SYSTEM AND METHOD FOR AUTOMATING PRODUCTION OF ELECTROSPUN TEXTILE PRODUCTS

Abstract

A system and method for producing a textile product which includes an insulated enclosure; an electrospinning dispensing system positioned along at least one face of the insulated enclosure; a solution supply system with a solution transport connection to the electrospinning dispensing system; a mold structure; a cyclical mold actuator mechanically coupled to the mold structure; and a charge unit electrically connected to the electrospinning dispensing system and the mold structure.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This Application claims the benefit of U.S. Provisional Application No. 62/037,238, filed on 14 Aug. 2014, U.S. Provisional Application No. 62/089,447, filed on 9 Dec. 2014, and U.S. Provisional Application No. 62/161,404, filed on 14 May 2015, which are all incorporated in their entireties by this reference.

TECHNICAL FIELD

This invention relates generally to the field of textile production, and more specifically to a new and useful system and method for automating production of electrospun textile products.

BACKGROUND

Electrospinning is the process of using electrical charges to pull fibers out of a solution, typically consisting of a polymer dissolved in a solvent, although the term can also be used to describe alternative solutions, such as melting polymers and pulling fibers from the resulting liquid. Electrospinning is primarily used in biomedical research, and is limited to the manufacturing of simple geometries such as sheets and tubes. This process is typically achieved through the use of a fluid-dispensing nozzle to which a strong electrical charge is applied. A collector placed in front of the nozzle is then used to collect the fibers and form the sheet or tube. Existing electrospinning processes fail to produce complex geometries. Additionally, existing electrospinning processes fail to provide for dynamic geometries. Thus there is a need in the electrospinning field to create a new and useful system and method for automating production of electrospun textile products. This invention provides such a new and useful system and method.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a perspective view of a schematic representation of a system of a preferred embodiment

FIG. 2 is an exploded schematic representation of portions of the system during electrospinning onto 2D projection mold;

FIG. 3 is an exploded schematic representation of portions of the system during electrospinning onto 3D mold;

FIG. 4 is an exploded schematic representation of portions of the system during electrospinning onto a multi-faceted mold;

FIG. 5 is a schematic representation of insulating features of an enclosure;

FIG. 6 is a cutaway view of an electrospinning dispensing system directing fiber at the internal chamber of a mold structure;

FIG. 7 is a detailed schematic of an electrospinning dispensing system;

FIG. 8 is a detailed schematic of a representative nozzle;

FIGS. 9A and 9B are schematic representations of exemplary actuated electrospinning nozzles;

FIGS. 10A-10D are schematic representations of alternative electrospinning dispensing techniques;

FIGS. 11A and 11B are schematic representations of a system with electrospinning solution options;

FIGS. 12A and 12B are schematic representations of exemplary cleaning systems;

FIG. 13 is a schematic representation of a solution supply system;

FIG. 14 is a schematic representation of an exemplary cartridge;

FIG. 15 is a schematic representation of an exemplary pneumatic syringe cartridge;

FIG. 16 is a schematic representation of a syringe cartridge;

FIG. 17 is a detailed schematic representation of a mold structure;

FIGS. 18 and 19 are exemplary 2D projection molds with surface features;

FIG. 20 is a schematic representation of a variation of the system with an internal 3D printer;

FIGS. 21A and 21B are a schematic representations of 3D mold variations;

FIG. 22 is a schematic representation of a mold structure with a charged core;

FIG. 23 is a schematic representation of a method of a preferred embodiment;

FIGS. 24 and 25 are flowchart representations of variations of fabricating a mold structure;

FIG. 26 is a flowchart representation of an alternative method of a preferred embodiment;

FIG. 27 is a schematic representation with a cross sectional detail view illustrating an exemplary transitional edge;

FIGS. 28A and 28B are schematic representations of discrete and gradient transitions along the fabric surface;

FIG. 29 is a schematic representation of a discrete transition; and

FIG. 30 is a schematic representation of a gradient transition.

DESCRIPTION OF THE EMBODIMENTS

The following description of the embodiments of the invention is not intended to limit the invention to these embodiments but rather to enable a person skilled in the art to make and use this invention.

1. Introduction

The system and method for automating production of electrospun textile products of preferred embodiments function to produce complex three-dimensional shapes through the process of electrospinning. Electrospinning uses strong electric fields to pull fibers from liquids. The system and methods of the preferred embodiments involve the design and use of a device employing electrospinning to facilitate on-demand production of textile products and fabrics in complex 3D shapes. The systems and methods detailed herein include approaches for electrospinning for clothing on demand, larger scale electrospinning chambers to contain large textiles and articles of clothing, and controlled deposition of fibers in and onto complex molds. The system and method preferably involve the use of a standalone device wherein an electrospinning dispensing system deposits fibers onto a mold structure. The mold structure is changeable so as to enable customization of shape, size, and features of an electrospun product.

The system and method enable the creation of electrospun fabrics and textiles in 2-dimensional configurations as well as complex, non-uniform 3-dimensional configurations. The process is enabled by a variety of mechanisms that offer novel and highly controlled approaches to fiber deposition. Using the process of electrospinning to create articles of clothing and other textiles on demand is itself a novel use for this technology. As opposed to traditional textile manufacturing of 2D rolls of fabric that require additional processing, the system and method can create seamless 3D textile products in unique user-defined shapes. Another unique element of the system and method described herein is large-scale production capacity in three axes. Chambers large enough to fit entire articles of clothing have not been utilized in state-of-the-art electrospinning setups described in the literature. Seamless one-piece textiles can be produced on complex 2D projection molds or 3D mold scaffolds of the necessary size. Another aspect of the system and method is the controlled deposition of fibers into complex shapes.

The system and method can also be used as a post-processing technique for existing 3D structures and shapes. The system and method can add layers of fibers to existing structures that would otherwise be difficult to cover in a precise manner. The design and approach of the system and method can be used to create patterns and detail work in a controlled manner through management of the electrospinning process and through mold design.

As one potential benefit, the system and method produce a seamless textile product through a single manufacturing process—textile production, patterning, and assembly can be reduced to the electrospinning manufacturing process of a system of a preferred embodiment. This can greatly simplify prototyping stage of textile production as well as production.

The system and method can additionally function to provide a substantially convenient approach to producing products in a variety of forms through the use of dynamic mold systems. A user can use 3D printing, laser cutting, and other suitable prototyping techniques to easily create new molds that can be used to produce a variety of clothing products.

The system and method function to address the unmet needs of creating complex shapes through electrospinning. Traditional electrospinning technology is limited to simple sheets and cylinders. Such systems do not address complex geometry production, adaptability of forms, or product scale that can result from producing textile products. Collectors with complex shapes present unique challenges for current electrospinning setups, resulting from a number of factors, including non-uniform charge distributions that prevent full deposition of fibers, and an inability to produce patterned or textured fabrics. The use of dynamic 3D geometries in electrospinning setups presents its own unique set of challenges arising from a number of factors, including regulating a gap distance between the structures and dispensing array.

