# US 11,993,048 B2 · Footwear assembly method with 3D printing > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,993,048 B2 - Document ID: US11993048B2 - Status: Granted - Kind: B2 - Application number: 17/389,876 - Filed: 2021-07-30 - Published: 2021-11-18 - Granted: 2024-05-28 - Earliest claimed: 2012-07-19 - Assignees: NIKE, Inc. - Applicants: NIKE, Inc. - Inventors: David P. Jones; Ryan R. Larson - Web page: https://patentgrep.com/patent/US11993048B2 ## CPC - B29D 35/122: {Soles} - A43B 3/0084: {Arrangement of flocked decoration on shoes} - A43B 13/14: characterised by the constructive form - A43B 23/0235: {Different layers of different material} - A43B 23/026: {Laminated layers} - A43D 11/00: Machines for preliminary treatment or assembling of upper-parts, counters, or insoles on their lasts preparatory to the pulling-over or lasting operations; Applying or removing protective coverings - B29C 64/106: using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material - B29C 64/112: using individual droplets, e.g. from jetting heads - B29C 64/245: Platforms or substrates (support structures intended to be sacrificed after manufacture B29C64/40) - B29C 64/393: for controlling or regulating additive manufacturing processes - B29C 70/78: Moulding material on one side only of the preformed part - B29D 35/12: Producing parts thereof, e.g. soles, heels, uppers, by a moulding technique - B33Y 10/00: Processes of additive manufacturing - B33Y 80/00: Products made by additive manufacturing - A43D 2200/00: Machines or methods characterised by special features - A43D 2200/60: Computer aided manufacture of footwear, e.g. CAD or CAM - B29C 64/264: Arrangements for irradiation - B29K 2713/00: Use of textile products or fabrics for preformed parts, e.g. for inserts (B29K2105/06 takes precedence) - B29L 2031/50: Footwear, e.g. shoes or parts thereof - B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00) - A43B: CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR - A43D: MACHINES, TOOLS, EQUIPMENT OR METHODS FOR MANUFACTURING OR REPAIRING FOOTWEAR - 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) - B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - 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 Methods and systems are disclosed for apparel assembly using three-dimensional printing directly onto fabric apparel materials. Disclosed is a method and system for direct three-dimensional printing and assembly of an article of apparel, including designing a three-dimensional pattern for printing, positioning at least a portion of the article on a tray in a three-dimensional printing system, the portion being positioned substantially flat on the tray, printing a three-dimensional material directly onto the article using the designed pattern, curing the printed material, and removing the article from the three-dimensional printing system. ## Claims ### Claim 1 A method of three-dimensional printing onto a fabric material, comprising: positioning a fabric material on a tray in a three-dimensional printing system to provide a first printing substrate, wherein the fabric material comprises the first printing substrate; printing at least a first three-dimensional material directly onto the first printing substrate, based on at least one first three-dimensional pattern, wherein the printing of the at least a first three-dimensional material onto the first printing substrate comprises: printing a first layer of the at least a first three-dimensional material while the fabric material is positioned on the tray in the three-dimensional printing system; allowing the first layer of the at least a first three-dimensional material to at least partially absorb into the first printing substrate; curing the first layer of the at least a first three-dimensional material after the first layer is allowed to at least partially absorb into the first printing substrate; printing at least one additional layer of the at least a first three-dimensional material on the cured first layer of the at least a first three-dimensional material while the fabric material is positioned on the tray in the three-dimensional printing system; and curing the at least one additional layer of the at least a first three-dimensional material; and removing the fabric material from the three-dimensional printing system, wherein the printing of the at least a first three-dimensional material onto the first printing substrate comprises printing such that each of the cured first layer of the at least a first three-dimensional material and the cured at least one additional layer of the at least a first three-dimensional material extends above a surface of the fabric material with a predetermined thickness. ### Claim 2 (depends on 1) The method according to claim 1, wherein the printed first layer of the at least a first three-dimensional material has a first modulus of elasticity and the at least one additional layer of the at least a first three-dimensional material has a second modulus of elasticity different than the first modulus. ### Claim 3 (depends on 1) The method according to claim 1, wherein the first layer of the at least a first three-dimensional material