of material may be located at some other location of the printing device 102 and fed to the nozzle assembly 116 via a tube, conduit, or other arrangement. For example, the material supply may be in a portion of the nozzle assembly 116.

In some embodiments, the nozzle assembly 116 is associated with the actuation system 114. The actuation system 114 may include various components, devices, and systems that facilitate movement of the nozzle assembly 116 within the housing 110. In particular, the actuation system 114 may include an arrangement to move the nozzle assembly 116 in any horizontal and/or vertical direction to facilitate depositing material to form a three-dimensional object. To this end, embodiments of the actuation system 114 may include one or more rails, tracks, and/or the like to maintain the nozzle assembly 116 in various positions and/or orientations within the housing 110. Embodiments may also include any kind of motor, such as a stepper motor or a servo motor, to move the nozzle assembly 116 along the rail or track, and/or to move one or more rails or tracks relative to each other.

The printing system may move the nozzles in various directions and/or along one or more axes. In at least some embodiments, actuation system 114 may provide for movement of nozzle assembly 116 in any of an x-axis, a y-axis, and a z-axis defined with respect to printing device 102. For example, the x-axis, y-axis, and z-axis defined with respect to printing device 102 may be a Cartesian coordinate system. In one embodiment, the printing system may be configured to move the nozzle 118 in one or two directions along a first axis. For example, the printing system 100 may include an actuation system 114 configured to move the nozzle 118 in one or two directions along the first axis 160. In certain embodiments, the first axis is approximately orthogonal to the upper surface and/or orthogonal to the substrate. As used herein, an axis is approximately normal to a surface when the axis is within 10 degrees of normal to the surface. For example, as shown, the first axis 160 is orthogonal to the upper surface 148 and the base 144. In some embodiments, the printing system may be configured to move the nozzle in one or two directions along the second axis. For example, the printing system 100 may include an actuation system 114 configured to move the nozzle 118 in one or two directions along the second axis 162. In certain embodiments, the second axis is approximately parallel to the upper surface and/or approximately parallel to the substrate. As used herein, an axis is approximately parallel to a surface when the axis is within 10 degrees of being parallel to the surface. For example, as shown, the second axis 162 is parallel to the upper surface 148 and the base 144. In some embodiments, the second axis is approximately perpendicular to the first axis. For example, as shown, the second axis 162 is approximately perpendicular to the first axis 160. Similarly, in various embodiments, the printing system may be configured to move the nozzle in one or two directions along the third axis. For example, the printing system 100 may include an actuation system 114 configured to move the nozzle 118 in one or two directions along the third axis 164. In certain embodiments, the third axis is parallel to the upper surface and/or parallel to the substrate. For example, the third axis 164 may be parallel to the upper surface 148 and the base 144. In some embodiments, the third axis is perpendicular to the first axis and/or the third axis is perpendicular to the second axis. For example, the third axis 164 may be perpendicular to the first axis 160. In another example, the third axis 164 may be perpendicular to the second axis 162.

In certain embodiments, the printing system selectively moves the nozzles. In one embodiment, the printing system moves the nozzle along three axes simultaneously. For example, the printing system may move the nozzle 118 away from the substrate 144 along the first axis 160 while moving the nozzle 118 along the second axis 162 and/or along the third axis 164. In other embodiments, the position along an axis is maintained while the printing system selectively moves the nozzle along another axis. In certain embodiments, the printing system may move the nozzle along the first axis toward or away from the substrate while maintaining the substrate position of the nozzle along the second axis and along the third axis. For example, the printing system 100 may move the nozzle 118 away from the substrate 144 along the first axis 160 while maintaining the substrate position of the nozzle 118 along the second axis 162 and along the third axis 164 (see fig. 8-10 and 14-16). In some embodiments, the printing system may maintain a predetermined distance from the nozzle to the upper surface while moving the nozzle parallel to the upper surface. For example, printing system 100 may maintain a predetermined distance between nozzle 118 and upper surface 148 along first axis 160 while moving nozzle 118 along second axis 162 and/or along third axis 164.

It should be understood that the components, devices, and systems of printing device 102 are schematically illustrated in FIG. 1 for illustrative purposes. Accordingly, it should be understood that embodiments may include additional arrangements not shown, including specific components, parts, and devices that facilitate operation of the actuation system 114 and the nozzle assembly 116. For example, the actuation system 114 is schematically illustrated as including several rails or tracks, but the particular configuration and number of components comprising the actuation system 114 may vary from embodiment to embodiment.

In different embodiments, printing device 102 may form 3D parts using a variety of different materials, including but not limited to: thermoplastics, high density polyethylene, eutectic metals, rubber, clays (including metal clays), room temperature vulcanized silicone (RTV silicone), porcelain, and possibly other types of materials known in the art. As used herein, thermoplastics may include polylactic acid and acrylonitrile butadiene styrene. In embodiments where two or more different printing materials or dispensing materials are used to form the component part, any two or more of the above disclosed materials may be used. In some embodiments, the printing device 102 may use a yarn Composition having one or more of the characteristics described in U.S. patent publication No. ____ to Sterman et al, entitled "Thread Structure Composition and Method of Making" (now U.S. patent application No. 14/466,319, filed on 8/22 2014), which is hereby incorporated by reference.

As discussed above, printing system 100 may include settings to control and/or receive information from printing device 102. These settings may include computing system 104 and network 106. In general, the term "computing system" refers to a computing resource of a single computer, a portion of a computing resource of a single computer, and/or two or more computers in communication with each other. Any of these resources may be operated by one or more human users. In some embodiments, the computing system 104 may include one or more servers. In some cases, the print server may be primarily responsible for controlling the printing device 102 and/or communicating with the printing device 102, while a separate computer may facilitate interaction with the user. As used herein, a stand-alone computer may refer to a desktop, laptop, or tablet computer. Computing system 104 may also include one or more storage devices, including but not limited to: a magnetic storage device, an optical storage device, a magneto-optical storage device, and/or a memory including a volatile memory and a non-volatile memory.

In the exemplary embodiment of fig. 1, computing system 104 may include a central processing device 185, a viewing interface 186, an input device 187, and software for designing a computer-aided design ("CAD") representation 189 of a printed structure. As used herein, viewing interface 186 may include a monitor or screen. As used herein, input devices 187 may include a keyboard and a mouse. In at least some embodiments, the CAD representation 189 of the printed structure can include information not only about the geometry of the structure, but also information relating to the materials required to print various portions of the structure.

In some embodiments, computing system 104 may be in direct contact with printing device 102 via network 106. Network 106 may include any wired or wireless arrangement that facilitates the exchange of information between computing system 104 and printing device 102. In some embodiments, network 106 may also include various components, such as network interface controllers, repeaters, hubs, bridges, switches, routers, modems, and firewalls. In some cases, network 106 may be a wireless network that facilitates wireless communication between two or more systems, devices, and/or components of printing system 100. 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 802.11WLAN standard), wireless mesh networks, mobile device networks, and other kinds of wireless networks. In other cases, network 106 may be a wired network including a network whose signals are facilitated by twisted pair (twister pair wires), coaxial cable, and optical fiber. In still other cases, a combination of wired and wireless networks and/or connections may be used.

In some embodiments, the printed structure may be printed directly to one or more articles. The term "article" is intended to include articles of footwear and articles of apparel. As used throughout this disclosure, the terms "article of footwear" and "footwear" include any footwear and any material associated with footwear (including an upper), and may also be applied to a variety of athletic footwear styles, including baseball shoes, basketball shoes, cross-training shoes, cycling shoes, football shoes, tennis shoes, soccer shoes, and hiking boots, for example. As used throughout this disclosure, the terms "article of footwear" and "footwear" also include types of footwear generally considered to be non-athletic, formal, or ornamental, including dress shoes, loafers, sandals, slippers, boat shoes, and work boots.

