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.

A method for locating critical control points on a part or combination of parts during a manufacturing process involves mating, directly or indirectly, a jig extension to the part or parts. A pattern on the jig extension defines an origin point that is used to track the position of the part or parts during manufacturing, such as during location-sensitive operations. The jig extension may be a shoe last extension which connects to a shoe or shoe component via a shoe last.

A method for locating critical control points on a part or combination of parts during a manufacturing process involves mating, directly or indirectly, a jig extension to the part or parts. A pattern on the jig extension defines an origin point that is used to track the position of the part or parts during manufacturing, such as during location-sensitive operations. The jig extension may be a shoe last extension which connects to a shoe or shoe component via a 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.

Manufacturing of article of footwear include temporarily mating a sole and an upper to determine processes to be performed to the sole and/or the upper before permanently mating. As specific operations are determined based on the particular combination of a sole and an upper, the sole and upper are individually tracked through the subsequent processes to ensure the correct pairing is achieved at the time of permanent mating. The tracking may leverage identifiers in the tooling supporting the upper and in the sole.

Manufacturing of article of footwear include temporarily mating a sole and an upper to determine processes to be performed to the sole and/or the upper before permanently mating. As specific operations are determined based on the particular combination of a sole and an upper, the sole and upper are individually tracked through the subsequent processes to ensure the correct pairing is achieved at the time of permanent mating. The tracking may leverage identifiers in the tooling supporting the upper and in the sole.

A machine (10) for roughing a shoe sole comprises a support (17) for a sole, a rouging head (14) and a movement system (13) for moving the roughing head (14) relative to the support (17) under the control of a control system (15) so as to follow with the roughing head (14) roughing trajectories on a sole placed in the support (17). The roughing head (14) comprises a radial roughing tool (42), motorized to rotate about its transverse axis (46), and an axial roughing tool (43), motorized to rotate about its longitudinal axis (44). The radial roughing tool (42) and the axial roughing tool (43) are mutually interchangeable by means of a selection actuator (49) controlled by the control system (15) so as to operate alternately on a sole in the support (17).

A machine (10) for roughing a shoe sole comprises a support (17) for a sole, a rouging head (14) and a movement system (13) for moving the roughing head (14) relative to the support (17) under the control of a control system (15) so as to follow with the roughing head (14) roughing trajectories on a sole placed in the support (17). The roughing head (14) comprises a radial roughing tool (42), motorized to rotate about its transverse axis (46), and an axial roughing tool (43), motorized to rotate about its longitudinal axis (44). The radial roughing tool (42) and the axial roughing tool (43) are mutually interchangeable by means of a selection actuator (49) controlled by the control system (15) so as to operate alternately on a sole in the support (17).

A method of making an article of footwear is disclosed. The method may include the steps of selecting a family of article types, selecting a customized article type, manufacturing an article of footwear with the customized article type and shipping the article of footwear to a pre-designated shipping address. The customized article type can be configured with a user selected characteristic. The method can also include limiting the number of article types displayed to a user at any time.