An EVA sole having an upper face and a bottom, comprising an inscribed channel and a plurality of recesses positioned on the upper face, a TPU material disposed of within the inscribed channel, and a nylon stabilizer, which is bonded to the upper face inside of the inscribed channel.

An outsole component for use in an article of footwear is manufactured using a molding process that incorporates a second polymeric material with a film component including a first layer formed of a polymeric hydrogel material. The first layer forms the external or ground-facing layer of the outsole. Methods of manufacturing the outsole component, as well as articles of footwear including outsole component and methods of manufacturing such articles of footwear are also described.

The present disclosure is related to three-dimensionally printed articles for use in footwear and associated systems and methods. In some embodiments, a three-dimensionally printed article may comprise a closed-cell foam. The closed-cell foam may have a gradient in and/or may be a single integrated material. In some embodiments, a three-dimensionally printed article may comprise a sensor. The use of such arrangements can, according to certain embodiments, allow for the production of improved articles of footwear and/or customized articles of footwear.

The present disclosure is related to three-dimensionally printed articles for use in footwear and associated systems and methods. In some embodiments, a three-dimensionally printed article may comprise a closed-cell foam. The closed-cell foam may have a gradient in and/or may be a single integrated material. In some embodiments, a three-dimensionally printed article may comprise a sensor. The use of such arrangements can, according to certain embodiments, allow for the production of improved articles of footwear and/or customized articles of footwear.

A method of forming a plate for an article of footwear includes applying a first strand portion to a base layer including positioning adjacent segments of the first strand portion to form a first layer on the base layer. The adjacent segments of the first strand portion having a greater density across a width of the plate between a medial side and a lateral side at a midfoot region of the plate than at a forefoot region of the plate and at a heel region of the plate. The method also includes applying at least one of heat and pressure to the first strand portion and to the base layer to conform the first strand portion and the base layer to a predetermined shape.

Methods for manufacturing cushioning elements for sports apparel are described. A method is provided for manufacturing a cushioning element for sports apparel from randomly arranged particles of an expanded material. The method includes positioning a functional element within a mold and loading the mold with the particles of the expanded material, wherein the loading occurs through at least two openings within the mold and/or wherein the loading occurs between different movable parts of the mold.

Presented are manufacturing systems, methods, and devices for forming footwear using scrap or waste plastic materials. A method for manufacturing an article of footwear, such as an athletic shoe, begins with receiving a batch of recycled plastic, which may include thermoplastic elastomers or ethylene-vinyl acetate, and grinding the batch of recycled plastic material. The ground recycled material is processed, for example, by adding a foaming agent that activates at elevated temperatures. The processed recycled material is placed into the internal cavity of a final mold that is shaped like a segment of the footwear, such as a unitary sole structure. To form the footwear segment, the processed recycled material is heated past the threshold activation temperature of the foaming agent such that the foaming agent causes the recycled material to expand and fill the internal cavity of the final mold. The formed footwear segment is then extracted from the mold.

A method of manufacturing an article that includes providing an element formed of an elastomeric material or composite; placing the surface of the element in contact with a substrate; and affixing the element to the substrate. The element includes an uncured, partially cured, or fully cured UV radiation curable elastomeric material and optionally one or more regions of an adhesive material. The element is affixed to the substrate while the surface of the element is in contact with a surface of the substrate by increasing a temperature of at least a portion of the element, applying pressure to at least a portion of the element, or exposing the uncured or partially cured UV radiation curable material to UV radiation in an amount and for a duration of time that is sufficient to partially cure the uncured material or to fully cure the partially cured material.

A footwear assembly having an upper that comprises a neoprene sock with a foot portion integrally connected to a leg portion. The foot portion has heel, vamp and under-foot portions. The leg portion has front shin, side wall, and rear calf-side portions. The upper has a unitary, outer, injection molded layer molded directly onto the foot and shin portions of the neoprene sock, while the sidewall and rear calf-side portions remain substantially uncovered by the injection molded layer. The injection molded layer encases the foot portion of the neoprene sock. The injection molded layer on the shin portion defines a shin guard portion having a necked down area integrally connected to the injection molded layer at the vamp portion, wherein the shin guard extends upwardly from the necked-down portion in an outwardly diverging shape away from the vamp.

An article of footwear includes an upper assembly having a foot insertion volume. The foot insertion volume includes a proximal part and a lateral part. A first layer and a second layer each have a lateral surface and a medial surface, respectively. The second layer is positioned between the foot insertion volume and the medial surface of the first layer. A sole assembly includes an upper facing surface and a ground contacting surface. The upper facing surface is connected to the proximal part of the upper assembly. A peripheral part of the sole assembly overlaps a proximal part of the first outer layer and/or the second layer. The first outer layer includes a through-going opening extending from the lateral surface and towards the medial surface. A part of the overlapping material of the sole penetrates the opening to bond to the second layer.