Although the disclosed embodiments are described in the context of footwear, the disclosed embodiments may also be equally applicable to any article of clothing, apparel, or equipment that includes 3D printing. For example, the disclosed embodiments may be applicable to hats, beanie hats, shirts, sweaters, jackets, socks, shorts, pants, undergarments, athletic support garments, gloves, wrist/arm bands, sleeves, headbands, any knitted material, any woven material, any non-woven material, athletic equipment, and the like. Thus, as used throughout this disclosure, the term "article of apparel" may refer to any article of footwear or garment, including any article of footwear, as well as hats, shirts, sweaters, jackets, socks, shorts, pants, undergarments, athletic support apparel, gloves, wrist/arm bands, sleeves, headbands, any knitted material, any non-woven material, and the like.

In an exemplary embodiment, the printing device 102 may be configured to print one or more structures directly onto a portion of one of the exemplary articles 130. Example article 130 includes example articles that may receive printed structures directly from printing device 102, including article of footwear 132 having a three-dimensional configuration and upper 134 having a flat configuration. Exemplary item 130 also includes a T-shirt 136. Thus, it should be understood that printing device 102 may be used to apply printing material to an article in a three-dimensional configuration and/or a flat configuration.

In order to apply printing material directly to one or more articles, printing device 102 may be capable of printing onto the surface of various materials. Specifically, in some cases, the printing device 102 may be capable of printing onto the surface of various materials (e.g., textiles, natural fabrics, synthetic fabrics, knits, woven materials, non-woven materials, meshes, leathers, synthetic leathers, polymers, rubbers, and foams, or any combination thereof) without requiring a release layer (release layer) to be placed between the substrate and the bottom of the printed material, and without requiring the substrate surface printed thereon to be completely or near completely flat. For example, the disclosed methods may include printing a resin, acrylic, thermoplastic, or ink material onto a fabric (e.g., a knitted material), wherein the material is bonded/bonded to the fabric, and wherein the material does not generally delaminate when bent, rolled, worked, or subjected to additional assembly processes/steps. As used throughout this disclosure, the term "fabric" may be used to generally refer to a material selected from any textile, natural fabric, synthetic fabric, knit, woven material, non-woven material, mesh, leather, synthetic leather, polymer, rubber, and foam.

While some embodiments may use printing apparatus 102 to print structures directly onto the surface of a material, other embodiments may include the steps of printing the structures onto a tray or release paper, and then coupling the printed structures to the article in a separate step. In other words, in at least some embodiments, the printed structure need not be printed directly to the surface of the article.

Printing system 100 may operate as follows to provide one or more structures formed using 3D printing or additive processes. The computing system 104 may be used to design a structure. This may be accomplished using some type of CAD software or other type of software. The design may then be converted into information that may be interpreted by the printing device 102 (or an associated print server in communication with the printing device 102). In some cases, the design may be converted into a 3D printable file, such as a stereolithography file (STL file).

Prior to printing, the item may be placed on a tray 112. Once the printing process is initiated (e.g., by a user), the printing device 102 may begin depositing material onto the article. This may be accomplished by moving nozzle 118 (using actuation system 114) to build up a layer of the structure with the deposited material. In embodiments made using molten wire, the material dispensed from nozzle 118 may be heated to increase the flexibility of the thermoplastic material as it is deposited.

While some embodiments shown in the figures depict systems using filament melt fabrication printing techniques, it should be understood that still other embodiments may incorporate one or more different 3D printing techniques. For example, the printing system 100 may use a stick and drag printing method. In addition, still other embodiments may include a combination of filament melt fabrication and another type of 3D printing technique to achieve the desired results for a particular printed structure or part.

As previously mentioned, the printing device 102 may be configured to print directly onto various articles. Similarly, printing device 102 may be configured to print on various surface geometries (e.g., flat, curved, and/or irregular surfaces). For example, as shown in fig. 2, the tray 112 supports a substantially planar base 144. In other embodiments, the substrate 144 may include one or more protrusions and/or one or more cavities. Further, the printing device 102 may print on surfaces having various shapes. For example, as shown, the tray 112 supports a rectangular base 144. In other embodiments, tray 112 may support substrates that are circular, triangular, shaped as uppers for articles of footwear, and the like. As shown, the substrate 144 includes an upper surface 148 and a lower surface 150.

In some cases, it is desirable to dampen the impact as the nozzle descends toward the tray. In one embodiment, printing system 100 may include an elastic layer to prevent tray 112 from impacting nozzle 118. In other embodiments, the elastic layer is omitted.

In those cases where an elastomeric layer is used, any suitable location may be used to dampen the impact as the nozzle descends toward the tray. In one embodiment, an elastic layer may be placed between the tray and the substrate. Referring to fig. 1-2, an elastic layer 146 may be placed on the tray 112 to separate the tray 112 from the substrate 144. In other embodiments, the elastic layer may be positioned in other locations.

In those cases where an elastomeric layer is used, any suitable number of layers may be used to dampen the impact as the nozzle descends toward the tray. In some embodiments, the lower surface directly contacts the elastic layer. For example, the lower surface 150 directly contacts the elastic layer 146. In some embodiments, another layer separates the lower surface from the elastic layer (not shown). In other embodiments, other layers may be used.

In those cases where an elastomeric layer is used, the elastomeric layer may have any suitable shape to facilitate dampening of the impact as the nozzle descends toward the tray. Referring to fig. 2, the elastic layer 146 may have a rectangular shape. In some embodiments, the elastic layer may be circular (not shown). In some embodiments, the elastic layer may be triangular (not shown). In other embodiments, the elastic layer may have other shapes.

Some embodiments may be configured to allow the elastic layer to have a shape corresponding to another component of the printing system. In one embodiment, the elastic layer may have a shape corresponding to the substrate. Referring to fig. 2, the elastic layer 146 may have a shape corresponding to the substrate 144. In some embodiments, the elastic layer may have a shape corresponding to the tray. Referring to fig. 2, the elastic layer 146 may have a shape corresponding to the tray 112. In other embodiments, the elastic layer may have a shape corresponding to the other components.

In those cases where an elastomeric layer is used, the elastomeric layer may be of any suitable material to help dampen the impact as the nozzle descends toward the tray. In some embodiments, the elastic layer is formed of an elastic material. As used herein, the resilient material may include natural and/or synthetic rubber, nylon, polystyrene, polytetrafluoroethylene, polyethylene, and the like. In other embodiments, the elastic layer may be formed of other materials.

In those cases where nozzles are used to dispense printing material, any suitable material may be used. In one embodiment, the nozzle dispenses the yarn. Referring to fig. 2, nozzle 118 may dispense yarn 151. In other embodiments, the nozzle dispenses other materials.

In those cases where the nozzle dispenses the yarn, the yarn may be formed of any suitable material. Such yarns may include a yarn construction Composition having one or more of the characteristics described in U.S. patent publication No. ____ to Sterman et al, entitled "Thread Structure Composition and Method of Making" (now U.S. patent application No. 14/466,319 filed on 8/22/2014), which is hereby incorporated by reference. For example, in some embodiments, yarns 151 may include a melt-resistant material and/or a thermoplastic material. As used herein, a thermoplasticable material can be any material that is substantially moldable (or pliable) above a predetermined temperature, such as a glass transition temperature and/or a melting temperature. As used herein, the term "melt-resistant material" may refer to any material that has no melting temperature (or any material that has a melting temperature well above a predetermined threshold temperature). The melt-resistant material may comprise a material that burns above a predetermined temperature, such as paper. Another melt-resistant material may include a metal having a melting temperature significantly higher than a threshold temperature of about 500 ℃. In other embodiments, the yarns may be formed from other materials.

