Invented by Travis Alexander Busbee, Kornit Digital Technologies Ltd

The market for 3D-printed articles of footwear with sensors is rapidly growing, and with good reason. 3D printing technology has revolutionized the way we manufacture products, and the footwear industry is no exception. With the ability to create custom-fit shoes and embed sensors that track movement and performance, 3D-printed footwear is quickly becoming the go-to choice for athletes and fitness enthusiasts. One of the biggest advantages of 3D-printed footwear is the ability to create shoes that are tailored to the individual’s foot shape and size. This is achieved through a process called additive manufacturing, where layers of material are added on top of each other to create a three-dimensional object. By scanning the foot and using computer-aided design (CAD) software, shoe designers can create a shoe that fits the individual’s foot perfectly. This not only improves comfort, but also reduces the risk of injury. Another advantage of 3D-printed footwear is the ability to embed sensors that track movement and performance. These sensors can provide valuable data on how the foot moves during exercise, which can be used to improve technique and prevent injury. For example, sensors can track the pressure points on the foot during running, which can help athletes adjust their stride to reduce the risk of injury. Methods for forming 3D-printed footwear with sensors vary depending on the manufacturer. Some companies use a process called fused deposition modeling (FDM), where a thermoplastic material is melted and extruded through a nozzle to create the shoe. Other companies use a process called stereolithography (SLA), where a liquid resin is cured with a laser to create the shoe. Both methods have their advantages and disadvantages, but both can produce high-quality 3D-printed footwear with sensors. The market for 3D-printed footwear with sensors is expected to grow significantly in the coming years. According to a report by MarketsandMarkets, the global market for 3D-printed footwear is expected to reach $6.3 billion by 2025, with a compound annual growth rate (CAGR) of 19.5% from 2020 to 2025. This growth is being driven by the increasing demand for custom-fit shoes and the growing awareness of the benefits of sensor technology in footwear. In conclusion, the market for 3D-printed articles of footwear with sensors is rapidly growing, and for good reason. With the ability to create custom-fit shoes and embed sensors that track movement and performance, 3D-printed footwear is quickly becoming the go-to choice for athletes and fitness enthusiasts. As technology continues to advance, we can expect to see even more innovative 3D-printed footwear designs with advanced sensor technology.

The Kornit Digital Technologies Ltd invention works as follows

The present disclosure relates to three-dimensionally patterned articles used in footwear, and related systems and methods. In certain embodiments, the three-dimensionally-printed article can be made of closed-cell foam. The closed-cell material may be integrated or have a gradient. In certain embodiments, the three-dimensionally fabricated article can include a sensor. According to certain embodiments of the invention, such arrangements allow for improved footwear articles and/or customized footwear articles.

Background for 3D-printed articles of footwear with sensor and methods for forming same

Footwear, in general, is mass-produced from large batches using complex supply chains. Consequently, parts of an article of footwear that have different properties are usually formed by uniform components of standard sizes and properties, which are then adhered or disposed one on top of the other. The resultant footwear is of lower quality and customization to specific users becomes difficult. “Accordingly, improved articles that can be used in footwear and allow for greater integration or customization of different components may be beneficial.

The present invention relates in general to three-dimensionally printed footwear articles and systems. In some cases, the subject matter of this invention includes interrelated products, alternative approaches to a problem and/or multiple uses for one or more articles and/or systems.

In some embodiments, 3D-printed articles for footwear can include a plurality sensors. The sensors can be pressure sensors in some embodiments.

In some embodiments, the method of designing a 3D-printed personalized article for use in shoes may include acquiring information from multiple pressure sensors located within a 3D printed article. The method can also include printing a 2nd 3D-printed object with a gradient for a particular property. The property can be chosen from a group that includes average Shore A hardness (hardness), average pore size and average density.

In one set of embodiments 3D-printed shoes are provided. The 3D printed article can have a gradient between a first and second portion. In some embodiments the property can be selected from a group including average stiffness (average Shore A hardness), average pore size and average density. In some embodiments the 3D-printed foam closed cell may be an integrated material.

In another set of embodiments are provided methods. A method can include 3D printing an article with a gradient between a first and second portion. In some embodiments the property can be selected from a group including average stiffness (average Shore A hardness), average pore size and average density. In some embodiments the foam article may be made of a single material.