The system and method described herein is primarily described as being applied to production of textile products such as shirts, skirts, pants, hats, gloves, undergarments, or any suitable textile product. However, the system and method may alternatively be applied to the production of any suitable product such as custom formed air filters, custom textile solutions, on-demand textile solutions, or other suitable applications.

The systems and methods described herein include new elements of electrospinning technologies including electrospinning dispensing and collector design, and/or interaction of involved subsystems.

As an exemplary list of features, the system and methods for automating production of electrospun textile products may include the following features and/or variations addressing the electrospinning dispensing system: pneumatic syringes to provide electrical insulation between the pump and dispensing array; syringe cartridges for quick reloading of solutions; specific tubing formulations and modifications that can promote consistent pumping and charge distribution (including the minimization of charge leakage/buildup); applications of near-field electrospinning, which can be used to control the confinement of the electrospun beam to produce highly controlled colors, patterns, and details; combinations of electrospinning and melt spinning for particular applications; methods to aid in fluid charge residence and speed of fiber deposition; automated cleaning systems; using reloadable cartridges; formation of fiber with multiple colors (including different colors dispensed simultaneously through various nozzles); formation of fibers of varying fiber types; motion systems that control the gap distance (the distance between the end of the nozzles and the surface of the structure) and position of the dispensing system required to achieve uniform coverage across sufficiently complex shapes; free-surface electrospinning dispensing system, which may increase throughput and reduce garment completion time; and/or other suitable variations in the electrospinning delivery system and process.

As another exemplary list of features, the system and methods for automating production of electrospun textile products may include the following features and/or variations addressing the electrospinning collector: use of “2D projection electrospinning” to create seamless 3D shapes out of 2D projection plates while avoiding many of the problems and challenges faced by electrospinning to form complex 3D geometries; special coatings for the 2D/3D scaffolding to ease in fabric confluence and removal; charged or grounded cores to allow use of non-conductive scaffolds; use of complex 3D structures as a fiber deposition target; mold structures made from or coated in conductive paint/material; folded mold structures to reduce system volume and promote textures; patterns, and features in finished garments; and/or other suitable variations in the electrospinning collector system and process.

2. System for Automating Production of Electrospsun Textile Products

As shown in FIG. 1, a system for automating production of electrospun textile products can include an insulated enclosure 110, an electrospinning dispensing system 120, a solution supply system 130, a mold structure 140, a cyclical mold actuator 150, and a charge unit 160.

In a preferred embodiment, the system is used in 2D projection electrospinning, wherein the electrospun fibers are deposited onto a flattened 2D projection mold as shown in FIG. 2. The flattened 2D projection mold is preferably moved in a cyclical pattern. Over time, the fibers coat the mold, and wrap around the edges, creating a seamless object. The object, in this case a garment, can then be removed from the mold and opened to fit over a 3D shape (e.g., a wearer's body). There are a number of advantages to 2D projection electrospinning, including control of the dispensing system, and possible elimination of the motion in multiple dimensions. The machine depicted in FIG. 1 allows for translation of the 2D projection mold along one defined axis. Another potential benefit can include the reduction in the size and footprint of the machine, which can enable the device to more easily fit inside homes, closets, workshops, etc.

The preferred embodiment preferably includes a first and second dispensing area that are directed in opposing directions so as to dispense fiber on both sides of the 2D projection mold simultaneously as shown in FIGS. 1 and 2. Alternative embodiments could include a two-stage production process with a mold rotation. The mold rotation can be manually performed or may be mechanically automated.

In alternative embodiments, the system may alternatively be applied to electrospinning onto 3D molds as shown in FIG. 3. The 3D mold embodiment can include a mechanically actuated dispensing system and/or or mold structure. In yet another embodiment, the system can include a multi-faced (i.e., “faceted”), wherein at least two electrospinning dispensing areas are aligned in non-parallel orientations. The multi-faced embodiment can function to apply the 2D projection electrospinning approach to 3D molds with a limited set of substantially flat faces, wherein some of the faces are aligned on intersecting planes as shown in FIG. 4. A multi-faced approach may include variations of the 2D projection electrospinning embodiment and/or 3D mold electrospinning embodiment.

2.1 Insulated Enclosure

The insulated enclosure 110 of a preferred embodiment functions to limit interference from the outside environment. The insulated enclosure 110 is a structural chamber in which active electrospinning occurs during the production process. The active electrospinning area is the space between the charged parts of the electrospinning dispensing system 120 and the mold structure 140.

Various components of the system use and control high voltages of electricity that can be damaging to other components of the system. The insulated enclosure along with other protective elements isolates the source of electrical discharge in order to prevent interference through (but not limited to) electrical arcing. This can be done by way of a Faraday cage around sensitive components and/or insulating the actuation seam to the area of active electrospinning as shown in FIG. 5.

The insulated enclosure, in addition to providing electrical insulation, can additionally function as a structural chassis on which some or all of the components of the system may be directly or indirectly coupled. The insulated enclosure 110 can include an electrospinning sub-chamber and a controller sub-chamber. The electrospinning sub-chamber can include insulating design elements to shield electrical components in the control chamber from the electromagnetic fields generated in the electrospinning sub-chamber. The electrospinning sub-chamber of the insulated enclosure can include framing supports and a set of walls. The walls can be made from electrically insulating material such as acrylic, glass, polycarbonate, or any suitable insulating material. The insulated enclosure 110 can additionally include insulating systems such as a Faraday cage. Additionally the walls can be used as a mounting structure of the electrospinning dispensing system. In one variation, a wall used to mount the electrospinning dispensing system can include an array of possible nozzle mounting elements. The nozzle mounting elements can be an array of electrospinning nozzle holes. The number of electrospinning nozzle holes can be greater than the number of supported electrospinning nozzles which can function to give positioning options for the electrospinning nozzles as shown in FIG. 1. A nozzle mounting system can additionally include positioning options. In one variation, a nozzle mounting element can enable a nozzle to be repositioned along at least one axis and/or rotate about at least one axis. In one variation, the nozzle mounting elements are static positioning elements, but in an alternative variation, the positioning of a nozzle mounting elements could be actuated and controlled.

The controller sub-chamber is preferably a substantially enclosed container, which can contain processors, solution supply components of the solution supply system 130. The controller sub-chamber can be a walled structure that acts as a base of the system wherein the electrospinning sub-chamber sits above or on top of the controller sub-chamber. Other arrangements or configurations may alternatively be used. The controller sub-chamber can additionally isolate components from the electrospun fiber.

The controller sub-chamber can include an access port wherein the cyclical mold actuator 150 couples to the mold structure 140. The cyclical mold actuator 150 is preferably substantially contained within the controller sub-chamber to isolate the motor and actuating components from the electromagnetic fields of the electrospinning sub-chamber. The access port can be a seam, gap, or defined hole. Insulating padding or other insulation mechanisms can be used.