In those cases where the yarns are formed from a thermo-plastic material, the thermo-plastic material may have any suitable properties. In one embodiment, the thermoplastically moldable material has one or more thermal properties, such as a glass-liquid transition ("glass transition") temperature and/or a melting temperature. For example, the thermoplastic material may be a thermoplastic material having a glass transition temperature and a melting temperature. In other embodiments, the thermoplastic material may have other properties.

In those cases where the yarns are formed of a thermo-moldable material, any suitable material may be used to form the thermo-moldable material. As used herein, thermoplastic materials may include, for example, acrylics, nylons, polybenzimidazoles, polyethylenes, polypropylenes, polystyrenes, polyvinyl chlorides, polytetrafluoroethylene (TEFLON), and the like. In other embodiments, the thermo-moldable material may be formed from other materials.

In those cases where the yarns are formed of a melt-resistant material, any suitable melt-resistant material may be used. In one embodiment, the melt resistant material may include materials associated with yarns and threads used to form textiles. For example, the melt-resistant material may be cotton. Additionally, exemplary materials for the melt-resistant material may include wool, linen, and cotton, among other one-dimensional materials. Various sources of yarn material may be used to form the melt resistant material. Such sources may include animal sources, plant sources, mineral sources, and synthetic sources. Animal materials may include, for example: hair, animal fur, animal skin, and silk. Plant material may include, for example: grass, rush (rush), hemp and sisal (sisal). Mineral materials may include, for example: basalt fibers, glass fibers, and metal fibers. Synthetic yarns may include, for example, polyester, aramid, acrylic, and carbon fibers. In other embodiments, the melt-resistant material may be formed from other materials.

In the embodiment shown in fig. 2-5, yarn 151 can be seen to include a strand of melt-resistant material and a strand of thermoformable material. Specifically, the melt resistant material 158 (see fig. 3) and the thermo-plastic material 156 (see fig. 3) may be wrapped around each other to form a composite yarn structure (or composite thread structure). Accordingly, as described in further detail below, melt-resistant material 158 may provide tensile strength and prevent adjacent segments of yarn 151 from separating, while thermo-moldable material 156 may be used to fuse yarn 151 to an underlying substrate.

In some cases, it is desirable to selectively attach the yarn to the substrate to allow the yarn to have any number of attachments to the substrate. In some embodiments, the yarns are attached to the substrate at an attachment region of the substrate and are unattached to the substrate at a non-attachment region of the substrate. Referring to fig. 2, upper surface 148 may include an attachment region 152 and a non-attachment region 154. In other embodiments, the yarns may be attached to the substrate differently.

Some embodiments may be configured to allow the yarn to have segments of various sizes to allow various yarn structures to be printed onto the substrate. In one embodiment, the yarn may comprise a single continuous segment. In other embodiments, the yarn may comprise a plurality of discrete segments.

In those instances where the yarn comprises a single continuous segment, the continuous segment may extend over any suitable distance. In some embodiments, continuous segments of yarn may extend across some of the upper surface of the substrate. In other embodiments, the continuous segments extend across other surfaces.

In those instances where the yarn includes continuous segments, the continuous segments may extend across various regions of the upper surface of the substrate. In some embodiments, a continuous segment of yarn may extend from the nozzle assembly over the attachment zone of the base. Referring to fig. 2, a continuous segment 149 of yarn 151 may extend from nozzle 118 past an attachment region 152 of base 144. In some embodiments, a continuous segment of yarn may extend from the nozzle assembly across a non-attachment zone of the substrate. Referring to fig. 2, a continuous segment 149 of yarn 151 may extend from nozzle 118 past a non-attachment region 154 of base 144. In other embodiments, the continuous segments of yarn may extend across other regions of the upper surface of the base.

In those instances where the yarns have continuous segments that extend across various regions of the upper surface of the base, the continuous segments may extend across any number of regions of the upper surface of the base. In some embodiments, the continuous segments may extend across multiple attachment zones (see fig. 16). In some embodiments, the continuous segment may extend across multiple non-attachment regions (see fig. 16). In some embodiments, the continuous segments may extend across one or more non-attachment zones and one or more attachment zones (see fig. 16). In other embodiments, the continuous segments of yarn may extend across other numbers of zones of the upper surface of the base.

In those cases where the yarn has a melt-resistant material, the melt-resistant material may extend over any suitable distance. In some embodiments, the melt-resistant material of the yarn may extend across the upper surface of the substrate. In other embodiments, the melt-resistant material may extend across other surfaces.

In those instances where the melt resistant material of the yarns may extend across the upper surface of the substrate, the melt resistant material may extend across various regions of the upper surface of the substrate. In some embodiments, the melt resistant material of the yarn may extend from the nozzle assembly over the attachment region of the base. Referring to fig. 3, the melt-resistant material 158 of the continuous segments 149 (see fig. 2) of the yarns 151 may extend from the nozzle 118 (see fig. 2) past the attachment region 152 of the base 144. In some embodiments, the melt resistant material of the yarn may extend from the nozzle assembly over a non-attachment region of the substrate. Referring to fig. 4, the melt-resistant material 158 of the continuous segments 149 of the yarns 151 may extend from the nozzle 118 past the non-attachment region 154 of the base 144. In other embodiments, the melt resistant material 158 of the yarn may extend over other areas of the upper surface of the substrate.

In those cases where the yarns have a melt-resistant material extending across various regions of the upper surface of the substrate, the melt-resistant material may extend across any number of regions of the upper surface of the substrate. In some embodiments, the melt-resistant material can extend across multiple attachment zones (see fig. 16). In some embodiments, the melt-resistant material may extend across a plurality of non-attachment regions (see fig. 16). In some embodiments, the melt-resistant material may extend across one or more non-attachment regions and one or more attachment regions (see fig. 16). In other embodiments, the melt-resistant material of the yarns may extend across other numbers of zones of the upper surface of the substrate.

Some embodiments may be configured to allow the yarn to be attached to a substrate. In one embodiment, the yarns may be attached to the substrate using a thermo-plastic material. In other embodiments, other materials and/or methods may be used to attach the yarns to the substrate.

In those instances where the yarns are attached to the substrate using a thermo-plastic material, the thermo-plastic material may be bonded to various portions of the substrate. In some embodiments, the thermo-moldable material may be bonded directly to the attachment region. Referring to fig. 3, the thermo-moldable material 156 of yarn 151 may be bonded directly to attachment region 152. In other embodiments, the thermoplastic material may be bonded to other portions of the substrate.

In those instances where the yarns are attached to the substrate using a thermo-plastic material, the thermo-plastic material may be bonded to various portions of the yarns. In some embodiments, the thermoplastic material may be bonded directly to the melt-resistant material. Referring to fig. 3, the thermoplasticity material 156 of yarn 151 may be bonded directly to the melt resistant material 158. In other embodiments, the thermoplastic material may be bonded to other portions of the yarn.

In those cases where the yarns are not attached to the substrate at the unattached regions of the substrate, various methods may be used to allow the yarns to separate from the substrate. In some embodiments, the yarns may be spaced from the unattached regions. In some embodiments, the yarns may be separated from the non-attachment zones. As used herein, materials may be separated if the materials can be moved away from each other without breaking bonds between the materials and/or without damaging either material.

