Some embodiments relate to a method for the direct soling of a multilayered shoe sole. The method can provide two distinct sets of mold frames for a first and a second shoe sole layer and a distinct order for the soling of the layers. In contrast to art traditional approaches, a first layer (e.g. a midsole) is first soled to an upper in a first mold frame and subsequently a second layer (e.g. an outer sole) is soled onto said first layer in a second mold frame. The method can allows for an increased design flexibility and the inclusion of additional functional or aesthetic features, such as air pockets, undercuts, toe caps or running sole tips previously not possible with direct soling processes. Some embodiments relate to an injection molding system equipped and configured for carrying out the method.

A heat-press system for use in the production of footwear or apparel can include at least a hollow first roll comprising an external surface and an internal surface. The internal surface can define a core. The core can include a first heating element.

A heat-press system for use in the production of footwear or apparel can include at least a hollow first roll comprising an external surface and an internal surface. The internal surface can define a core. The core can include a first heating element.

Aspects hereof relate to a multi-part mold assembly for use in manufacturing articles. The mold assembly provides for contouring, shaping and cutting materials to form articles via a continuous single processing operation. The mold assembly includes an upper mold portion with a three-dimensional contouring/shaping portion and a first cutting edge, a lower mold portion with a three-dimensional contouring/shaping portion and a second cutting edge, and a base portion into which the lower mold portion may retract during use. Upon application of a first force, the upper and lower mold portions cooperate to contour/shape a material from which an article is to be formed. Upon application of a second force greater than the first, the first cutting edge and the second cutting edge interact to shear the material that extends beyond the respective cutting edges. The result is an article that is contoured, shaped and cut/trimmed utilizing a single processing operation.

A sole structure includes a compressible elastomer and a knitting texture wrapped around the compressible elastomer and fused with a surface of the compressible elastomer. The compressible elastomer is formed from the thermoplastic filling material after being melted and cooled. The knitting texture is formed from the knitted fabric and is capable of being directly observed from an appearance of the sole structure.

A method for manufacturing a midsole of an article of footwear includes generating a positive model of a midsole. The positive model includes a region of empty volume that defines an aperture or channel. The method further includes creating a negative model based on the positive model, and printing, layer by layer, a negative mold to form a physical representation of the negative model. The negative mold includes a region of solid volume that corresponds with the region of empty volume in the positive model. The method further includes supplying a midsole material to the negative mold to form the midsole. The midsole includes a midsole aperture or channel formed therein by the region of solid volume in the negative mold.

Articles of footwear include an upper and a sole structure having a fluid-filled element in the heel region. The fluid-filled element includes: (a) an upper surface, (b) a lower surface, and (c) an outer peripheral surface extending between the upper surface and lower surface. The fluid-filled element also includes a pair of spaced apart, substantially U-shaped voids that extend through a central region of the fluid-filled element. A first void of the pair of voids is located closer to a forward end of the fluid-filled element than a second void of the pair. Both the first void and the second void have an open portion of its U-shape oriented toward the forward end of the fluid-filled element.

An article of footwear flat pattern upper (126, 300, 302) portion (216) is provided. The upper portion (302) has a midline reference line (415, 416) extending between the toe end apex (316) and a midpoint on the heel end (314). The upper portion (302) also is comprised of an origin (344) aperture that is located within 10 millimeters of the midline reference line (415, 416) between the toe end (306) and the heel end (314) of the upper portion (302). The upper portion (302) is also formed with an overlay (500) that is coupled with the upper portion (302) between the toe end (306) and the heel end (314) and between the medial side (315) and the lateral side (317). The overlay (500) has an alignment aperture (345) that is aligned with the origin (344) aperture.

An article of footwear has an upper that is direct attached with the sole in a article of footwear mold. The sole has a film extending up sidewalls of the sole to a film edge that is prior to the sidewall and the upper joining. Method of manufacture of the article of footwear includes steps of positioning a film over a mold cavity and then securing the film to the mold. The film is heated and then drawn into the mold cavity under a vacuum. The film forms a liner of the mold cavity. A foam composition is injected into the lined mold cavity. As the foam composition expands, the foam composition interacts with and mechanically engages with the upper that is poisoned at the mold cavity to allow for the mechanical engagement that results in the direct attach of the sole to the upper.

An environmentally friendly shoe material and method of manufacturing the same is disclosed, wherein the method includes: mixing scraps and a foaming material to provide a shoe material mixture, the scraps including bottle scraps formed by crushing plastic bottles; putting the shoe material mixture into a mold and compression molding the shoe material mixture into the environmentally friendly shoe material; and separating the environmentally friendly shoe material from the mold. In this way, the environmentally friendly shoe material may not only maintain its due function, but also take environmental protection into account.