2.2 Electrospinning Dispensing System

The electrospinning dispensing system 120 of a preferred embodiment functions to deliver, eject, or otherwise dispense electrospun fiber onto the mold structure 140. The electrospinning dispensing system employs the process of electrospinning but can alternatively use alternative process variations such as melt electrospinning, coaxial electrospinning, emulsion electrospinning, and other suitable variations. The electrospinning dispensing system 120 preferably delivers fiber to the outside of a mold structure 140. However, alternatively or additionally, the electrospinning dispensing system 120 can be centrally located with a surrounding mold structure, and the electrospinning dispensing system 120 can direct fiber application to the inside walls of a mold structure as shown in FIG. 6.

The electrospinning dispensing system 120 preferably acts as a source of fiber formed during extraction of the electrospinning solution through an electrical charge. The electrospinning dispensing system 120 preferably receives a supply of electrospinning solution from the solution supply system 130. The charge unit 160 can charge the electrospinning solution relative to the mold structure to a charge point resulting in an eruption of the electrospinning solution from a point on the electrospinning dispensing system 120. During travel towards the mold structure, the liquid transforms into a fiber. The fiber is preferably substantially uniform and can have various properties depending on the electrospinning solution and electrospinning process. As a result of electrostatic repulsion, the fiber can experience a whipping process wherein different parts of the fiber are pulled in different directions towards the collector so as to contact the collector over a collection zone.

The electrospinning dispensing system 120 preferably includes an array of electrospinning dispensing nozzles 122 as shown in FIG. 7. The array of electrospinning dispensing nozzles 122 includes a set of nozzles 124, alternatively referred to as spinnerets. A nozzle 124 can be a hypodermic needle or any suitable type of localized solution deliver mechanism. The nozzle 124 is connected to the charge unit that delivers a high-voltage current (preferably a direct current 5 to 50 kV) to the solution delivered through the solution supply system 130.

In one variation, a longer nozzle can be used. An alternative approach is to use a flange, wire, or other metallic leads that extend from the body of the nozzle back into the tubing, as shown in FIG. 8, thereby increasing charge residence time without extending the length of the nozzle.

A nozzle is preferably mechanically coupled to a point on the insulated enclosure 110, but may alternatively be structurally supported by any suitable chassis. The nozzle 124 is preferably fixtured so that a delivery port of the nozzle 124 is directed at the mold structure 140. The nozzles can be repositionable through a dynamic nozzle positioning system. In one variation, the nozzles can be repositionable across a set of nozzle mounting elements (i.e., a set of fixture points for a nozzle) in the insulated enclosure 112. The repositionable property of the nozzles functions to ensure the adaptability of an electrospinning setup with various sized molds. The dynamic nozzle positioning system can be a grid of nozzle support structures that allows nozzles to be placed in custom arrangements depending on the requirements of the mold, and adjusted throughout the electrospinning process, or through the use of nozzles that can be slid along paths in the support structure. A nozzle mounting element can be support structure such as a defined cavity that presents a single positioning option (e.g., a nozzle hole), a positioning axis (e.g., a defined groove in which a nozzle may be fixed), or any suitable mechanism in which a nozzle can be positioned.

The array of electrospinning nozzles 122 is preferably positioned along one face of the insulated enclosure. The dispensing area is preferably a surface of the insulated enclosure 110 and is preferably a flat, planar surface. The array of electrospinning nozzles 122 are preferably mounted across a two-dimensional area. The dispensing area can alternatively be along a curved or non-uniform surface. The dispensing area surface is preferably substantially parallel to a surface of the mold structure to which the fiber will be deposited, which functions to promote uniform gap distance between the nozzles and the collection zone of a nozzle. There is preferably at least one subset of the array of electrospinning nozzles 122 distributed on a first surface. There can alternatively be multiple surfaces along which a subset of the array of electrospinning nozzles 122 can be mounted. The various subsets are preferably positioned around a substantially centrally located mold structure 140. Preferably, there is a first array of electrospinning nozzles 122 mounted along a first surface and a second array of electrospinning nozzles 122 on a second surface as shown in FIGS. 1 and 2. The first array of electrospinning nozzles is preferably mounted so as to direct electrospinning in a direction opposing the direction of electrospinning of the second array. The second array of electrospinning nozzles are preferably positioned along a face such that electrospinning on an opposing side of a mold structure.

As described below, the mold structure 140 is preferably actuated relative to the electrospinning dispensing system 120, but a subset or all of the nozzles in the array of electrospinning nozzles 122 can be actuated as a group or individually as shown in FIGS. 9A and 9B.

Alternative, electrospinning dispensing systems may alternatively be used such as free surface or wire electrospinning. To increase the rate of fiber deposition, and eliminate problems caused by nozzle dispensing systems, a free surface electrospinning setup can be used in conjunction with 2D projections or 3D molds. Free surface electrospinning can be uniquely used in conjunction with 2D projection molds, as movement of a free surface electrospinning apparatus is prohibitively difficult due to its size and complexity. A static, flat free surface electrospinning setup may produce complex 3D garments from a 2D projection mold without any motion of the dispensing system.

Free surface electrospinning uses a large surface area electrode coated with conductive solution to produce a field of fiber jets, as opposed to the one-jet-per-nozzle setup traditionally used. In one variation, a free surface electrospinning system includes a solution faucet that dispenses the solution down a charged plate, and allow electrospinning to take place from the surface of the plate as shown in FIG. 10A. This could also be adapted to remove the plate, and allow charged fluid to fall through the air while electrospinning before being collected and recirculated. In another variation, a gravity-driven system can use a solution reservoir positioned above a nozzle array. Gravity drives the solution through nozzles composing a nozzle array as shown in FIG. 10B. Another approach could use a “bowl” system that dispenses electrospun fibers from the edge of the bowl as shown in FIG. 10C. This could also make use of an off-axis cleaning plate that spins and effectively cuts off polymer build up from the edges of the plate. Lastly, a drum system could allow for polymer to be electrospun from the edges of a rotating drum, either through pump action or by the centrifugal force of the fluid on the edge of the drum as shown in FIG. 10D.

In one variation, the electrospinning dispensing system 120 can be used to deliver varying colors, fiber types, and/or fiber/textile qualities. The electrospinning dispensing system 120 can include individually configurable dispensing nozzles.

In a color control variation, at least a first and second nozzle can be configured for a first and second fiber color. In one implementation, fiber color configuration is controlled by connection to different solution sources as shown in FIG. 11A. In another implementation, an individual dispensing nozzle system can include a colorant system that can dynamically color the solution during delivery to the nozzle or during the electrospinning process as shown in FIG. 11B. The colorant system may alternatively be any suitable solution augmentation system that can act inline to one or more nozzles. The first and second nozzles can be positioned in substantially the same region (i.e., adjacent nozzle placement) so as to have similar collection zones. The adjacent nozzles can be individually controlled so as to control the mixing and/or layering of fiber application during actuation of the mold structure 140. Alternatively, the nozzles of different colors can be placed in distinct regions in the array of electrospinning dispensing nozzles 122.

Similarly, at least a first and second nozzle can be configured for different fiber types. For example, a first nozzle can include a connection to a silk solution while a second nozzle includes a connection to cotton solution.

In yet another alternative, the electrospinning process can be altered through varying a property of the dispensing charge, collector charge, nozzle properties, solution properties, nozzle positioning (e.g., gap distance, angle, etc.), mold structure actuation, or any suitable properties. These changes can be substantially fixed changes or modulated over time.