In those instances where the yarns are spaced from the unattached regions of the upper surface of the base, any suitable portion of the yarns may be spaced from the unattached regions. In some embodiments, the thermoplastic material of the yarn may be spaced from the unattached zone. Referring to fig. 4, the thermo-moldable material 156 of yarn 151 may be spaced apart from non-attachment region 154. In some embodiments, the melt resistant material of the yarn may be spaced from the unattached region. Referring to fig. 4, the melt resistant material 158 of yarn 151 may be spaced apart from non-attachment region 154. In other embodiments, other portions of the yarn may be spaced from the unattached regions of the upper surface of the substrate.

In those cases where the thermo-moldable material of the yarn is spaced apart from the unattached regions of the upper surface of the substrate, the thermo-moldable material may be attached to various portions of the yarn. In some embodiments, the thermoplastic material may be bonded to the melt resistant material of the yarn while being spaced apart from the unattached regions. Referring to fig. 4, thermoplastically processable material 156 of yarn 151 can be bonded to melt resistant material 158 of yarn 151, while yarn 151 is spaced from non-attachment region 154. In other embodiments, the thermoplastic material may be attached to other portions of the yarn while the yarn is spaced from the unattached zone.

In those cases where the yarn is separated from the non-attachment areas of the upper surface of the substrate, any suitable portion of the yarn may be separated from the non-attachment areas. In some embodiments, the thermoplastic material can be detached from the non-attachment region of the upper surface of the substrate. Referring to fig. 4, the thermo-moldable material 156 is separated from the non-attachment region 154. In other embodiments, other portions of the yarn may be separated from non-attachment regions of the upper surface of the substrate.

In those cases where the thermoplastic material of the yarn is separated from the non-attachment zones of the upper surface of the substrate, the thermoplastic material may be attached to various portions of the yarn. In some embodiments, the thermoplastic material may bond to the melt resistant material of the yarn while being separated from the non-attachment zone. Referring to fig. 4, thermoplastically processable material 156 of yarn 151 can be bonded to melt resistant material 158 of yarn 151 while yarn 151 is separated from non-attachment region 154. In other embodiments, the thermoplastic material may be attached to other portions of the yarn while the yarn is separated from the non-attachment zone.

Fig. 5 is an alternative view of a printing device 102 according to an example embodiment. As shown, the printing device 102 includes a tray 112, nozzles 118, a heating system 140, and a material source 142. In other embodiments, printing device 102 may have other components.

In those instances where the printing apparatus includes a heating system, the heating system may be configured to provide any suitable temperature to the yarn of material source 142. In some embodiments, the heating system 140 may provide a temperature within a particular temperature range. For example, the heating system 140 may provide a temperature greater than 500 ℃. In another example, the heating system 140 may provide a temperature greater than 300 ℃. In another example, the heating system 140 may provide a temperature greater than 230 ℃. In one example, the heating system 140 may provide a temperature between 110 ℃ and 200 ℃. In other embodiments, the heating system may provide other temperatures.

In those instances where the printing apparatus includes a material source, the material source may be configured to facilitate dispensing of the printing material using any suitable means. In one embodiment, the material source may include a worm drive (not shown) for pushing the printing material into the nozzle. In some embodiments, the material source may omit a worm drive for pushing the printing material into the nozzle. Referring to fig. 5, the material source 142 may omit the worm drive. In other embodiments, the material source 142 may include various drivers or pumps to cause material from the material source 142 to be dispensed to the nozzle 118 and out of the nozzle 118. In some embodiments, the material source may be configured to facilitate dispensing of the printing material using other components and/or methods.

In some embodiments, the printing device may use an actuation system to facilitate the dispensing of the printing material. Referring to fig. 5, printing device 102 may use actuation system 114 (see fig. 1) to provide material from material source 142 to nozzles 118 for dispensing yarn 151 onto a substrate. In other embodiments, the material source may be configured to facilitate dispensing of the printing material using other components and/or methods.

In those cases where a material source is used, any suitable material may be provided to the nozzle. In some embodiments, the material source may include a yarn having one or more features as described in U.S. patent publication No. ____ entitled "Thread Structure Composition and Method of Making" to Sterman et al (now U.S. patent application No. 14/466,319 filed on 8/22 2014), which is hereby incorporated by reference. In some embodiments, the yarn may include at least one yarn formed of a melt resistant material. In some embodiments, the material source 142 is substantially formed of a thermo-moldable material. In some other embodiments, the yarns may be different.

In those cases where a heating system is used, the heating system may be allowed to heat at least a portion of the printing material to a liquid state. In some embodiments, the heating system is configured to heat the thermoplastic material of the yarn to a liquid state. Referring to fig. 5, heating system 140 may be configured to heat thermo-moldable material 156 of yarn 151 to transform thermo-moldable material 156 into a liquid state. In other embodiments, the heating system is configured to heat other materials of the yarn to a liquid state.

In those cases where the heating system is used to heat the thermoplastic material of the yarn to a liquid state, the actuation system may facilitate bonding of the thermoplastic material to the substrate. In some embodiments, the actuation system moves the nozzle into an attachment zone of the upper surface of the substrate to facilitate bonding of the thermoplastic material to the substrate (see fig. 6-17). In other embodiments, the actuation system may facilitate bonding of the thermoplastic material to the substrate using other components and/or methods.

In some embodiments, the thermoplastic material may be bonded to the substrate. In some embodiments, the thermo-moldable material may transition from a liquid state to a solid state to bond with the attachment region (see fig. 3). In other embodiments, the thermo-moldable material may be combined with the attachment region using other components and/or methods.

Fig. 6-17 illustrate a method of selectively attaching a yarn to a substrate according to an exemplary embodiment. The illustrated method can be implemented on a variety of devices, can utilize a variety of materials, use of different types of substrates, and so forth. Thus, the methods illustrated in fig. 6-17 are for illustration purposes only.

Some embodiments may be configured to prevent portions of the yarn from contacting and/or binding with non-attachment areas. In one embodiment, the printing system may maintain a predetermined distance between the nozzle and the upper surface to prevent portions of the yarn from binding with unattached regions. Referring to fig. 6, printing system 100 may maintain a predetermined distance 202 between nozzle 118 and upper surface 148. In this manner, yarn 151 may not be pushed into upper surface 148 such that yarn 151 bonds with upper surface 148. In other embodiments, portions of the yarn may be prevented from contacting and/or bonding with non-attachment regions by other methods.

In those instances where the printing system may maintain a predetermined distance between the nozzle and the upper surface to prevent portions of the yarn from binding with the non-attachment regions, the predetermined distance may be any suitable distance to facilitate separation of the yarn from the non-attachment regions. In some embodiments, the predetermined distance is greater than the thickness 205 of the yarn (see fig. 9). In some embodiments, the predetermined distance is greater than the thickness of the melt-resistant material of the yarn. In some embodiments, the predetermined distance is greater than the thickness of the thermoplastic material of the yarn. In other embodiments, the predetermined distance may be different.

In those cases where the predetermined distance is greater than the thickness of the yarn, the predetermined distance may be greater than the thickness of the yarn by any amount. In some embodiments, the predetermined distance is greater than one and a half times the thickness of the yarn. In some embodiments, the predetermined distance is greater than two times the thickness of the yarn. In some embodiments, the predetermined distance is greater than two and a half times the thickness of the yarn. In some embodiments, the predetermined distance is greater than three times the thickness of the yarn. In other embodiments, the predetermined distance may be greater than other amounts of the thickness of the yarn.

In those instances where the predetermined distance is greater than the thickness of the melt-resistant material of the yarn, the predetermined distance may be greater than any amount of the thickness of the melt-resistant material of the yarn. In some embodiments, the predetermined distance is greater than one and a half times the thickness of the melt resistant material of the yarn. In some embodiments, the predetermined distance is greater than twice the thickness of the melt-resistant material of the yarn. In some embodiments, the predetermined distance is greater than two and a half times the thickness of the melt resistant material of the yarn. In some embodiments, the predetermined distance is greater than three times the thickness of the melt-resistant material of the yarn. In other embodiments, the predetermined distance may be greater than other amounts of the thickness of the melt-resistant material of the yarn.

