Abstract: Footwear fabrication methods are disclosed, having reduced material consumption and/or waste requirements, compared to conventional methods, as well as the footwear articles made by such methods. The fabrication methods and articles are characterized by the selective use of a bonding agent, in the form of a powder or tackified (e.g., preheated) powder, to bond various material panels, such substrate, mesh, and/or skin panels in the formation of a composite panel (e.g., a bonded mesh composite panel), which may in turn be used to provide a footwear upper and ultimately an article of footwear. The bonding agent is particularly applicable to fabrication processes utilizing a combination of heat and pressure for bonding or fusing material panels, each having a suitable composition, size, shape, and thickness, into the particular configuration of the footwear upper.

Abstract: Methods and systems are provided for color printing. A three-dimensional object can be printed onto an article using the methods and systems. The three-dimensional object can include a lower color graphic layer printed onto an article, one or more transparent structural layers printed onto the lower color graphic layer, and an upper color graphic layer printed onto an uppermost layer of the one or more transparent structural layers. The upper color graphic layer and the lower color graphic layer collectively visually depict a color graphic image.

Abstract: An article, such as an article of footwear or an article of apparel, includes an upper having a gradient-like coloring pattern. The article further includes protruding elements configured in a pattern that corresponds to the coloring pattern. The article may have a layered structure including a base layer, a coloring ink layer and a layer of protruding elements.

Abstract: A method of printing a three-dimensional structure onto a base having irregularities on the surface is disclosed. A sensing device determines the depth of the irregularity on the surface. A computing system receives an image file including a predetermined thickness of a layer to be printed onto the base. The predetermined thickness is adjusted based on the depth of the irregularity. A printing device prints a layer onto the base having the adjusted predetermined thickness print on the irregularity to make the surface substantially smooth.

Abstract: A method and system for printing 3D structures using 2D monochromatic images (for example, greyscale images) is provided. The method can include instructing a printing device to print a 2D monochromatic image using print material in a reservoir known to contain a structural print material. Greater amounts of print material are printed in locations corresponding to relatively darker regions of the 2D monochromatic image.

Abstract: A method of printing a three-dimensional color object having a contoured surface onto a substrate includes printing color ink layers and structural ink layers. A color ink layer is printed onto the substrate. Structural ink layers are printed onto the color ink layer to build the three-dimensional shape of the object. The contoured surface is formed from varying the heights of pixel columns in the printing information. The heights of the pixel columns may be varied by printing different numbers of layers in adjacent columns or by printing the same number of layers in adjacent columns where some pixels in a column have different thicknesses than other pixels in the column.

Abstract: Methods are provided for printing a three-dimensional structural component onto a base. For example, a method of printing is provided, including receiving a set of predetermined thicknesses for the three-dimensional structural component. The set of predetermined thicknesses has a first thickness and a second thickness. The first thickness is greater than the second thickness. The method further includes instructing a printing device to print a single layer for the three-dimensional structural component using the set of predetermined thicknesses. The method further includes printing a first portion of the single layer onto the base so that the first portion has the first thickness. The method further includes printing a second portion of the single layer onto the base so that the second portion has the second thickness.

Abstract: This application discloses methods of printing a three-dimensional object on a base using a printing device. One method includes printing a color layer of the three-dimensional object onto a region of the base. The color layer has a color thickness corresponding to a selected color intensity of a color. The method also includes determining a structural thickness for a structural layer of the three-dimensional object by calculating a difference between the color thickness and a target thickness of the three-dimensional object. The target thickness is greater than the color thickness. The method further includes printing the structural layer having the structural thickness directly onto the color layer.

Abstract: A method and apparatus for printing 2D layers and 3D structures is disclosed. The method includes dispensing a print material from a printhead assembly onto a base and curing the print material with a curing device assembly. The spacing between the printhead assembly and the curing device assembly can be adjusted to vary gloss levels in a printed feature. The printhead assembly can include at least one row of nozzles with colored inks and at least one row of nozzles with a clear structural print material.