In one variation, the electrospinning dispensing system 120 can include a multi-electrospinning process system, wherein there are at least two different electrospinning processes used simultaneously or in combination. In one implementation melt spinning (which is a type of electrospinning that uses a heating element to melt a polymer before fiber production through an electric field) and electrospinning can be used simultaneously. A melt electrospinning processes can be configured for a first nozzle, and a second electrospinning process as described herein can be used in a second nozzle, which can be used for a combination of rapid fiber production and detail work.

The electrospinning dispensing system 120 can additionally include a cleaning system, which functions to address the situation of polymer buildup on the ends of the nozzles that may inhibit the electrospinning process. In one variation, the cleaning system includes a friction pad that is retractable over a nozzle as shown in FIG. 12A. The friction pad can be a rubber diaphragm that a nozzle is placed into and then retracted when polymer buildup occurs. The contact with the friction pad is preferably sufficient to remove polymer buildup. Other individual nozzle cleaning systems may be used such as pressurized air systems, buildup-wiping arm, or any suitable mechanism. Alternatively, the cleaning system may be a nozzle array cleaning system wherein the cleaning mechanism type cleans a collection of nozzles. In one variation a roller could be used which extends a rubber surface or brushes over various nozzles in succession as shown in FIG. 12B. Alternative cleaning approaches also include the use of a moving plate that can remove built up polymer from each nozzle/nozzle, and spinning brushes or arms that can remove built up polymer from multiple nozzles on each pass.

2.3 Solution Supply System

The solution supply system 130 of a preferred embodiment functions to deliver the electrospinning fluid to the electrospinning dispensing system no.

The solution is preferably a solvent with melted or dissolved solids, wherein a resulting fiber is formed from the solution during the electrospinning process. The solution contains various mixtures of fabric materials and solutions to dissolve and carry them through the other components of the system. An electrospinning solution can be used to form synthetic fiber, cotton fiber, silk fibers, mixed fibers, and/or any suitable type of fiber. One such solution consists of polyester and cellulose (the main constituent found in cotton) dissolved in acetone. Varying the ratio of polyester to cellulose changes the look and feel of the resultant fibers. Another consists of silk that has undergone a solubilization process and been dissolved in water. The solution can also be comprised of non-fiber materials that add an additional level of functionality to the fabric that is not present in traditional textiles. For example, materials including (but not limited to) medicinal chemicals or fire-retardants can be added to the initial solution and carried with the resultant electrospun fiber to be embedded in the resultant electrospun fabric. These embedded materials can enable the use of the electrospun fabric in medicinal or protective applications.

In a preferred embodiment, the solution supply system 130 includes a solution reservoir (e.g., a tank) 132, solution transport 134 connected to the solution reservoir and the electrospinning dispensing system 120, and a pump system 136 as shown in FIG. 13. In the preferred dispensing system, the solution transport 134 (e.g., tubing) runs between the solution reservoir and/or a pump to at least one nozzle. The solution reservoir can be a tank or any suitable container that stores the solution for multiple nozzles. In another variation, there is a set of solution reservoirs. The set of solution reservoirs can include different solution types or the same solution type. Additionally, one of the sets of solution reservoirs can be used by a single nozzle or a set of nozzles. The solution transport 134 is preferably a set of tubing connections. The solution transport 134 may alternatively be any suitable piping system, channels, or other suitable system to transport solution to the electrospinning dispensing system 120. Herein, tubing will be used as the exemplary form of the solution transport system.

To prevent charge flowing back down the tubing lines, specific tubing formulations can be used. Less conductive plastic tubing such as FEP lined Tygon can aid in preventing charge leakage when compared to some varieties of soft rubber tubing. Additionally, chokes or ferrite beads placed on or around the tubing lines can be used to capture stray charge and prevent it from flowing down the tubing lines.

The solution supply system can include a solution cartridge system wherein the solution reservoir includes an attachable reservoir. A solution cartridge can be swapped in and out so as to enable easy and fast restocking of solution. Cartridges containing the material solution can contain a quick releasing mechanism to allow for easy insertion/removal in the device. Pods are also used for cleaning the system with various solutions and/or air. Special pods or subsections of existing pods are inserted for this purpose. As shown in FIG. 14, one variation can include a pump system actuator element such as a plunger or air connect; a bladder with a cleaning liquid or air that can be pumped when the bladder is punctured or otherwise engaged; a chamber of solution; and a release valve. The release valve can be a quick release valve, a puncturable seal, or any suitable type of valve.

A solution cartridge contains or can be filled with an electrospinning solution as described above. A solution cartridge can contain separation mechanisms within them to allow for separating of chemical constituents. Different solution types can be contained within one cartridge by leveraging specific gravities to promote separation of the solution types as shown in FIG. 14. Solution supplies of differing material may be mixed and blended to allow for precise material makeup of an end fibrous garment. Solution material control may be used to dynamically control color, material properties (e.g., strength, fiber thickness, and the like), fiber composition (e.g., breakdown of cotton, silk, polyester, etc.), or other suitable properties. In one variation solution mixing can be achieved through use of cartridges with different solutions. In another variation, multiple solution supply packages of differing solutions can be added to a cartridge. This might manifest in precise control over how much of a material constituent is present in the end product (e.g. 10% polyester). Moreover, unique material makeups could be achieved with this system when multiple solutions are available for selective supply through the solution supply system 130. For instance, layers or sections of a garment could be made of entirely different materials (e.g. silk on the inside, nylon on the outside) without adding seams, significant thickness, or other bonding steps or artifacts to the end product.

As described above, a colorant system can be used to alter the coloring of the solution. Dying the solution can be done to allow for colored products. The dye may be applied before any other processes, or dye can be placed within the nozzle, allowing for a base solution to be combined before the fiber-pulling process. The color-adding process can be remotely controlled; so various colors can be added at various points of a single job or garment.

As an alternative to pumping the conductive solutions through tubing to the dispensing nozzle, a pneumatic or hydraulic powered syringe can be used directly as the dispensing system. In this concept, a pneumatic or hydraulic line 1501 compresses a special plunger 1502 in the syringe body, as shown in FIG. 15, which dispenses the fluid at a controlled rate. This results in all the electrically conductive material remaining in the syringe, which is easier to control and mitigates charge leakage/interference with other components of the machine.

A syringe pumping system can similarly use replaceable cartridges. A syringe cartridge can include one or more loaded syringes as shown in FIG. 16. Alternatively, the solution reservoir of the cartridge can couple to form a syringe mechanism. A syringe system can include the ability to maintain uniform pressure across multiple lines of fluid simultaneously, and prevent clogging or other dispensing abnormalities from impairing system function. The replaceable cartridge system can use existing tubing, or contain its own clean set of one-time-use tubing.

