An apparatus including means for being remoldable with application of heat at a predetermined temperature, means for absorbing the remoldable means, and means for enclosing the absorbing means, wherein the enclosing means comprises a substantially sealed enclosing means configured to resist a leakage of the absorbing means saturated with the remoldable means. The apparatus further include a insole implement, in which the insole implement having an insole section and an arch pad area, wherein the arch pad area is operable for accepting the enclosing means, wherein the insole implement is operable for maintaining a molded shape as the heat activated and remoldable resin composition in the sealed chamber implement cools in temperature, and wherein the insole implement is further configured to be operable for being remolded to a different shape by reheating the enclosing means containing the absorbing means saturated with the remoldable means.

An apparatus including means for being remoldable with application of heat at a predetermined temperature, means for absorbing the remoldable means, and means for enclosing the absorbing means, wherein the enclosing means comprises a substantially sealed enclosing means configured to resist a leakage of the absorbing means saturated with the remoldable means. The apparatus further include a insole implement, in which the insole implement having an insole section and an arch pad area, wherein the arch pad area is operable for accepting the enclosing means, wherein the insole implement is operable for maintaining a molded shape as the heat activated and remoldable resin composition in the sealed chamber implement cools in temperature, and wherein the insole implement is further configured to be operable for being remolded to a different shape by reheating the enclosing means containing the absorbing means saturated with the remoldable means.

A method of forming a sole structure for an article of footwear. The method includes depositing a first outsole material including a first uncured polymeric material upon a mold surface of a mold cavity. The method also includes disposing a midsole element adjacent to the first outsole material within the mold cavity and subjecting the first outsole material and the midsole element to a molding process to form the sole structure having an outsole and a midsole.

A method of forming a sole structure for an article of footwear. The method includes depositing a first outsole material including a first uncured polymeric material upon a mold surface of a mold cavity. The method also includes disposing a midsole element adjacent to the first outsole material within the mold cavity and subjecting the first outsole material and the midsole element to a molding process to form the sole structure having an outsole and a midsole.

A method of manufacturing an article of footwear includes cutting a plurality of sipes into an outer surface of a pre-formed, foamed thermoplastic sole structure that has both an inner surface and an opposite outer surface. An adhesive is then applied to the inner surface of the pre-formed sole structure and the sole structure is heated to permit forming. The heated sole structure is positioned adjacent to a ground-facing surface of a lasted upper, and then is thermoformed against the lasted upper to draw the adhesive into contact with the ground-facing surface of the upper, and such that at least a portion of the pre-formed sole structure bends into contact with a sidewall of the upper.

A method of manufacturing an article of footwear includes cutting a plurality of sipes into an outer surface of a pre-formed, foamed thermoplastic sole structure that has both an inner surface and an opposite outer surface. An adhesive is then applied to the inner surface of the pre-formed sole structure and the sole structure is heated to permit forming. The heated sole structure is positioned adjacent to a ground-facing surface of a lasted upper, and then is thermoformed against the lasted upper to draw the adhesive into contact with the ground-facing surface of the upper, and such that at least a portion of the pre-formed sole structure bends into contact with a sidewall of the upper.

An article of footwear includes an upper and a sole structure that is thermoformed to the upper. The upper has a ground facing surface, and opposing medial and lateral sidewalls disposed on opposite sides of the ground facing surface. The sole structure has an inner surface adhered to the upper and an outer surface that is opposite the inner surface. The sole structure includes a thermoplastic base layer that defines the inner surface of the sole structure. The sole structure further includes a thermoplastic outer layer integrally formed with the base layer. The outer layer has a plurality of protuberances, each protuberance has an outer face that defines a portion of the outer sole surface, and the outer layer further includes a plurality of splayed sipes extending across a portion of the sole structure. Each splayed sipe generally extends between at least two adjacent protuberances.

An article of footwear includes an upper and a sole structure that is thermoformed to the upper. The upper has a ground facing surface, and opposing medial and lateral sidewalls disposed on opposite sides of the ground facing surface. The sole structure has an inner surface adhered to the upper and an outer surface that is opposite the inner surface. The sole structure includes a thermoplastic base layer that defines the inner surface of the sole structure. The sole structure further includes a thermoplastic outer layer integrally formed with the base layer. The outer layer has a plurality of protuberances, each protuberance has an outer face that defines a portion of the outer sole surface, and the outer layer further includes a plurality of splayed sipes extending across a portion of the sole structure. Each splayed sipe generally extends between at least two adjacent protuberances.

The present invention describes a shaped footwear device intended to be used as a supportive insole or orthotic and a system and methods for making the same. The footwear device includes a top foam layer, a light-cured composite material layer, and a bottom textile layer. The footwear device is created by conforming a pre-cured insole assembly to the plantar surface of a foot or foot mold and then exposing the pre-cured insole assembly to light to create a shaped footwear device with a light-cured composite material support plate.

Aspects of the present invention relate to systems and methods for customizing microwave energy distribution within a chamber to accommodate various load characteristics. Aspects of the present invention customized configurations of ports, deflectors, waveguides, conducting rods, and slots to shape and distribute energy.