Abstract: A method and system for printing 3D structures using 2D monochromatic images (for example, greyscale images) is provided. The method can include instructing a printing device to print a 2D monochromatic image using print material in a reservoir known to contain a structural print material. Greater amounts of print material are printed in locations corresponding to relatively darker regions of the 2D monochromatic image.

Abstract: An article of footwear can include a sole structure, an upper, and a printed layer. The upper can be coupled to the sole structure. The printed layer can be disposed on the upper and include a first printed material and a second printed material. The first printed material can have a plurality of spaced-apart first segments and have a first hardness. The second printed material can have a plurality of spaced-apart second segments and have a second hardness that is less than the first hardness of the first printed material. Each of the second segments can be disposed adjacent to one or more of the first segments.

Abstract: A method of printing a three-dimensional color object having a contoured surface onto a substrate includes printing color ink layers and structural ink layers. A color ink layer is printed onto the substrate. Structural ink layers are printed onto the color ink layer to build the three-dimensional shape of the object. The contoured surface is formed from varying the heights of pixel columns in the printing information. The heights of the pixel columns may be varied by printing different numbers of layers in adjacent columns or by printing the same number of layers in adjacent columns where some pixels in a column have different thicknesses than other pixels in the column.

Abstract: A method of printing a three-dimensional structure onto a base having irregularities on the surface is disclosed. A sensing device determines the depth of the irregularity on the surface. A computing system receives an image file including a predetermined thickness of a layer to be printed onto the base. The predetermined thickness is adjusted based on the depth of the irregularity. A printing device prints a layer onto the base having the adjusted predetermined thickness print on the irregularity to make the surface substantially smooth.

Abstract: A method and apparatus for printing on an article are disclosed. An embodiment of a method may include the generation of a virtual mask that can designate areas for printing and/or designate areas to exclude from printing. A method may include utilization of the virtual mask during either 2D or 3D printing such that a print design is printed in areas designated for printing by the virtual mask.

Abstract: A printing system is used to selectively print a layer material on a surface that is initially in a planar or two-dimensional shape. After the layer material is printed onto the surface, it is exposed to an amount of radiation from a radiation source and partially cured. Several layer materials may be placed on top of one another and are also partially cured. The flat surface may be reshaped into a nonplanar or three-dimensional shape, and the layer materials are again exposed to an amount of radiation and fully cured.

Abstract: A method and apparatus for printing on an article are disclosed. An embodiment of a method may include the generation of a virtual mask that can designate areas for printing and/or designate areas to exclude from printing. A method may include utilization of the virtual mask during either 2D or 3D printing such that a print design is printed in areas designated for printing by the virtual mask.

Abstract: A method of printing a three-dimensional structure onto a base having irregularities on the surface is disclosed. A sensing device determines the depth of the irregularity on the surface. A computing system receives an image file including a predetermined thickness of a layer to be printed onto the base. The predetermined thickness is adjusted based on the depth of the irregularity. A printing device prints a layer onto the base having the adjusted predetermined thickness print on the irregularity to make the surface substantially smooth.

Abstract: Methods and systems are provided for color printing. A three-dimensional object can be printed onto an article using the methods and systems. The three-dimensional object can include a lower color graphic layer printed onto an article, one or more transparent structural layers printed onto the lower color graphic layer, and an upper color graphic layer printed onto an uppermost layer of the one or more transparent structural layers. The upper color graphic layer and the lower color graphic layer collectively visually depict a color graphic image.

Abstract: A method and apparatus of providing varying gloss levels for a printed surface of a two-dimensional or three-dimensional printed structure is disclosed. The method includes dynamically adjusting the spacing between a printhead assembly and a curing device according to a target gloss level for the resulting printed structure.

Abstract: A method for printing on an article can include selecting a shape model. The shape model is generated from a first image and includes a fiducial, a reference location, and a graphic marker, the fiducial is located in the first image. The reference location is based on a location of the fiducial in the first image, and the graphic marker is positioned at a pre-selected location relative to the reference location. The method can also include locating the fiducial in a second image of an article, by a computing device, establishing the reference location in the second image of the article, positioning the graphic marker within the second image of the article at the pre-selected location, and printing a graphic on the article at a graphic location, the graphic location on the article corresponds to the pre-selected location of the graphic marker on the second image of the article.