A method for assembling shoe components includes the steps of: providing at least two shoe components, a shoe last and a film unit; placing the at least two shoe components on an outer surface of the shoe last; removably covering an assembly of the at least two shoe components and the shoe last with the film unit such that the film unit and the shoe last cooperatively define a confining space therebetween; and pumping air out of the confining space and heating the at least two shoe components to shrink and deform the film unit so as to press the at least two shoe components to adhere tightly to each other.

Manufacturing and assembly of a shoe or a portion of a shoe is enhanced by automated placement and assembly of shoe parts. For example, a part-recognition system analyzes an image of a shoe part to identify the part and determine a location of the part. Once the part is identified and located, the part can be manipulated by an automated manufacturing tool.

Manufacturing and assembly of a shoe or a portion of a shoe is enhanced by automated placement and assembly of shoe parts. For example, a part-recognition system analyzes an image of a shoe part to identify the part and determine a location of the part. Once the part is identified and located, the part can be manipulated by an automated manufacturing tool.

A shoe may comprise an upper and a comfort sole attached to an outsole, the comfort sole having a radius of curvature at any point of a line from a heel to a toe and interfacing with outsole, wherein the lowest point of comfort sole and outsole, called the center of mass or balance point of the sole or natural balance point of the shoe, when placed on a substantially horizontal reference plane defines a transition zone of the roll of the foot having the highest radius of the comfort sole and the outsole, and in that the center of mass is behind point (B) of the metatarsals; and a rigid shell interposed between the upper and the comfort sole.

The present disclosure is directed to systems and methods of forming a modular footwear sole. The modular sole includes a midsole layer having a first attachment fixture disposed on at least a portion of the lower surface of the midsole layer. A heel member includes a deformable heel layer that includes a plurality of deformable elements having the same or different mechanical properties. The heel member includes a second attachment fixture that couples to the first attachment fixture. An outsole member includes a deformable outsole layer that includes a plurality of deformable elements having the same or different mechanical properties. The outsole member includes a third attachment fixture that couples to the first attachment fixture. The deformable elements may be selected based on a user's foot pressure map.

The present disclosure is directed to systems and methods of forming a modular footwear sole. The modular sole includes a midsole layer having a first attachment fixture disposed on at least a portion of the lower surface of the midsole layer. A heel member includes a deformable heel layer that includes a plurality of deformable elements having the same or different mechanical properties. The heel member includes a second attachment fixture that couples to the first attachment fixture. An outsole member includes a deformable outsole layer that includes a plurality of deformable elements having the same or different mechanical properties. The outsole member includes a third attachment fixture that couples to the first attachment fixture. The deformable elements may be selected based on a user's foot pressure map.

A shoe or apparel, including a first material layer with a first plurality of protrusions, a flexible layer with a plurality of apertures, and a second material layer. The flexible layer is positioned between the first material layer and the second material layer. Each protrusion of the first plurality of protrusions of the first material layer extends through at least one aperture of the plurality of apertures of the flexible layer and is connected to the second material layer. The flexible layer is not connected to the first material layer and the second material layer, and thereby can freely move between the first material layer and the second material layer.

An article of footwear includes an upper and a strobel stitched to the upper at a series of stitches disposed in stitch holes that extend through the strobel. The strobel and the upper define a foot-receiving cavity with an inner surface of the strobel disposed at the foot-receiving cavity. A midsole is secured to the upper and an outer surface of the strobel is disposed at the midsole. The stitch holes are obstructed such that the stitch holes are not exposed to both the midsole and the foot-receiving cavity. Accordingly, when a flowable polymeric material is injected in a mold cavity to form the midsole with the lower portion of the upper and the strobel in the mold cavity, the stitch holes will not provide a path for entry of the flowable polymeric material into the foot-receiving cavity. A method of manufacturing an article of footwear is disclosed.

An article of footwear includes an upper and a strobel stitched to the upper at a series of stitches disposed in stitch holes that extend through the strobel. The strobel and the upper define a foot-receiving cavity with an inner surface of the strobel disposed at the foot-receiving cavity. A midsole is secured to the upper and an outer surface of the strobel is disposed at the midsole. The stitch holes are obstructed such that the stitch holes are not exposed to both the midsole and the foot-receiving cavity. Accordingly, when a flowable polymeric material is injected in a mold cavity to form the midsole with the lower portion of the upper and the strobel in the mold cavity, the stitch holes will not provide a path for entry of the flowable polymeric material into the foot-receiving cavity. A method of manufacturing an article of footwear is disclosed.

Articles of footwear, including athletic footwear, include one or more of: (a) an upper; (b) a sole structure including a midsole and an outsole, the outsole having a plurality of polygonal lugs arranged about a base surface of the outsole. The outsole may include one or more regions wherein the characteristics of a portion of the lugs within a region differ from the characteristics of a portion of the lugs in another region. The lugs may differ, for example based on size, construction and/or spacing between the lugs. Methods of manufacturing such articles of footwear also are disclosed.