A large-scale additive manufacturing system for printing a structure includes an extrusion system and a knitting system. The extrusion system includes a nozzle configured to receive a supply of structural material and to selectively dispense the structural material in flowable form, and a first gantry configured to move the nozzle along toolpaths defined according to a structure to be printed such that structural material may be dispensed along the toolpaths to print a series of structural layers, wherein the series of structural layers bond together to form all or a portion of the structure. The knitting system includes a tow feeder configured to feed a supply of tow material to a location proximate a current course of loops extending above an upper surface of a current structural layer or extending above a base surface in regions where no structural layer has been printed, and a hooking device configured to engage the tow material and bring it through the current course of loops to form a subsequent course of loops interwoven with the current course of loops. A controller is configured to operate the knitting system to form additional subsequent courses of loops each interwoven with a current course of loops after each of the series of structural layers are printed, wherein the interwoven courses of loops create a reinforcement network of knitted loops embedded in the structure, and wherein the series of structural layers are tied together.

A method monitors/controls unwinding and supplying thread from a supply device to a textile machine. The supply device includes a control unit and a thread collection and supply unit moved by a motor. A first sensor detects first data indicative of a current driving torque applied to the collection and supply unit. A second sensor detects second data indicative of a current tension value of thread supplied to the textile machine. A first indicator representing driving torque values is calculated, each variation of the first indicator representing a variation of the driving torque value to compensate for a deviation of the first data. A second indicator is calculating representing tension values applied to the thread supplied to the textile machine. Each variation of the second indicator representing a deviation of the second data. Based on the indicators, malfunctions in the unwinding and supply of thread are detected and signaled.

Method and system for managing and controlling feeding of at least one thread to a textile machine as a function of the machine operating step in product production or thread processing, such production or processing providing for a succession of steps corresponding to obtaining product parts or treating thread. The thread fed to the machine by a feeder at constant tension and/or speed and/or controlled by a sensor which monitors sliding or inherent characteristic thereof such as tension, speed, diameter, quantity and color. The sensor and/or feeder controlled by a setting controller. The setting controller receiving synchronization signals from the machine and detectingaccording to the latterthe operating steps and thus product or production status. The operation setting programmed as a function of operating steps. The machine generates a unique synchronization signal, for each operating step, independently from step length.

Method and system for managing and controlling feeding of at least one thread to a textile machine as a function of the machine operating step in product production or thread processing, such production or processing providing for a succession of steps corresponding to obtaining product parts or treating thread. The thread fed to the machine by a feeder at constant tension and/or speed and/or controlled by a sensor which monitors sliding or inherent characteristic thereof such as tension, speed, diameter, quantity and color. The sensor and/or feeder controlled by a setting controller. The setting controller receiving synchronization signals from the machine and detectingaccording to the latterthe operating steps and thus product or production status. The operation setting programmed as a function of operating steps. The machine generates a unique synchronization signal, for each operating step, independently from step length.

A customized, flat-knit multi-zonal element for a shoe upper and a method of producing such an element that allows for continuous knitting while controlling positioning of individual threads. One or more carriages may move continuously along the needle bed while threads are provided to the needles for a complete stroke. Knit elements may include multiple zones with differing properties. Threads may alter positions within knit structures from zone to zone. A knit element may include a first zone in a first plane that includes at least two merged threads to form a merged knit structure and a second zone in a second plane connected to the first zone seamlessly. Some knit structures may be positioned throughout the knit element such that they control a position of zones relative to each other.

A customized, flat-knit multi-zonal element for a shoe upper and a method of producing such an element that allows for continuous knitting while controlling positioning of individual threads. One or more carriages may move continuously along the needle bed while threads are provided to the needles for a complete stroke. Knit elements may include multiple zones with differing properties. Threads may alter positions within knit structures from zone to zone. A knit element may include a first zone in a first plane that includes at least two merged threads to form a merged knit structure and a second zone in a second plane connected to the first zone seamlessly. Some knit structures may be positioned throughout the knit element such that they control a position of zones relative to each other.

A yarn-winding assembly mounted on a support is provided with a motorized spool and with an oblique spacing pin, between which a yarn is wound. The spacing pin is supported so that it can rotate about an axis of the motorized spool by unidirectional rotary support elements. The spacing pin rotates freely with respect to the spool when the latter rotates in the yarn unwinding direction and the former is retained from rotating by stop elements, and is instead integral with the spool when the spool rotates in the opposite yarn rewinding direction.

An automated unspooling mechanism capable of dispensing of knitting material strands in a dynamically-controlled tension on a knitting machine. An unspooling device is configured to sense the tension of a strand fed to the knitting machine, and responsively adjust the strand deployment speed to avoid too little or too much strand dispensing without interrupting the knitting process. The unspooling device includes a variable motor drive that can rotate the strand package in various speeds, and a spring arm trigger that can sense the current tension of the dispensed material. The spring arm trigger can vary its arm position based on the sensed tension. The arm position is then processed and converted to a signal to vary the motor speed. Therefore, the deployment speed of the strands can be dynamically controlled based on a sensed tension of feeding the strand.

An automated unspooling mechanism capable of dispensing of knitting material strands in a dynamically-controlled tension on a knitting machine. An unspooling device is configured to sense the tension of a strand fed to the knitting machine, and responsively adjust the strand deployment speed to avoid too little or too much strand dispensing without interrupting the knitting process. The unspooling device includes a variable motor drive that can rotate the strand package in various speeds, and a spring arm trigger that can sense the current tension of the dispensed material. The spring arm trigger can vary its arm position based on the sensed tension. The arm position is then processed and converted to a signal to vary the motor speed. Therefore, the deployment speed of the strands can be dynamically controlled based on a sensed tension of feeding the strand.

A knit fabric production method includes a step of producing a knit fabric K1 from an untwisted yarn Y0 while producing the untwisted yarn Y0 by disposing a fiber bundle FB around a linear core member CP formed of a soluble polymer, falsely twisting the fiber bundle FB by using an air flow swirling in a predetermined first direction and simultaneously causing open end fibers OF to adhere to an outer circumferential surface of the falsely twisted fiber bundle FB by using an air flow swirling in a second direction opposite the first direction, and untwisting the falsely twisted fiber bundle FB.