In those cases where the predetermined distance is greater than the thickness of the thermoplastic material of the yarn, the predetermined distance may be greater than any amount of the thickness of the thermoplastic material of the yarn. In some embodiments, the predetermined distance is greater than one and a half times the thickness of the thermoplastic material of the yarn. In some embodiments, the predetermined distance is greater than twice the thickness of the thermoplastic material of the yarn. In some embodiments, the predetermined distance is greater than two and a half times the thickness of the thermoplastic material of the yarn. In some embodiments, the predetermined distance is greater than three times the thickness of the thermoplastic material of the yarn. In other embodiments, the predetermined distance may be greater than other amounts of the thickness of the thermoplastic material of the yarn.

In some cases, it is desirable to prevent portions of the yarns from bonding with non-attachment areas of the upper surface of the substrate. In one embodiment, the nozzle is moved toward the attachment zone while maintaining a predetermined distance between the nozzle and the upper surface of the substrate to prevent portions of the yarns from bonding with non-attachment areas of the upper surface of the substrate. Referring to fig. 7, printing system 100 may move nozzle 118 along upper surface 148 toward attachment region 152 while maintaining a predetermined distance 202 between nozzle 118 and upper surface 148. In this example, yarn 151 may not be pushed into upper surface 148 but yarn 151 may be bonded to upper surface 148, allowing for one or more non-attachment zones.

Some embodiments may include provisions for selectively attaching some segments of the yarn to the substrate. In some embodiments, the printing system lowers the nozzles from a predetermined distance into the attachment zone to facilitate attachment of the yarn to the substrate. Referring to fig. 8, the printing system 100 lowers the nozzles 118 from a predetermined distance 202 (i.e., the printing system 100 lowers the nozzles 118) into the attachment zone 152. As used herein, lowering and raising may refer to any suitable movement orthogonal to the substrate. It should be understood that in some embodiments, the substrate may be positioned laterally or otherwise at an angle to the ground plane (e.g., the earth's surface), and in such embodiments, lowering and raising may refer to motion parallel to the ground plane as well as motion perpendicular to the ground plane. In some embodiments, the printing system lowers the nozzle from a predetermined distance into direct contact with the attachment zone to facilitate attachment of the yarn to the substrate. Referring to fig. 8, the printing system 100 lowers the nozzle 118 from the predetermined distance 202 into direct contact with the attachment region 152. In other embodiments, the yarns are attached to the substrate by other methods.

In those instances where the printing system lowers or moves the nozzle from a predetermined distance into or in direct contact with the attachment region to facilitate attachment of the yarn to the substrate, the nozzle may have a tip area (tip area) having any surface area. In some embodiments, the nozzle has a tip area approximately equal to the surface area of the attachment region. Referring to fig. 8 and 9, the nozzle 118 has a tip area 153 that is approximately equal to the surface area 155 of the attachment region 152. As used herein, surface areas may be approximately equal when the difference in area is less than 20% of either area. In some embodiments, the surface areas may be approximately equal when the difference in area is less than 10% of either area. In some embodiments, the surface areas may be approximately equal when the difference in area is less than 5% of either area. In other embodiments, the nozzle may have other tip areas.

In those instances where the printing system lowers the nozzle from a predetermined distance into or into direct contact with the attachment area to facilitate attaching the yarn to the substrate, the nozzle may remain in position along the upper surface of the substrate. In some embodiments, the nozzle may be lowered into the attachment zone along the first axis while maintaining the position of the substrate along the second axis. Referring to fig. 8 and 9, the printing system 100 may lower the nozzle 118 into the attachment zone 152 along the first axis 160 while maintaining the substrate position 208 along the second axis 162. In some embodiments, the nozzle may be lowered into the attachment zone along the first axis while maintaining the position of the substrate along the third axis. Referring to fig. 8 and 9, printing system 100 may move or lower nozzle 118 into attachment zone 152 along first axis 160 while maintaining substrate position 208 along third axis 164 (see fig. 1). In some embodiments, the nozzle may be lowered into the attachment zone along the first axis while maintaining the position of the substrate along the second axis and along the third axis. Referring to fig. 8 and 9, the printing system 100 may lower the nozzle 118 into the attachment zone 152 along the first axis 160 while maintaining the substrate position 208 along the second axis 162 and along the third axis 164. In other embodiments, the nozzle may remain in other positions.

In those instances where the printing system lowers or moves the nozzles from a predetermined distance into or in direct contact with the attachment area to facilitate attaching the yarns to the substrate, the thickness of the substrate between the upper and lower surfaces may be reduced. In some embodiments, the printing system can lower the nozzle from a predetermined distance into the attachment zone such that the thickness of the substrate between the upper surface and the lower surface reduces the penetration distance. Referring to fig. 9, printing system 100 may move or lower nozzle 118 from predetermined distance 202 into attachment region 152 such that substrate thickness 204 between attachment region 152 and lower surface 150 of upper surface 148 decreases penetration distance 206. In other embodiments, the thickness of the substrate between the upper surface and the lower surface may not be reduced.

In some embodiments, raising the nozzle away from the attachment region can cause the thickness of the substrate between the upper surface and the lower surface to increase by an amount substantially equal to the piercing distance. As used herein, distances may be substantially equal when within 10% of each other. Referring to fig. 10, the base thickness 204 between the attachment region 152 of the upper surface 148 and the lower surface 150 may be increased by an amount substantially equal to the penetration distance 206 (see fig. 9). In some embodiments, after selectively attaching the yarns, the attachment zone of the upper surface may be spaced from the lower surface by the substrate thickness. Referring to fig. 10, after selectively attaching yarns 151, attachment regions 152 of upper surface 148 may be spaced from lower surface 150 by a base thickness 204. In other embodiments, raising the nozzle away from the attachment region may increase the thickness of the substrate between the upper surface and the lower surface by other amounts.

In those instances where a penetration distance is used, the penetration distance may be any suitable distance to facilitate attachment of the yarn to the substrate. In some embodiments, the penetration distance may be less than the substrate thickness, as further characterized below. In some embodiments, the penetration distance may be less than the thickness of the yarn, as further characterized below. In some embodiments, the penetration distance may be less than the thickness of the melt resistant material of the yarn, as further characterized below. In other embodiments, the penetration distance may be different.

In those instances where the penetration distance may be less than the thickness of the substrate, the penetration distance may be less than the thickness of the substrate by any suitable amount. In some embodiments, the penetration distance may be less than three-quarters of the thickness of the substrate. In some embodiments, the penetration distance may be less than two-thirds of the thickness of the substrate. In some embodiments, the penetration distance may be less than half the thickness of the substrate. In some embodiments, the penetration distance may be less than one third of the thickness of the substrate. In some embodiments, the penetration distance may be less than one-quarter of the thickness of the substrate. In other embodiments, the penetration distance may be less than other amounts of the thickness of the substrate.

In those instances where the penetration distance may be less than the thickness of the yarn, the penetration distance may be less than the thickness of the yarn by any suitable amount. In some embodiments, the penetration distance may be less than three-quarters of the thickness of the yarn. In some embodiments, the penetration distance may be less than two-thirds of the thickness of the yarn. In some embodiments, the penetration distance may be less than half the thickness of the yarn. In some embodiments, the penetration distance may be less than one third of the thickness of the yarn. In some embodiments, the penetration distance may be less than one-quarter of the thickness of the yarn. In other embodiments, the penetration distance may be less than the thickness of the yarn by other amounts.

