# US 10,160,244 B1 · Method for dye-sublimation printing an orthotic substrate and orthotic product made thereby > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,160,244 B1 - Document ID: US10160244B1 - Status: Granted - Kind: B1 - Application number: 15/486,775 - Filed: 2017-04-13 - Granted: 2018-12-25 - Earliest claimed: 2017-04-13 - Applicants: John Garrett Whitt - Inventors: John Garrett Whitt - Web page: https://patentgrep.com/patent/US10160244B1 ## CPC - B41M 5/0358: {characterised by the mechanisms or artifacts to obtain the transfer, e.g. the heating means, the pressure means or the transport means} - B29C 51/264: {Auxiliary operations prior to the thermoforming operation, e.g. cutting (B29C51/42, B29C51/46 take precedence)} - B41M 5/0256: {the transferable ink pattern being obtained by means of a computer driven printer, e.g. an ink jet or laser printer, or by electrographic means} - B41M 5/035: by sublimation or volatilisation of {pre-printed} design {, e.g. sublistatic (B41M5/0256 takes precedence; printing on textiles D06P5/00)} - A43B 3/0078: {provided with logos, letters, signatures or the like decoration (A43B23/24 takes precedence)} - A43B 17/00: Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined - A43B 19/00: Shoe-shaped inserts; Inserts covering the instep - A43D 3/021: {for orthopaedic footwear} - A43D 8/22: by embossing or printing (printing per se, stamping per se B41) - B29C 51/02: Combined thermoforming and manufacture of the preform - B29C 51/10: Forming by pressure difference, e.g. vacuum - B29C 51/268: {Cutting, rearranging and joining the cut parts} - B29C 2791/006: Using vacuum - B29K 2023/06: {PE, i.e. polyethylene} - B29K 2105/256: {Sheets, plates, blanks or films} - B29L 2031/50: Footwear, e.g. shoes or parts thereof - B29L 2031/502: {Heels} - B29L 2031/505: {Uppers} - B41M: PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING, (correction of typographical errors B41J; processes for applying transfer pictures or the like B44C1/16; fluid media for correction of typographical errors by coating C09D10/00; printing textiles D06P) - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - A43B: CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR - A43D: MACHINES, TOOLS, EQUIPMENT OR METHODS FOR MANUFACTURING OR REPAIRING FOOTWEAR - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES ## Abstract A two-part method for dye-sublimation printing a decorative design on a moldable orthotic substrate comprising a first digital printing step of printing a computer image file of a decorative design on a digital transfer paper substrate using dye-sublimation CMYK inks, and a second dye-sublimation printing step comprising the steps of heating an oven to a first temperature, placing a moldable orthotic substrate inside the oven, heating the moldable orthotic substrate to a second temperature, positioning the digital transfer paper substrate on the moldable orthotic substrate with the decorative design down and in contact with the moldable orthotic substrate, and sublimating the at least one color of dye-sublimation CMYK inks from the digital transfer paper substrate to the moldable orthotic substrate. A custom orthotic product may be manufactured by wrapping the dye-sublimation printed moldable orthotic substrate around an orthotic mold and applying a vacuum. ## Claims ### Claim 1 A method for dye-sublimation printing a decorative design on a moldable orthotic substrate comprising: providing an oven heated to a first temperature; placing a moldable orthotic substrate inside the oven; heating the moldable orthotic substrate to a second temperature; positioning a transfer paper substrate having a digitally printed decorative design on the moldable orthotic substrate with the digitally printed decorative design down and in contact with the moldable orthotic substrate to form a duo-layered substrate; and sublimating the digitally printed decorative design instantaneously from the transfer paper substrate to the moldable orthotic substrate upon formation of the duo-layered substrate, wherein all sublimating is performed without applying pressure other than optionally rubbing the transfer paper substrate manually to ensure that the entire digitally printed decorative design transfers to the moldable orthotic substrate. ### Claim 2 (depends on 1) The method of claim 1, wherein at least one color of dye-sublimation CMYK inks is used to print the digitally printed decorative design on the transfer paper substrate. ### Claim 3 (depends on 2) The method of claim 2, wherein at least one color of the dye-sublimation CMYK inks sublimate when heated to between 370-390 degrees Fahrenheit. ### Claim 4 (depends on 1) The method of claim 1, wherein the transfer paper substrate has a weight range of 33-70 grams per square meter. ### Claim 5 (depends on 1) The method of claim 1, wherein the moldable orthotic substrate is a sheet of polypropylene. ### Claim 6 (depends on 5) The method of claim 5, wherein the sheet of polypropylene is ⅛ to ¼ inches thick. ### Claim 7 (depends on 1) The method of claim 1, wherein the moldable orthotic substrate is a sheet of polyethylene. ### Claim 8 (depends on 7) The method of claim 7, wherein the sheet of polyethylene is ⅛ to ¼ inches thick. ### Claim 9 (depends on 1) The method of claim 1, wherein the first temperature has a range of 350 to 400 degrees Fahrenheit. ### Claim 10 (depends on 2) The method of claim 2, wherein a digital web press configured with at least one color of the dye-sublimation CYMK inks is used to print the digitally printed decorative design on the transfer paper substrate. ### Claim 11 (depends on 1) The method of claim 1, wherein the oven is a masonry oven. ### Claim 12 (depends on 1) The method of claim 1, further comprising rubbing the transfer paper substrate manually to ensure that the entire digitally printed decorative design transfers to the moldable orthotic substrate. ### Claim 13 A method for manufacturing an orthotic product having a dye-sublimation printed decorative design comprising: a dye-sublimation printing part comprising the steps of: providing an oven heated to a first temperature; placing a moldable orthotic substrate inside the oven; heating the moldable orthotic substrate to a second temperature; positioning a transfer paper substrate having a digitally printed decorative design on the moldable orthotic substrate with the digitally printed decorative design down and in contact with the moldable orthotic substrate to form a duo-layered substrate; and sublimating the digitally printed decorative design without pressure from the transfer paper substrate to the moldable orthotic substrate upon formation of the duo-layered substrate, wherein all sublimating is performed without applying pressure other than optionally rubbing the transfer paper substrate manually to ensure that the ensure digitally printed decorative design transfers to the moldable orthotic substrate; and a manufacturing part comprising the steps of: wrapping the printed moldable orthotic substrate around an orthotic mold; applying a vacuum to the orthotic mold to conform the printed moldable orthotic substrate to the orthotic mold to form an orthotic product. ### Claim 14 (depends on 13) The method of claim 13, further comprising attaching one or more accessories to the orthotic product. ### Claim 15 (depends on 14) The method of claim 14, wherein the one or more accessories are dye-sublimation printed with a decorative design. ### Claim 16 (depends on 13) The method of claim 13, wherein the moldable orthotic substrate is a sheet of polypropylene. ### Claim 17 (depends on 13) The method of claim 13, wherein at least one color of the dye-sublimation CMYK inks is used to print the digitally printed decorative design on the transfer paper substrate.