2.4 Mold Structure

The mold structure 140 of a preferred embodiment functions to provide a collector element that acts as the mold for a resulting textile product. The mold structure preferably includes a mold collector 142 that can be mechanically coupled to the cyclical mold actuator 150. The mold collector 142 functions as the core element to which fiber is deposited during the electrospinning process and, as such, includes a structural form that can define the 3D properties of a resulting textile product. In one variation, the mold collector 142 is a fixed element so as to produce substantially similar textile products repeatedly. In another variation, the mold collector 142 can be a transformable mold collector wherein the shape, size, texture, conductive/collector properties, and/or other properties can be manipulated so as to alter the resulting 3D structural form of a resulting textile product.

In a preferred embodiment, the core collector is replaceable mold collector and couples to a mold fixture, which functions to enable the mold collector to be exchanged so as to alter the structural form of a resulting textile product through use of different mold collector forms.

As shown in FIG. 17, the mold structure can include a mold fixture base 144 that can be selectively and mechanically coupled to a mold collector 142. The mold fixture base is preferably a structural element that enables a mold structure to be slotted, snapped, screwed, held, or otherwise held into a first position. The mold fixture base 144 is preferably directly coupled to the cyclical mold actuator 150 so as to transfer physical translation of the mold actuator 150 to a fixture mold collector 142. The mold fixture base 144 may be selectively coupled to the cyclical mold actuator. In one variation, the mold structure 140 comprises of the mold fixture base 144 without a mold collector 142—a user of the system can supply a customized mold collector element during use.

The mold collector 142, as described above, functions as molded scaffolding to which fiber is deposited during use of the system. Upon completion of a production process, a resulting textile object can be released from the molded structure. In a particular implementation, the resulting textile product can be a substantially fully constructed textile product. Subtractive manufacturing steps (e.g., cutting), textile treatment, and other post-processing steps may be performed to finalize a constructed product. However, the system can be used in the construction of a base textile product as a fully realized 3D shape. For example, a t-shirt, a skirt, pants, a hat, gloves, under garments, and other textile products can be produced in a fully realized, 3D form without requiring assembly of patterned fabric pieces.

The mold collector 142 can be a 2D projection mold. A 2D projection mold is preferably a plate formed as a 2D projection pattern. The fabric produced during the electrospinning process is preferably applied to both sides (simultaneously or in different stages), and the fabric on a front side and backside forms a connected structure around the edges of the 2D projection pattern. The 2D projection mold has some minimal thickness so as to provide structural support.

2D projection molds can include surface features. Surface features can be holes, grooves, ridges, depressions, convex and/or concave reliefs, bumps, surface curvature, texturing, or other features. In one variation, a surface feature can be a feature cutout. A feature cutout can be sized or formed so as to promote fabric formation suspended across the cavity. A feature cutout can result in different fabric thickness, transparency, texture, or other fabric qualities depending on the formation of the pattern feature cutout. As shown in FIG. 18, feature cutouts can be used to cause a pattern to form along the bottom of a dress. Textured surface features can also be used as shown in a shirt 2D projection mold of FIG. 19, which will produce a corresponding texture on the electrospun fibers covering them.

The 2D projection mold can optionally be formed with beveled or curved edges, which may function to promote varying fabric qualities on the transition from the front and back sides of the 2D projection mold. Complex geometries are possible with 2D projection molds, as depicted in FIG. 2, which shows a tank top complete with straps, neck, and arm features. Complex geometries can include non-linear edges as well as convex and/or concave edges.

A 2D projection mold will include an outer perimeter forming the outside form. The 2D projection mold can additionally include cutouts such as holes, slits, or other defined cavities within the outer perimeter border. In some variations, a feature cutout or other suitable surface features can be made so as to promote transition between a front and backside. In another variation, ridges, caverns, and other surface features can be placed along the edges of the molds to prevent deposition of fibers and maintain patency where desired (e.g. neck holes and arm holes). The molds can also be coated with “mold release” agents such as PTFE and silicon to assist with easy removal of electrospun material, and prevent fibers from sticking to the mold causing layer separation.

One potential benefit of the 2D projection mold is common manufacturing tools exist to make it feasible for customized 2D projection molds to be produced quickly and affordably. For example, laser cutting, plotters, two-axis CNC machines, sheet stamping, 3D printers, and other suitable manufacturing tools may be used to create a 2D projection mold. As another variation, a 2D projection mold template set can be used to construct different 2D projection molds. Alternatively, the electrospinning system can be augmented with a traditional FDM extruder head and gantry system to print a mold inside of the chamber before coating it in electrospun fabric.

The 2D projection mold can include varying levels of complexity. The outer perimeter as well as internal cutouts can include any suitable mixture of convex corners, concave corners, or continuous contours. A convex corner is a substantially distinct intersection of two edges that form a convex (i.e., greater than 180 degrees). A concave corner is a substantially distinct intersection of two edges that forms a concave angle (i.e., less than 180 degrees). Herein, the angle is measured from the outer side of one edge to the outer side of a second edge. As shown in FIG. 19, a t-shirt 2D projection mold will include convex corners on the two bottom corners of the shirt as well as the sleeves, a concave corner at each of armpit regions, and a curved contour along the neck region.

At least one edge is preferably a transition edge. A transition edge is where at least two faces of the mold are connected during the electrospinning process. A transition edge can be formed from some minimal thickness and edge spacing. The 2D projection mold may include a set of non-transitional edges along the perimeter where the back and front do not connect. A non-transition edge can be formed from a 2D projection mold extending beyond the electrospinning collection zone such that fiber is not collected at a portion of an edge. Alternatively, the charging or insulating properties of the 2D projection mold can be configured so as to not receive substantial fiber collection. As yet another variation, surface features can promote a non-transition edge as shown in FIG. 27. As shown in FIG. 17, a 2D projection mold with a trapezoidal 2D projection can be used to create a skirt. The top and bottom openings of a skirt can be formed through non-transition edges or through post-processing (e.g., cutting).

A mold collector 142 may alternatively be a three dimensional form. A system using a three dimensional mold collector 142 preferably includes actuation components either in the nozzles or in the mold actuator 150 so as to regulate the gap distance between the collector and the electrospinning dispensing system (e.g., each of an array of nozzles). The gap distance is preferably maintained within a determined window.

3D mold collectors 142 can be static manufactured structures. The whole 3D mold collector or a portion may be 3D printed. The electrospinning setup itself could also be combined with traditional 3D printing to create the unique 3D structures and deposit fibers onto them all in one machine as shown in FIG. 20. The design of certain 3D printed shapes themselves is also unique to this system. The 3D printed shapes can include folds or undulations to reduce their spatial volume while maximizing their surface area as shown in FIG. 21A, thereby allowing a full sized textile or article of clothing to be produced in a much more compact volume. In conjunction with this (or independently) the fibers can be deposited onto the inside of hollow structures as opposed to the outside as shown in FIG. 6, to make fiber deposition more contained and removal of the fibrous material easier. This method would include elements related to contouring the fibers into non-uniform areas of the hollow shape (for example, the sleeves on a shirt) using a mechanical system or a combination of electrical/magnetic controlled fiber deposition. To allow for electrical conductivity, these structures can be printed/created with electrically conductive material, or coated with electrically conductive paint/coatings before acting as scaffolds for electrospinning. A grounded rod, shaft, or other structure may also be placed inside the 3D printed mold, thus generating the appropriate electric field between the grounded object and the dispensing system so that electrospun fibers are deposited on the 3D printed mold.