In those instances where the penetration distance may be less than the thickness of the melt resistant material of the yarn, the penetration distance may be any suitable amount less than the thickness of the melt resistant material of the yarn. In some embodiments, the penetration distance may be less than three-quarters of the melt resistant material of the yarn. In some embodiments, the penetration distance may be less than two-thirds of the melt resistant material of the yarn. In some embodiments, the penetration distance may be less than half of the melt resistant material of the yarn. In some embodiments, the penetration distance may be less than one third of the melt resistant material of the yarn. In some embodiments, the penetration distance may be less than one-fourth of the melt resistant material of the yarn. In other embodiments, the penetration distance may be less than the other amounts of the melt-resistant material of the yarn.

In those instances where the printing system lowers or moves the nozzle from a predetermined distance into or in direct contact with the attachment region to facilitate attaching the yarn to the substrate, any suitable spacing between the nozzle and the lower surface may be used to facilitate attaching the yarn to the substrate. In some embodiments, the nozzle may be spaced apart from the lower surface when the nozzle is lowered into the attachment zone. Referring to fig. 9, the printing system 100 may move or lower the nozzles 118 along the first axis 160 into the attachment region 152 while spacing the nozzles 118 from the lower surface 150. In some embodiments, the nozzles are spaced from the lower surface 150 by a spacing distance greater than the thickness of the yarn during movement or lowering of the nozzles into the attachment zone. In some embodiments, the separation distance is greater than the thickness of the melt-resistant material of the yarn. In some embodiments, the separation distance is greater than the thickness of the thermoplastic material of the yarn. Further, in some embodiments, the nozzle may not penetrate and/or pierce the upper surface during movement or lowering of the nozzle into the attachment zone. Referring to fig. 9, the nozzle 118 does not penetrate or pierce the upper surface 148. In other embodiments, other spacings between the nozzle and the lower surface may be used to facilitate attachment of the yarn to the substrate.

Referring to fig. 10, moving or lowering the nozzle into direct contact with the attachment zone may place the yarn in direct contact with the attachment zone to allow the yarn to bond with the attachment zone. For example, moving or lowering nozzle 118 into direct contact with attachment region 152 may result in yarn 151 being placed in direct contact with attachment region 152. Referring to fig. 11, a first portion 157 (see fig. 3) of the thermo-moldable material 156 may be transformed from a liquid state to a solid state to bond the attachment region 152.

In some embodiments, the nozzle may be raised after the yarn is attached to the upper surface. Referring to fig. 10, printing system 100 may raise nozzle 118 to a predetermined distance 202 along first axis 160 after attaching yarn 151 to attachment region 152. In other embodiments, the nozzles may be raised differently.

In those instances where the nozzle is raised to a predetermined distance along the first axis after the yarn is attached to the upper surface, the nozzle may maintain a base position along any number of axes. In some embodiments, the nozzle may maintain a substrate position along the second axis while the nozzle is raised along the first axis. Referring to fig. 9 and 10, as the nozzle 118 is raised along the first axis 160, the printing system 100 may maintain a substrate position 208 along the second axis 162. In some embodiments, the nozzle maintains the substrate position along the third axis while the nozzle is raised along the first axis. Referring to fig. 9 and 10, as the nozzle 118 is raised along the first axis 160, the printing system 100 may maintain a substrate position 208 along the third axis 164 (see fig. 1). In some embodiments, the nozzle may maintain a substrate position along the second axis and along the third axis while the nozzle is raised along the first axis. Referring to fig. 9 and 10, as the nozzle 118 is raised along the first axis 160, the printing system 100 may maintain a substrate position 208 along the second axis 162 and along the third axis 164. In other embodiments, the nozzle may maintain a substrate position along one or more different number of axes.

In some embodiments, the printing system may be configured to allow the yarn to be selectively attached to any number of attachment areas and may position the yarn over any number of non-attachment areas. In some embodiments, the printing system moves the nozzle to another attachment region to facilitate selectively attaching the yarn to the substrate. Referring to fig. 11, printing system 100 (see fig. 1) may move nozzle 118 along second axis 162 and/or along third axis 164 (see fig. 1) to attachment zone 210.

In some embodiments, the nozzle can be moved along the upper surface toward the attachment zone while maintaining a predetermined distance between the nozzle and the upper surface to allow the yarn to separate from the non-attachment zone. Referring to fig. 11, printing system 100 may maintain a predetermined distance 202 between nozzle 118 and upper surface 148. In this way, yarn 151 may not be pushed into upper surface 148, but instead yarn 151 may be bonded to upper surface 148, thereby allowing for one or more non-attachment zones. In other embodiments, the nozzle may be moved differently along the upper surface toward the attachment region.

In some embodiments, the unattached portions of the yarn may be free to move. For example, yarn 151 may be free to move between state 214 (adjacent to the substrate) and state 216 (disposed away from the substrate) (see fig. 12). Referring to fig. 12, yarns 151 may be in direct contact with upper surface 148 of substrate 144. In this example, yarn 151 may be spaced from upper surface 148 of base 144 in state 224 (see fig. 17).

In some cases, it is desirable to prevent the yarn from separating from the substrate. In some embodiments, attaching the yarn to one or more attachment zones may prevent the yarn from separating from the substrate. Referring to fig. 12, attachment zones 152 may prevent yarn 151 from separating from substrate 144.

In some embodiments, the attachment zones may hold the yarn to the upper surface as the yarn is free to move between states. Referring to fig. 12, attachment zone 152 may hold yarn 151 to upper surface 148 as yarn 151 moves between state 214 and state 216.

In some cases, it is desirable to move the nozzle after attaching the yarn to the base to allow the yarn to separate from non-attached regions of the upper surface of the base. In some embodiments, the nozzle can be moved along the upper surface toward the attachment zone while maintaining a predetermined distance between the nozzle and the upper surface to allow the yarn to separate from the non-attachment zone. Referring to fig. 13, printing system 100 (see fig. 1) maintains a predetermined distance 202 between nozzle 118 and upper surface 148. In this way, yarn 151 may not be pushed into upper surface 148, but instead yarn 151 may be bonded to upper surface 148, thereby allowing for one or more non-attachment zones. In other embodiments, the nozzle may be moved differently after attaching the yarn to the substrate.

In those instances where the nozzle may be moved along the upper surface toward the attachment region while maintaining a predetermined distance between the nozzle and the upper surface to allow the yarn to separate from the non-attachment region, it may be desirable to attach the yarn to the attachment region of the base after allowing the yarn to separate from the non-attachment region. In some embodiments, after allowing the yarn to separate from the non-attachment region, the printing system may move the nozzle from a predetermined distance into the attachment region to attach the yarn to the attachment region of the substrate. Referring to fig. 14, the printing system 100 (see fig. 1) may move the nozzle 118 from the predetermined distance 202 (see fig. 13) into the attachment zone 210. In some embodiments, the printing system may move the nozzle from a predetermined distance into direct contact with the attachment region. Referring to fig. 14, the printing system 100 may move the nozzle 118 from the predetermined distance 202 into direct contact with the attachment zone 210. In other embodiments, the nozzles may attach the yarn differently to the substrate after allowing the yarn to separate from the non-attachment zones.