The following detailed description will reveal other advantages and novel features when viewed in conjunction with the accompanying illustrations.

The general provision is that “3D printed articles for use as footwear, comprising a number of sensors, and methods of designing personalized 3D printed articles for footwear using information obtained from a plurality pressure sensors distributed in a 3D printed article” are provided. In certain embodiments, 3D printed articles with multiple sensors can sense conditions related to the wearer. The 3D printed article can be used to collect information on the wearer. This information may include their health and fitness, or footwear designs that are more advantageous for them based upon their biomechanics.

The invention also includes methods for creating inventive three-dimensionally-printed (3D-printed), articles that can be used in footwear and other applications. In certain embodiments, a 3D-printed product may include one or more features which are difficult or impossible to achieve in other articles. The 3D-printed material may, for example, be a single integrated piece of material that has a gradient of one or more properties between two or three portions. The 3D-printed articles can be printed using inks that are dynamically altered as they are being printed. In certain embodiments, a 3D printed article may include one or more features which are desired by the users of the 3D printed article or footwear in which the 3D printed article is incorporated. The 3D-printed articles may, for example, be made from a single material or may not have seams, adhesives and other features used to join materials together. These and other 3D printed articles may be more comforting for users and/or less susceptible to degradation or damages during normal use of the article.

It should be understood that the references to 3D-printed items may include articles with more than one layer, e.g. articles consisting of multiple layers printed over each other, and/or articles with a single material layer. 3D printed articles can include articles produced by 3D printers and/or those that are macroscopically extended in three dimensions. 3D-printing can also include printing multiple layers or a single one. 3D printing can include printing on 3D printers and printing in three dimensions.

It should be understood that other articles than 3D printed articles and other printing methods than 3D printing are also contemplated. Some embodiments, for example, relate to articles having one or more features of 3D printed articles described herein, but which are not 3D printed articles (e.g. a gradient of one or multiple properties), Some articles can include one or both 3D-printed and non-3D printed components. Some embodiments also relate to methods which have some of the features described herein, but do not include 3D printing (e.g. may include employing a multiple-axis deposition systems). Some methods can include one or several 3D-printing and non-3D printing steps.

Certain methods (e.g. methods that include exclusively 3D printing steps, or methods that include both 3D printing and non-3D print steps) involve depositing a film onto a 3D surface. If more than one film is deposited, some or all may be thin films.

Certain Methods (e.g. methods that include exclusively 3D printing steps, or methods that include both 3D printing and non-3D print steps) involve depositing a non-filming material on a substrate. A material can be deposited on a substrate and then infiltrated. A material can be deposited on a porous surface (e.g. a porous fabric) and infiltrated into at least some of its pores. It may be deposited on the porous surface and then fill in a portion or all of the pores. The material can enhance the mechanical properties. In certain embodiments, the material that is deposited on a substrate in which it penetrates, like a porous one, does not extend a significant distance (or even at all) past the surface of the substrate.

In some embodiments, certain methods and/or articles described herein can include 3D printed articles that are capable of sensing the properties of the user, an article in which the 3D printed article is a component, or the 3D printed article itself. The information sensed by the 3D printed article can be used to recommend a second 3D printed article to be used in footwear, and/or provide information to the user of the 3D printed article (e.g. health information, fitness data). These methods and articles can allow users to discover footwear designs that are especially beneficial to them. This may enable users to receive medical advice and/or training assistance, or allow them to manufacture customized 3D printed articles of footwear which are beneficial for individuals.

In one set of embodiments one or more methods described herein for manufacturing 3D printed articles may be superior to other methods used for articles intended for footwear. A footwear manufacturer using a method described herein could be able use fewer processes in order to create an article than they would in other processes comparable (e.g. the manufacturer might use a 3D printer in a single step to make a part that would otherwise require a combination or several processes, such as injection molding, laminate, etc.). It may be possible to manufacture the article more quickly and/or easily. Another example is that one or more methods described herein do not require expensive equipment to be manufactured and whose costs are typically only recovered after repeated usage (e.g. molds). Some of the methods described may use a 3D-printer to create articles that can be customized as desired at little or no additional cost. In certain embodiments, methods described herein may make it economical to produce small batches (3D-printed items) (e.g. batches less than 100 or 50 or 10). Manufacturers can use some of the described methods to adapt to market changes, create footwear articles that are tailored to individual users or groups, etc. In certain embodiments, one or more methods described herein may be used to fabricate 3D-printed articles at the point of purchase and/or avoid long distance shipment.