The structures can alternatively include dynamic form features. A 3D mold collector can include adjustable mechanisms that allow for custom sized garments or other textiles. The adjustable mechanisms can include a manual belt/dial system, a ratchet system, and a “puzzle” system as shown in FIG. 21B.

To allow for a much wider array of structure/scaffold material options, the mold collector can include a grounded or charged core as shown in FIG. 22. The core would be either charged or grounded and would provide the electrical attraction force (also known as a Coulombic attraction force). The mold collector 142 preferably provides the shaped form to which fiber is to temporarily adhere during the electrospinning process. The cold is preferably an internal component charged or grounded that attracts the fibers towards it and onto the outside of the mold collector 142. Using this configuration, plastic or other non-conductive materials can be electrospun to directly, which is not possible using current electrospinning technology. Additionally, the core can be shaped with non-uniform shape so as to alter the attractive forces. When using conductive structures, the charged core can allow for an easy connection to the structure (via a wired connection or by using a conductive platform).

2.5 Mold Actuator

The cyclical mold actuator 150 of a preferred embodiment functions to move the mold structure 140 so as to achieve desired fiber coverage. The cyclical mold actuator promotes relative motion of the mold structure to the fiber deposition nozzles/system. A flexible seam will be used to seal off the electronic/mechanical connections and maintain an electrically insulated chamber ideal for electrospinning.

In a preferred implementation, the cyclical mold actuator can be a linear actuator that moves a mold structure 140 back and forth along an axis. An axis of motion is preferably aligned in a plane that is perpendicular to the main direction of electrospinning of the electrospinning dispensing system, which functions to move the mold collector such that the gap distance is maintained between the mold collector and the nozzles. The actuation is preferably horizontal but may alternatively be vertical, or along any suitable axis. In alternative variations, the cyclical mold actuator can move in a circular pattern. In yet other variations, the cyclical mold actuator 150 can rotate and/or translate the mold structure 140 in any suitable manner.

In one mode, the cyclical mold actuator 150 can actuate so to achieve substantially uniform fiber coverage on the mold collector 142. A production process instance may desire non-uniform fiber coverage, and the cyclical mold actuator 150 may be used to achieve the non-uniform properties. The cyclical mold actuator 150 may be controlled in combination with the electrospinning dispensing system 120, the solution supply system 130 and the charge unit 150. Different fabric effects may be achieved by altering the electrospinning process in synchronization with the position of the mold collector manipulated by the cyclical mold actuator 150.

The charge unit 160 of a preferred embodiment functions to charge the solution so as to promote the electrospinning process. The charge unit 160 can be any suitable voltage source. The charge unit 160 can be electrically connected to an electrical applicator in the electrospinning system 120. The electrical applicator in one variation is a conductive nozzle acting as an emitter of the solution/fiber. Alternatively, a conductive lead could be situated so as to apply a charge to the solution. The charge unit 160 may additionally or alternatively be applied to the mold structure. In a preferred variation, the mold structure is grounded. In another variation, the mold structure can be charged with preferably an opposite polarity. In yet another variation, the electrospinning dispensing system can be grounded while the mold structure can be charged so as to attract the solution. The charge unit 160 can be a regulated constant charge. The charge unit 160 may alternatively include a dynamically controlled charge output. The voltage output may be altered during the electrospinning process, which may function to alter the electrospinning process.

The system preferably includes a control unit, which functions to manage the operation of the system. The controller can be an internal processing system, but may alternatively be an external application operative on an outside computing device (e.g., desktop computer). The controller is preferably communicatively connected to each of the active components such that solution delivery, electrospinning process (e.g., charge and/or nozzle control), and/or actuation can be controlled. The system may additionally include any suitable commonly found device components such as a user interface elements; a data link; safety mechanisms; power supply, and/or any suitable components.

3. Method for Automating Production of Electrospun Textile Products

As shown in FIG. 23, a method for automating production of electrospun textile products of a preferred embodiment can include fixing a mold structure to a textile production system S110, actuating the mold structure S120, and executing an electrospinning process across a dispensing area S130. As with the system above, the method functions to produce three dimensional textile forms during a self-contained manufacturing process. The method preferably employs the fiber production process of electrospinning across a two dimensional area to form at least one circumferential covering of electrospun fabric on a mold structure. The mold structure through its 2D projection form and/or 3D form promotes a resulting shape of a three dimensional textile product. Accordingly, one potential benefit is the customization and control of a resulting three-dimensional form through use of a replaceable mold structure.

The method is preferably implemented through a textile production system such as the system described above. The textile production system is preferably a self-contained electrospinning setup within which the mold structure can be fixture and where the electrospinning process can be managed and controlled. The method may alternatively be implemented through any suitable system or combination of system setups.

Block S110, which includes fixing a mold structure to the textile production system, functions to accept a replaceable mold structure. Fixing a mold structure preferably enables a mold structure to be configured specifically for a production run. A mold structure can be used repeatedly to produce multiple textile products. A first mold structure may additionally be exchanged for a second mold structure. The mold structure preferably defines the resulting 3D form of the textile product. The mold structure can additionally alter the fabric texture or properties.

In a preferred variation, the mold structure is a 2D projection mold. A 2D projection is preferably a substantially planar structure with a front and back face cut out with a 2D projection that maps to a 3D form. The 2D projection mold is preferably substantially similar a 2D projection mold as described above. The method can additionally include translating a 3D form into a 2D projection mold. For example, a designer may use a 3D design program to create a 3D model of a desired form. Translating the three dimensional form into a 2D projection mold produces a 2D projection mold shape that can be used in achieving at least an approximation of 3D form. Translating to a 2D projection mold may include modification of a source 3D model to enable use of a 2D projection mold, which functions to adapt a 3D model when particular details are not readily feasible through a 2D projection mold. Alternatively, the mold structure can be a 3D mold. Application of the method for 3D molds can include actuating the gap distance of an electrospinning dispensing system and the 3D mold. Such actuation can be performed on the 3D mold, the dispensing system (e.g., the nozzle), or a combination. The method can additionally be applied to multi-faced molds in a similar manner as described in the system above.

The method can additionally include fabricating the mold structure S100. Fabricating the mold structure S100 can include fabricating the mold structure through an internal fabrication process of the textile production system S102 as shown in FIG. 24. An internal fabrication process can include a 3D printing process, computer controlled plotting process, or laser cutting process.

Fabricating the mold structure can additionally or alternatively include producing surface features on the mold structure S104 as shown in FIG. 25. The surface features can produce various textile artifacts on produced textile products. Surface features can include texturing, producing three-dimensional reliefs, defined cavities, and/or other types of reliefs on the mold structure. In one variation, a surface features can include applying conductive and non-conductive regions onto the mold structure which functions to augment the attraction of electrospun fibers to a specific region of the mold structure. A mold structure can additionally include release coatings to aid in the removal of a manufactured textile product.