In those instances where the printing system may move the nozzles from a predetermined distance into the attachment area after allowing the yarn to separate from the non-attachment area to attach the yarn to the attachment area of the base substrate, the yarn may be attached to the attachment area of the base substrate using any suitable method. In one embodiment, the nozzle may be moved or lowered along the first axis into the attachment zone while maintaining the substrate position. Referring to fig. 13-14, the printing system 100 may move or lower the nozzles 118 along the first axis 160 into the attachment region 210. In some embodiments, the nozzle maintains a position of the substrate along the second axis while moving or lowering the nozzle into the attachment zone. Referring to fig. 13-14, the printing system 100 may maintain the substrate position 218 along the second axis 162 while moving or lowering the nozzles 118 into the attachment zone 210. In some embodiments, the nozzle may maintain a position of the substrate along the third axis while moving or lowering the nozzle into the attachment zone. Referring to fig. 13-14, the printing system 100 may maintain a substrate position 218 along the third axis 164 (see fig. 1) while moving or lowering the nozzles 118 into the attachment zone 210. In some embodiments, the nozzle may maintain a position of the substrate along the second axis and along the third axis while moving or lowering the nozzle into the attachment zone. Referring to fig. 13-14, the printing system 100 may maintain the substrate position 218 along the second axis 162 and along the third axis 164 as the nozzles 118 are moved or lowered into the attachment zone 210. In other embodiments, the yarns may be attached differently to the attachment regions of the substrate.

In certain embodiments, the printing system moves the nozzle from a predetermined distance into the attachment zone such that the substrate thickness is reduced. Referring to fig. 15, printing system 100 (see fig. 1) lowers nozzle 118 into attachment zone 210 such that substrate thickness 204 is reduced by piercing distance 206. In other embodiments, the printing system moves the nozzle from a predetermined distance into the attachment zone without reducing the thickness of the substrate.

In those instances where the printing system moves the nozzles from the predetermined distance into the attachment zone such that the substrate thickness is reduced, the substrate thickness may be reduced by any suitable amount. In some embodiments, the penetration distance for attaching the yarn to each attachment zone is the same. For example, as shown in fig. 9 and 15, the piercing distance 206 for attaching yarn 151 to attachment region 210 is the same as the piercing distance 206 for attaching yarn 151 to attachment region 152. In other embodiments, the penetration distance for attaching the yarn to each attachment zone is different.

Referring to fig. 15, moving or lowering the nozzle into direct contact with the attachment zone may place the yarn into direct contact with the attachment zone to allow the yarn and attachment zone to bond. For example, moving or lowering nozzle 118 into direct contact with attachment region 210 may result in yarn 151 being placed in direct contact with attachment region 210. In this example, the second portion 159 of the thermo-moldable material 156 (see fig. 3) may transition from a liquid state to a solid state to bond the attachment region 210 (see fig. 16).

In some cases, it is desirable to raise the nozzle to a predetermined distance along the first axis after attaching the yarn to the upper surface. Referring to fig. 16, after attaching yarn 151 to attachment region 210, printing system 100 (see fig. 1) may raise nozzle 118 to a predetermined distance 202 (see fig. 7) along first axis 160. In some embodiments, the nozzle may maintain a substrate position along the second axis while the nozzle is raised along the first axis. For example, the printing system 100 may maintain the substrate position 218 along the second axis 162 while the nozzle 118 is raised along the first axis 160. In some embodiments, the nozzle may maintain the substrate position along the third axis while the nozzle is raised along the first axis. Referring to fig. 16, while raising nozzles 118 along first axis 160, printing system 100 may maintain a substrate position 218 along third axis 164 (not shown). In some embodiments, the nozzle may maintain a substrate position along the second axis and along the third axis while the nozzle is raised along the first axis. Referring to fig. 16, as the nozzle 118 is raised along the first axis 160, the printing system 100 may maintain a substrate position 218 along the second axis 162 and along the third axis 164. Where different coordinate systems are used to characterize the movement of the nozzle, the nozzle may maintain the substrate position along one or more different axes.

In some cases, it may be desirable to have a continuous section of yarn extending from the attachment region to the non-attachment region. In some embodiments, the non-attachment region may abut the attachment region to facilitate the extension of the connected segments of yarn from the attachment region to the non-attachment region. Referring to fig. 16, the non-attachment region 212 may abut the attachment region 152. In this example, the non-attachment region 230 may abut the attachment region 152 or otherwise be disposed near the attachment region 152. In this example, the non-attachment region 230 abuts the attachment region 210. In other embodiments, the non-attachment region may be separate from the attachment region.

In those cases where the non-attachment area may abut the attachment area, the yarns may extend along any area of the upper surface. In some embodiments, the yarns may extend between adjacent non-attachment zones and attachment zones. Referring to fig. 16, yarn 151 may extend from non-attachment region 212 to attachment region 152. In this example, yarn 151 may extend from non-attachment region 230 to attachment region 152. In this example, yarn 151 may extend from non-attachment region 230 to attachment region 210. In other embodiments, the yarns may extend to other areas of the upper surface of the substrate.

In some embodiments, the printing system may move the nozzle away from the attachment zone. Referring to fig. 17, the printing system 100 (see fig. 1) may move the nozzle 118 away from the attachment region 210 along the second axis 162 and/or along the third axis 164 (see fig. 1). In some cases, it may be desirable to move the nozzle away from the attachment zone along the upper surface 148 while maintaining a predetermined distance between the nozzle and the upper surface to allow the yarn to separate from the non-attachment zone. Referring to fig. 17, printing system 100 may maintain a predetermined distance 202 between nozzle 118 and upper surface 148. In this way, yarn 151 may not be pushed into upper surface 148, but instead yarn 151 may be bonded to upper surface 148, thereby allowing for one or more non-attachment zones. In other embodiments, the printing system may move the nozzles differently away from the attachment region.

In some embodiments, the unattached portions of the yarn may be free to move. For example, successive segments 220 of yarn 151 may be free to move between state 222 (adjacent to the base) and state 224 (away from the base and arranged in an endless configuration). Referring to fig. 17, the continuous segment 220 may directly contact the upper surface 148 and the non-attachment region 226 in state 222. In this example, the continuous segment 220 may be spaced from the upper surface 148 and the non-attachment region 226 in state 224.

In some cases, it is desirable to prevent the yarn from separating from the substrate. In some embodiments, attaching the yarn to one or more attachment zones may prevent the yarn from separating from the substrate. Referring to fig. 17, attachment zones 152 and 210 may prevent yarn 151 from separating from base 144.

In some embodiments, the attachment zones hold the yarn to the upper surface while the yarn is free to move between states. Referring to fig. 17, attachment regions 152 and 210 hold continuous segment 220 and yarn 151 to upper surface 148 while continuous segment 220 transitions between states 222 and 224.

Some embodiments may include provisions for quick attachment of the yarn to the substrate. In some cases, the attachment regions may be spaced apart by a spacing length. Referring to fig. 18 and 19, a first attachment zone 1910 of the substrate 1902 may be formed by a first step 1810 of lowering the nozzle, and a second attachment zone 1912 of the substrate 1902 may be formed by a second step 1812 of lowering the nozzle. In this example, the first step 1810 and the second step 1812 may be spaced apart by a spacing length 1804, thereby causing the first attachment zone 1910 to be spaced apart from the second attachment zone 1912 by a first spacing 1924. In other cases, the attachment regions may be contiguous (see fig. 23).

In those embodiments where the attachment zones are spaced apart by a spacing length, the spacing length may have any suitable length to allow the printing process to quickly attach the yarns to the substrate. In some embodiments, the spacing length can be greater than the width of the attachment zone. Referring to fig. 18 and 19, the spacing length 1804 can be greater than the width 1906 of the first attachment region 1910. In other embodiments, the spacing lengths may be different.

In some embodiments, the separation distance between the nozzle and the substrate may be less than the separation length. Referring to fig. 18, the separation distance 1806 may be less than the spacing length 1804. In other embodiments, the separation distance may be different.

