An automated production line for transferring and processing multiple shoe members includes multiple transferring rail units aligned along a transferring direction, multiple handoff rail units aligned along the transferring direction and alternately arranged with the transferring rail units, multiple transferring unit each being movably mounted to a respective one of the transferring rail unit for transferring the shoe members onto an adjacent one of the handoff rail units, multiple handling units each being movably mounted to a respective one of the handoff rail units and being adapted to transfer the shoe members onto an adjacent one of the transferring rail units, and multiple processing units disposed beside the transferring rail units for processing the shoe members.

An automated production line for transferring and processing multiple shoe members includes multiple transferring rail units aligned along a transferring direction, multiple handoff rail units aligned along the transferring direction and alternately arranged with the transferring rail units, multiple transferring unit each being movably mounted to a respective one of the transferring rail unit for transferring the shoe members onto an adjacent one of the handoff rail units, multiple handling units each being movably mounted to a respective one of the handoff rail units and being adapted to transfer the shoe members onto an adjacent one of the transferring rail units, and multiple processing units disposed beside the transferring rail units for processing the shoe members.

A last extension for a shoe last provides a pattern defining an origin location. The origin location on the last extension can be used to identify locations or points on a last or a shoe component on a last for control of location-critical manufacturing operations, including decorative and functional operations.

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.

An automatic shoe-making device includes a bottom mold unit having a shoe last for selectively receiving an upper, two side mold units driven to combine with or separate from each other, a pressing mold unit driven to be movable relative to the bottom mold unit, and a control unit configured to: control the two side mold units to move toward the bottom mold unit to form a combined configuration, so the two side mold units surround the shoe last to form a mold cavity for receiving a sole material, control the pressing mold unit to hot-press the sole material to form a shoe product or a shoe component, and control the pressing mold unit and the two side mold units to move away from the bottom mold unit to allow the shoe product or the shoe component to be removed from the shoe last.

A foam article, such as a cushioning element for an article of footwear, apparel or sporting equipment is provided that comprises a foam component, such as a midsole, having a number of beneficial physical characteristics. The cushioning element is a low-density foamed component with a surface skin that encases the remaining foam volume. The cushioning element has a number of foam volumes, arranged to achieve a more consistent foam component. Additionally, the cushioning element includes a series of concentric ridges extending radially outwardly from injection gate vestige locations, and a number of striation bands near the perimeter of the cushioning element. The location of the gate vestiges can be beneficially arranged to produce intersecting flow boundaries that are located away from key strain areas of the cushioning element. The cushioning element is more environmentally-friendly, requiring less energy to produce while still providing acceptable energy return and low density.

A foam article, such as a cushioning element for an article of footwear, apparel or sporting equipment is provided that comprises a foam component, such as a midsole, having a number of beneficial physical characteristics. The cushioning element is a low-density foamed component with a surface skin that encases the remaining foam volume. The cushioning element has a number of foam volumes, arranged to achieve a more consistent foam component. Additionally, the cushioning element includes a series of concentric ridges extending radially outwardly from injection gate vestige locations, and a number of striation bands near the perimeter of the cushioning element. The location of the gate vestiges can be beneficially arranged to produce intersecting flow boundaries that are located away from key strain areas of the cushioning element. The cushioning element is more environmentally-friendly, requiring less energy to produce while still providing acceptable energy return and low density.

A custom footwear sole component may have an upper surface conforming to a lower surface of an underfoot component. A method of making the custom sole component includes detecting a shape of a lower surface of the underfoot component. An upper surface of the sole component may be designed that has an upper surface conforming to the detected shape of the lower surface of the underfoot component. The sole-component upper-surface design may conform to three-dimensional geometrical surface data describing an as-worn shape of the lower surface of the underfoot component. Portions of the upper surface of the sole component may extend beyond an upper surface of the underfoot component to form with the underfoot component a combined continuous upper surface. The designed sole component and custom footwear may then be manufactured.

A custom footwear sole component may have an upper surface conforming to a lower surface of an underfoot component. A method of making the custom sole component includes detecting a shape of a lower surface of the underfoot component. An upper surface of the sole component may be designed that has an upper surface conforming to the detected shape of the lower surface of the underfoot component. The sole-component upper-surface design may conform to three-dimensional geometrical surface data describing an as-worn shape of the lower surface of the underfoot component. Portions of the upper surface of the sole component may extend beyond an upper surface of the underfoot component to form with the underfoot component a combined continuous upper surface. The designed sole component and custom footwear may then be manufactured.