Block S120, which includes actuating the mold structure, functions to move the mold structure to promote desired fiber coverage on the mold structure. A mold structure is preferably actuated during the electrospinning process. In one variation, the actuation is controlled. Actuation of the mold structure is preferably a cyclical actuation pattern. More specifically, the cyclical actuation pattern is a repeated path in a plane substantially perpendicular to the direction in which fiber is dispensed during electrospinning. In the case of a 2D projection mold, perpendicular can be defined as an angular alignment such that actuation of the 2D projection mold within the plan does not result in a change in the general gap distance between the 2D projection mold and a nozzle. Particular gap distances may change during the course of actuation such as when the edge of a 2D projection mold is actuated back and forth in front of a nozzle. The actuation is preferably a linear cyclical motion back-and-forth along an axis (e.g., horizontal, vertical, etc.). The actuation may alternatively be along two axes, one or more rotational axis, or in any suitable dimension. The actuation speed can be constant, follow an acceleration pattern, and/or dynamically change according to the mold. While the actuation is preferably a repeated cyclical pattern, the motion can alternatively be a singular complex path, dynamically determined, even random, or any suitable motion pattern. In the case of a 3D mold, multi-axis actuation (three or more) may be used to regulate gap distance within a gap distance window. In an alternative implementation, actuation of an electrospinning nozzle can be used to regulate gap distance.

Block S130, which includes executing electrospinning process across a dispensing area, functions to dispense fiber from an electrospinning dispensing system. In one variation the dispensing area is defined by an array of dispensing nozzles. In alternative variations, the dispensing area may be defined by a set of electrospinning wires, a pool of solution, or a free-surface electrospinning system.

The fiber size and morphology, and therefore the resulting “feel” and mechanical properties can be partially controlled in a number of ways when executing the electrospinning process, including alternating the gap distance using custom sized wiring/gaps on the structure, and/or changing the mechanical characteristics of the charge and spin. The fabric solution can also contain additives such as dyes and colorants that will remain on the electrospun fiber after it has been pulled from solution. This system can also create patterns of color and texture on complex or flat shapes. The method can achieve such results through the use of varying control processes including charge modification, electrical and magnetic field manipulation, and mechanical motion. By changing the electrical and magnetic fields that guide the fibers to the collector (electrostatic forces), the fibers can be directed to particular, discrete parts of the structure. This, in collaboration with dynamically manipulating the potential difference between the dispenser and collector, can create complex user-defined patterns of fibers.

Controlling the confinement of the electrospun fibers can promote obtaining precise fiber deposition and complex patterns. Through independent control of the voltages supplied to both the nozzles as well as the structure and motion systems that allow for single or multi axis movement of the nozzles and/or the structure, the confinement of the electrospun beam can be precisely controlled.

Executing the electrospinning process preferably includes executing the electrospinning process across a first dispensing area in a first surface and a second dispensing area in a second surface. This is of particular utility when actuating a 2D projection mold—a front face and back face of the 2D projection mold can receive fiber application simultaneously with two active dispensing areas.

Executing the electrospinning process preferably includes charging the solution supplied to the dispensing area and grounding a collector of the mold structure. The collector of the mold structure is charged to create a charge differential between the dispensing area and the mold structure. Alternatively, both the dispensing area and collector are charged to two different charges. In another variation, the dispensing area may be grounded while the collector is charged.

Additionally, the method can include managing delivery of electrospinning solution to the dispensing area. As one variation, managing can include accepting a solution cartridge, which functions to allow replaceable and/or refillable cartridges to be added or removed to the textile production system.

The method can additionally include controlling electrospinning process for a fabric property transition S140, which functions to augment or configure the electrospinning process to change fiber and/or fabric properties in a defined region of the mold structure. Fabric properties can include fabric type or composition, fabric formation (e.g. “weave” pattern), fabric color, and/or any suitable property. Controlling the electrospinning process for a fabric property transition S140 preferably includes controlling the electrospinning process over a defined region according to a discrete transition mode or a gradient transition mode.

Controlling electrospinning in a discrete transition mode promotes the creation of a discrete transition between fabric sections collected on the mold structure, wherein there is a substantially defined edge between the two fabric types. Herein, a defined edge can be where the fabric quality changes in less than one centimeter and preferably in under 0.25 centimeters. In one variation, the discrete transition is across the surface of the fabric as shown in FIG. 28B. For example, the sleeves of a t-shirt may be made of one fabric while the body is made of a second fabric with the transition happening at the beginning of the arm portion. In a second variation, the discrete transition can be in the layers of the fabric as shown in FIG. 29. A bottom layer may be a first fabric while a top layer can be of a second fabric. A discrete transition can be achieved through executing electrospinning process in a first mode and changing to executing electrospinning process in a second mode. In the case of the discrete layer transition, a first layer of fabric can be electrospun onto the mold structure and then, once the first layer is complete, a second layer of fabric can be electrospun onto the mold structure.

Controlling electrospinning in a gradient transition mode promotes the creation of a gradient transition, which is characterized as a gradual transition of fabric collected on the mold structure. A gradient transition can be achieved through executing electrospinning process in a first mode and progressively changing to executing electrospinning process towards a second mode. Gradient transitions can be across a fabric surface as shown in FIG. 28B or a fabric layer as shown in FIG. 30.

In the case of gradient surface transitions, the method can include augmenting the electrospinning process according to the actuation of the mold structure and control of a dispenser in the electrospinning process. The controlled dispenser is preferably at least one nozzle in the array of nozzles. Control of electrospinning from the at least one nozzle can be augmented by altering the charge applied to the solution electrospun from the nozzle; by altering the charge of the collector or mold structure, by altering the solution entering the nozzle, by actuating the nozzle (e.g., to modify the gap distance or direction solution erupts from the nozzle), and/or any suitable change. The changes are preferably gradual with multiple stages progressing towards a final mode. As in a gradient, there may be multiple transitional modes that act as guides in the transition. For example, a gradient transition from red fiber to green fiber may also have intermediary fiber qualities of blue and yellow.

The electrospinning process for a nozzle can be changed over time according to the position of the mold structure during actuation of the mold structure. For example, when the mold structure is in a first position, the electrospinning process for a first nozzle is in a first mode, and, when the mold structure is in a second position, the electrospinning process for the first nozzle is in a second mode. Such electrospinning process control can be applied across an array of nozzle such that the combined electrospun fabric creates a desired effect on the formed fabric. The nozzles in an array of nozzles can be in any suitable mode at different times.

In one variation, the method can include monitoring fiber coverage and augmenting the actuation and/or electrospinning process. Monitoring can include inspecting the mold structure with an imaging tool during the electrospinning process and characterizing fabric state in a region of the mold structure. The imaging tool can be a camera operating in the visual frequency range but may alternatively be an IR camera or any suitable type of imaging tool. Fabric state can include amount of coverage, depth of coverage, or any suitable type of characterization. In another variation, monitoring may be accomplished through alternative sensing approaches. For example, different regions of the mold structure can detect the state of adhered fiber to produce a fabric state characterization. Augmenting the actuation can be used to concentrate fiber application in particular regions. The electrospinning process can similarly be altered to change the fiber application for particular regions. For example, a nozzle substantially responsible for a particular region may be turned up or down (i.e., electrospun fiber production increased or decreased) according to the fiber covering for the particular region. Monitoring and resulting augmentation can happen in substantially real-time. Monitoring and augmentation may alternatively happen periodically.