In some embodiments, multiple pairs of attachment regions may be formed using a single separation distance. Referring to fig. 18, a separation distance 1806 may be used during a first step 1810 of lowering the nozzle to form a first attachment region 1910. In this example, the separation distance 1806 may be used during the second step 1812 of lowering the nozzle to form the second attachment zone 1912. In other embodiments, different separation distances may be used to form pairs of attachment regions (see FIG. 20).

In some embodiments, pairs of attachment regions may be spaced apart by a single spacing length, as further characterized below. In some embodiments, pairs of attachment regions may be spaced apart at different spacing lengths, as further characterized below.

In those instances where multiple pairs of attachment zones may be spaced apart by a single spacing length, any number of attachment zones may be used to facilitate the printing process to quickly attach the yarn to the substrate. Referring to fig. 18 and 19, a third attachment zone 1914 may be formed by a third step 1814 of lowering the nozzle to attach the yarn 1904. In this example, second step 1812 and third step 1814 may be spaced apart by spacing length 1804. Thus, the first and second attachment zones 1910, 1912 may be spaced apart by the spacing length 1804, and the second and third attachment zones 1912, 1914 may be spaced apart by the spacing length 1804. In other embodiments, different numbers of attachment regions may be spaced apart by a single spacing length.

In those instances where pairs of attachment regions may be spaced at different spacing lengths, any suitable spacing length may be used to facilitate the printing process to connect the yarns to the substrate. In some embodiments, the length of the space between different pairs of attachment regions may be reduced, as further characterized below. In some embodiments, the length of the space between different pairs of attachment regions may be increased, as further characterized below.

In those instances where the length of the space between different pairs of attachment regions may be reduced, any suitable length of space may be used to facilitate the printing process to attach the yarns to the substrate. In one embodiment, the spacing length may be reduced such that adjacent attachment regions abut. Referring to fig. 20 and 21, the fourth attachment region 2116 may be formed by a fourth step 2016 of lowering a nozzle and the fifth attachment region 2118 may be formed by a fifth step 2018 of lowering a nozzle. In this example, fourth step 2016 and fifth step 2018 may be spaced apart by a spacing length 2004. Thus, the fourth and fifth attachment zones 2116, 2118 may be contiguous, and the third and fourth attachment zones 1914, 2116 may be contiguous, while the second attachment zone 1912 is spaced apart from the third attachment zone 1914 by a first spacing 1924 (see fig. 19). In some embodiments, the spacing length may be reduced such that adjacent attachment regions are spaced apart. For example, the fourth step 2016 and the fifth step 2018 may be spaced apart by a spacing length such that the fourth attachment region 2116 and the fifth attachment region 2118 may be spaced apart by a second spacing (not shown). In other embodiments, the spacing length may be reduced differently.

In some embodiments, multiple pairs of attachment regions may be formed using different separation distances. Referring to fig. 20, a separation distance 1806 may be used during a second step 1812 of lowering the nozzle to form a second attachment zone 1912. In this example, the separation distance 2006 may be used during a fourth step 2016 of lowering a nozzle to form a fourth attachment region 2116. In other embodiments, multiple pairs of attachment regions may be formed using a single separation distance.

In those embodiments where the continuous segments extend between the attachment zones, the continuous segments may span any suitable length between the attachment zones to facilitate attachment of the yarns to the substrate. In some embodiments, the continuous segments may span between attachment zones that are spaced apart by a single spacing length (see fig. 19). In other embodiments, consecutive segments may span between attachment zones spaced at different spacing lengths (see fig. 21).

In those instances where the length of the space between different pairs of attachment regions may be increased, any suitable length of space may be used to facilitate the printing process to attach the yarns to the substrate. In one embodiment, the spacing length may be increased such that adjacent attachment regions are spaced apart by a length greater than the thickness of the substrate. Referring to fig. 22 and 23, fourth attachment area 2316 may be formed by fourth step 2216 of lowering the nozzle to attach yarn 1904. In this example, third step 1814 and fourth step 2216 may be spaced apart by a spacing length 2204. Thus, the third attachment zone 1914 and the fourth attachment zone 2316 may be spaced apart at a second spacing 2324, the second spacing 2324 being greater than the substrate thickness 2306. In other embodiments, the spacing length may be increased differently.

Some embodiments may include provisions that allow for slack in the yarn to facilitate molding the shape of the yarn attached to the substrate. In some embodiments, the separation distance between the nozzle and the substrate may be sized to facilitate the use of pillars. Referring to fig. 22, the separation distance 2206 may be less than a span 2326 of the yarn 1904 extending between the third attachment zone 1914 and the fourth attachment zone 2316. In this example, separation distance 2206 may allow for slack in yarn 1904 to facilitate molding the shape of the yarn attached to the substrate. In other embodiments, the separation distance between the nozzle and the substrate may be differently sized.

In some embodiments, the yarns may extend along the base along any number of axes. In some embodiments, the yarns may extend along multiple axes of the substrate. Referring to fig. 24, the yarns 2402 may extend along the second axis 162 and may extend along the third axis 164 of the substrate 2406. In other embodiments, the yarns may extend in other directions.

In some embodiments, the attachment regions of the substrate may be arranged in different positions along any number of axes. In some embodiments, the attachment zones may be disposed in different positions along multiple axes of the substrate. Referring to fig. 24, the first attachment region 2410 extends over a first width location 2510 of the second axis 162 and the second attachment region 2412 extends over a second width location 2512 of the second axis 162. In this example, the first attachment region 2410 extends over a first length position 2520 of the third axis 164, and the second attachment region 2412 extends over a second length position 2522 of the third axis 164. In other embodiments, the attachment region of the substrate may be disposed in other locations.

Some embodiments may include provisions that allow for shaping of the yarns attached to the substrate. In one embodiment, a post may be used to shape the yarn. Referring to fig. 25, one or more printing processes described above may be used to attach the yarn 2502 to the substrate 2506 at the first attachment region 2510 and at the second attachment region 2512. In this example, yarn 2502 may be arranged to directly contact column 2504. In this example, direct contact with the upright 2504 can create a curved portion 2508 for the yarn 2502 in the horizontal plane, allowing the yarn 2502 to travel in a non-linear path in the horizontal plane. In other embodiments, other components and/or methods may be allowed to be used to shape the yarns attached to the substrate.

Fig. 26-27 illustrate exemplary articles manufactured by one or more steps of various embodiments. As shown in fig. 26, article 2600 may include a substrate 2602. The substrate 2602 may be, for example, a portion of footwear, apparel, and the like. As shown, the substrate 2602 may include yarn structures 2604. As previously mentioned, various embodiments may allow for any number of attachment and non-attachment regions. As shown, the substrate 2602 can include an attachment region 2606 and a non-attachment region 2608. Accordingly, as shown in fig. 27, the yarn structure 2604 can have a first state in which the yarn structure 2604 is attached to a fastener 2610. Additionally, as shown in fig. 27, the yarn structure 2604 may have a second state in which the yarn structure 2604 is unattached to the fastener 2610.

One or more steps of various embodiments may be used to manufacture various articles for various uses. For example, as shown in fig. 26-27, article 2600 may allow yarn structures 2604 to move over fastener 2610 without excessive slack in yarn structures 2604. Further, the manufacture of the article may be simplified by selectively attaching the yarn structures to the substrate, for example, by reducing manufacturing operations (e.g., removing the release layer). In another example, the yarn structures are selectively partially attached to limit stretch in a first axis while allowing stretch in a second axis (not shown). In some examples, the yarn structures are selectively partially attached for aesthetic purposes. For example, yarn structures may be selectively attached to highlight logos, designs, colors, and the like.

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. Any feature of any embodiment may be used in combination with or instead of any other feature or element in any other embodiment, unless otherwise specifically limited. 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 appended claims.