An article comprised of tape segments embroidered in place is disclosed. One embodiment includes tape segments embroidered to a self-supporting embroidered structure. Another embodiment includes tape segments embroidered together to form an embroidered lattice structure. In one embodiment, some of the tape segments may expand when exposed to heat and may be used to form cushioning regions for the article.

A process for forming a seam construction on a substrate includes steps of: a) providing a first thread coated with a first curable resinous material; b) providing a second thread coated with a second curable resinous material; c) forming a stitch knot; and d) curing the stitch knot to chemically bond the first and second curable resinous materials together.

An article comprised of tape segments embroidered in place is disclosed. One embodiment includes tape segments embroidered to a self-supporting embroidered structure. Another embodiment includes tape segments embroidered together to form an embroidered lattice structure. In one embodiment, some of the tape segments may expand when exposed to heat and may be used to form cushioning regions for the article.