has a first color and the at least one additional layer of the at least a first three-dimensional material has a second color. ### Claim 4 (depends on 1) The method according to claim 1, wherein the fabric material comprises at least a portion of an article of apparel. ### Claim 5 (depends on 1) The method according to claim 1, wherein the fabric material comprises at least a portion of an undergarment. ### Claim 6 (depends on 1) The method according to claim 1, wherein the fabric material comprises at least a portion of an athletic support garment. ### Claim 7 (depends on 1) The method according to claim 1, wherein the fabric material comprises at least one of a textile, a natural fabric, a synthetic fabric, a knit, a woven material, a nonwoven material, a mesh, a leather, a synthetic leather, a polymer, a rubber, and a foam. ### Claim 8 (depends on 1) The method according to claim 1, wherein the first printing substrate of the fabric material has at least one irregular surface having an irregular surface topology. ### Claim 9 (depends on 8) The method according to claim 8, wherein printing the at least a first three-dimensional material comprises compensating for irregularities in the at least one irregular surface by at least one of adjusting a distance between a printhead and the at least one irregular surface and adjusting at least one of size, rate, and distribution of material ejected from the printhead. ### Claim 10 (depends on 1) The method according to claim 1, wherein the removing the fabric material does not require a release layer. ### Claim 11 (depends on 1) The method according to claim 1, wherein the at least a first three-dimensional material comprises at least one of an ink, a resin, an acrylic, a polymer, a thermoplastic material, a thermosetting material, and a light-curable material. ### Claim 12 (depends on 1) The method according to claim 1, wherein the at least a first three-dimensional material further comprises a first filler material. ### Claim 13 (depends on 1) The method according to claim 1, wherein the at least a first three-dimensional material is adhered or bonded to the first printing substrate of the fabric material. ### Claim 14 A method of fabricating a fabric material, comprising: providing at least one first three-dimensional pattern for printing onto a fabric material to a print server; positioning at least a first portion of the fabric material on a tray in a three-dimensional printing system; printing at least one first three-dimensional material directly onto the fabric material based on the at least one first three-dimensional pattern provided to the print server, wherein the printing of the at least a first three-dimensional material onto the fabric material comprises: printing a first layer of the at least a first three-dimensional material directly onto the fabric material; allowing the first layer of the at least a first three-dimensional material to at least partially absorb into the fabric material; curing the first layer of the at least a first three-dimensional material after the first layer is allowed to at least partially absorb into the fabric material; printing at least one additional layer of the at least a first three-dimensional material on the cured first layer of the at least a first three-dimensional material; and curing the at least one additional layer of the at least a first three-dimensional material; and removing the fabric material from the three-dimensional printing system, wherein the printing of the at least one first three-dimensional material directly onto the fabric material comprises printing such that each of the cured first layer of the of the at least a first three-dimensional material and the cured at least one additional layer of the at least a first three-dimensional material extends above a surface of the fabric material with a predetermined thickness. ### Claim 15 (depends on 14) The method according to claim 14, wherein the first layer of the at least one first three-dimensional material has a first modulus of elasticity and the at least one additional layer of the at least one first three-dimensional material has a second modulus of elasticity different than the first modulus. ### Claim 16 (depends on 14) The method according to claim 14, wherein the fabric material comprises at least a portion of an article of apparel. ### Claim 17 (depends on 14) The method according to claim 14, wherein the fabric material comprises at least a portion of an undergarment. ### Claim 18 (depends on 14) The method according to claim 14, wherein the fabric material comprises at least a portion of an athletic support garment. ### Claim 19 (depends on 14) The method according to claim 14, wherein the first portion comprises at least one of a textile, a natural fabric, a synthetic fabric, a knit, a woven material, a nonwoven material, a mesh, a leather, a synthetic leather, a polymer, a rubber, and a foam. ### Claim 20 (depends on 14) The method according to claim 14, wherein the at least one first three-dimensional material comprises at least one of an ink, a resin, an acrylic, a polymer, a thermoplastic material, a thermosetting material, and a light-curable material.