The method may additionally include applying a post-processing step, which can function to strengthen the fabric, add texture, or augment the formed fabric. In one variation, prior to removing electrospun fabric from the mold structure, light based or chemical based curing processes can take place inside the chamber. To cure, color, or texture only specific regions of the coated mold, projectors or lasers can be used to selectively expose areas of the electrospun fabric to light.

As one exemplary usage scenario, the method can include receiving design direction through a remote ordering system software that allows an individual to create unique clothing and fabric designs as 3D models, akin to CAD software for traditional 3D printing systems. This software would allow the full design and customization of apparel and fabric items, which includes the design elements (including but not limited to: colors, prints, patterns, and feel) as well as fit (including but not limited to: size of the overall item and subcomponents of a fabric item (e.g. a sleeve, a collar)).

Online software would enable orders for these designs to be submitted to a website, which could then produce and fulfill these orders as a service. Individuals would visit the website and select from items that are available and place orders for those items. Individuals would also have the ability to upload their own custom design and request fulfillment of the item to be sent to them. Users of the website would also have the option to purchase and/or download designs created by others for use a fabric printer that they own. This acquired design could then be created with their own machine, provided the materials were available.

As described above, one potential benefit of the method is the customization and control of a resulting three dimensional textile form through use of a replaceable mold structure. A user of the manufacturing process can alter, update, and/or define a completely different three-dimensional form through changing of a mold structure. The manufacturing process is preferably performed repeatedly in the same setup with differing mold structures. During an exemplary usage scenario, a method of a preferred embodiment can include producing a first textile product defined by a first mold structure and producing a second textile product defined by a second mold structure. As shown in FIG. 26, the method more specifically includes fixing a first mold structure to a textile production system S210, actuating the first mold structure S220 while executing a first electrospinning process across a dispensing area S230, removing the first mold structure, fixing a second mold structure to the textile production system S210′, actuating the second mold structure S220′ while executing a second electrospinning process across a dispensing area S230′. A first electrospun textile product can be removed from the first mold structure upon completion. Similarly, a second electrospun textile product can be removed from the second mold structure. The first and second mold structures can be substantially unique as will be the resulting three-dimensional forms of their respective textile products. Such a usage method can demonstrate the three dimensional form capabilities of the process as well as the control and adaptability over the resulting three dimensional textile product.

The systems and methods of the embodiments can be embodied and/or implemented at least in part as a machine configured to receive a computer-readable medium storing computer-readable instructions. The instructions can be executed by computer-executable components integrated with the application, applet, host, server, network, website, communication service, communication interface, hardware/firmware/software elements of a user computer or mobile device, wristband, smartphone, or any suitable combination thereof. Other systems and methods of the embodiment can be embodied and/or implemented at least in part as a machine configured to receive a computer-readable medium storing computer-readable instructions. The instructions can be executed by computer-executable components integrated by computer-executable components integrated with apparatuses and networks of the type described above. The computer-readable medium can be stored on any suitable computer readable media such as RAMs, ROMs, flash memory, EEPROMs, optical devices (CD or DVD), hard drives, floppy drives, or any suitable device. The computer-executable component can be a processor but any suitable dedicated hardware device can (alternatively or additionally) execute the instructions.

As a person skilled in the art will recognize from the previous detailed description and from the figures and claims, modifications and changes can be made to the embodiments of the invention without departing from the scope of this invention as defined in the following claims.

Claims

1. A system for producing a textile product comprising:

an insulated enclosure;

an electrospinning dispensing system positioned along at least one face of the insulated enclosure;

a solution supply system with a solution transport connection to the electrospinning dispensing system;

a mold structure;

a cyclical mold actuator mechanically coupled to the mold structure; and

a charge unit electrically connected to the electrospinning dispensing system and the mold structure.

2. The system of claim 1, wherein the mold structure comprises a mold fixture base that is interchangeably connectable to a mold collector.

3. The system of claim 2, wherein the mold structure further comprises a first mold collector that is a two-dimensional projection mold and that is connectable to the mold fixture base.

4. The system of claim 3, wherein the two-dimensional projection mold comprises convex and concave edges.

5. The system of claim 3, wherein the two-dimensional projection mold comprises at least one surface feature.

6. The method of claim 5, wherein the at least one surface feature is a feature cutout.

7. The system of claim 5, wherein the at least one surface feature is a textured pattern on the surface of the two-dimensional projection mold.

8. The system of claim 2, wherein the mold structure comprises a three-dimensional mold connectable to the mold fixture base.

9. The system of claim 1, wherein the mold fixture base is interchangeably connectable to a two-dimensional projection mold; and wherein the electrospinning dispensing system comprises a first dispensing area directed at a first face of a connected two-dimensional projection mold and a second dispensing area is directed to a second face of the connected two-dimensional projection mold.

10. The system of claim 9, wherein the cyclical mold actuator is a linear actuator with an oscillating motion along a defined axis in a plane defined by the first face.

11. The system of claim 1, wherein the electrospinning dispensing system comprises an array of electrospinning dispensing nozzles

12. The system of claim 1, wherein the solution supply system includes a solution cartridge system.

13. The system of claim 12, wherein the solution cartridge system includes a solution cartridge with a first type of solution and a second solution cartridge with a second type of solution, wherein electrospun fiber produced from the first type of solution possess different fiber properties from electrospun fiber produced from the second type of solution.

14. The system of claim 1, wherein the solution supply system includes a colorant system.

15. A method for producing a textile product comprising:

fixing a mold structure to a textile production system;

actuating the mold structure; and

executing an electrospinning process across at least one dispensing region onto the two-dimensional projection mold.

16. The method of claim 15, wherein the mold structure is a two-dimensional projection mold.

17. The method of claim 16, wherein executing the electrospinning process across at least one dispensing area comprises executing the electrospinning from a first array of nozzles that is arranged across a first dispensing region and from a second array of nozzles that is arranged across a second dispensing region, wherein electrospun fiber from the first array of nozzles is drawn towards a first face of the two-dimensional projection mold, and wherein electrospun fiber from the second array of nozzles is drawn towards a second face of the two-dimensional projection mold; and wherein at least one edge of the two-dimensional projection mold is a transition edge.

18. The method of claim 15, wherein the mold structure is a three-dimensional mold.

19. The method of claim 15, wherein executing an electrospinning process comprises controlling the electrospinning process in a fabric property transition mode, wherein the electrospinning process in the fabric property transition mode is applied to a defined region of the two dimensional projection mold.

20. The method of claim 19, wherein the fabric property transition mode is configured for a transition of fabric type.

21. The method of claim 19, wherein the fabric property transition mode is configured for a transition of fabric color.

22. The method of claim 19, wherein the fabric property transition mode is a gradient transition mode.

23. The method of claim 19, wherein the fabric property transition mode is a discrete transition mode.