A non-limiting illustration of a 3D printed article that can be used in footwear is shown on FIG. 1A. In this figure, 3D printed article 100 is divided into two portions 110 and 120. In the context of this invention, a part of an article can refer to any group of points contained within the article. (i.e. points located within the space defined by the outer surfaces of the piece). Parts of an article can be volumes of space, but are not necessarily so. (In some embodiments, portions may be a surface, line, or point within the article.) Portions of an article can be continuous (e.g., each point in the portion is connected by a path that does pass through points outside the portion), or discontinuous (i.e. the portion could include at least one point which cannot be connected with at least another point within the piece by a path that does pass through points outside the portion). Portions of an item may be substantially homogeneous in terms of one or several properties (e.g. one or two properties may vary by a standard error of less than or equivalent to 1% or 2% or 5% or 10% across the entire portion) and/or they may be heterogeneous.

Parts of an article can have any size that is suitable. In some embodiments a portion can have the largest dimension, and/or contain one or more features that are larger than 100 microns or 200 microns or 500 microns. Other examples include a greater or smaller size than 1 mm or 2 mm or 5 mm or 10 mm or 20 mm or 50 mm or even greater or less than 1 cm or 2 cm. In some embodiments a portion can have a large dimension, and/or one or more features may be smaller than 5 cm, 2 cm, 1 cm, 5 mm or 2 mm or 1 mm. It is also possible to combine the ranges above (e.g. greater than or less than 100 microns, and less than or equivalent to 5 cm). Other ranges may also be possible.

The one or two properties may be structural properties (e.g. average pore size and density, surface roughness and filler content), chemical properties (e.g. average degree of crosslinking, chemical formulation), mechanical properties (e.g. strength, elasticity, flexural modus, modulus at 100% strain, tensile elastic modulus), optical properties, such as color, opacity or reflectivity, or other properties, including dimensional change upon heat activation, thermal conductivity or electrical conductivity The properties can be structural (e.g. average pore size), chemical (e.g. average degree of chemical composition), mechanical (e.g. average stiffness), optical (e.g. color, opacity and reflectivity), or other (e.g. average thermal conductivity (e.g. a gradient of the one or more properties) properties. In some embodiments the difference between properties in the first and second portions may be a gradient (e.g. the property or properties can vary from a first to a second value relatively smoothly). In some embodiments, one or more properties may change abruptly at the boundary between the first and second portions.

It should be noted that although FIG. The second portion is shown above the first part in FIG. 1A, but other arrangements are possible. The first portion can be placed beside the second part, or the first part may surround the other. Or, they may both interpenetrate. Note that FIG. This configuration is not intended to be restrictive. In some embodiments the first and second portions may be separated by a portion positioned between them. In the context of this document, a portion positioned between? Two portions can be directly between two portions, so that there is no intervening part. Or an intervening part may be present.

While FIG. It should be understood that while FIG. In some embodiments portions of a 3D printed article may include sub-portions. Each portion or sub-portion can differ in at least a single way from the other (sub)portion (e.g. any two (sub)portions could have at least a property that’s different) or be substantially similar to another (sub)portion of the 3D printed article.

In some embodiments, the two or more portions can be disposed in a way that the 3D-printed articles lack an interface. Along the pathway, one or more properties may undergo step-changes (e.g. average pore size or density, stiffness or stiffness of the solid components, Shore A hardness or degree of crosslinking, color or chemical composition, abrasion resistant, thermal conductivity or electrical conductivity or stiffness anisotropy or stiffness anisotropy or elastic modulus The property or properties can be varied smoothly along the path. The pathway can be straight (e.g. a line segment) or include curves and corners (e.g. a meander as described below). The pathway can be a path along which the material was deposited when the 3D printed article was formed, such as the pathway traveled by a printhead (or a substrate in relation to the printhead) during 3D printing.

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