The present invention is directed to an adjustable footwear system to provide varying degrees of tightness in different areas of the footwear before and after the footwear is received on the foot. An extensor system is activated to open or close a cavity of the footwear between the upper and an insole. The extensor system can provide loosen the footwear to the foot.

A shoe has a sole having a capacitive sensor and a force actuating mechanism, and a wireless receiver. The capacitive sensor can detect and sense whether or not there is a foot is in the shoe. The force actuating mechanism can operate like a piston in an inactive mode (first position) and active mode (second position), wherein the active mode extends the force actuating mechanism's extending mechanism from first position to second position. The wireless receiver can retrieve any information in regards to geodetic locations from the capacitive sensor based on the capacitance signal.

A plurality of orthotic systems are provided. One bi-layer system is constructed from a single sheet of fabric that is molded into two layers. One tri-layer system includes a base layer; a mid-layer; and an upper layer. The upper layer is joined to the mid-layer and the mid-layer is joined to the base layer. The coupling of the base layer, the mid-layer and the upper layer create a rear spring section, a mid-spring section and a front spring section in which the upper layer is suspended over the mid-layer and the heel portion is suspended on the proximal heel end of the base layer.

A footbed system (10) for footwear comprises an insole mechanism (14), a midsole mechanism (11), wherein the insole mechanism is positioned on the midsole mechanism, and the outsole mechanism (15) is positioned under the midsole mechanism. The insole mechanism comprises a footbed insole (1), a heel pad (2) and a forefoot pad (3). The footbed insole comprises a pad anatomically shaped to correspond to the sole of a human foot, wherein the heel pad is positioned in the hindfoot portion of the footbed insole, and the forefoot pad is positioned in the forefoot portion of the footbed insole. The outsole mechanism comprises an opening (15A) for exposing a natural gait line groove of the midsole mechanism.

A method of making an orthotic is disclosed. The method includes the steps of taking measurements relating to a foot and then creating a digital representation of an orthotic on a display device based on said measurements. This digital representation of the orthotic having a heel portion for supporting a heel of a person and a distal portion located in front of the heel portion which can be divided into first and second distal portions. The thickness of the digital representation of the first and second distal portions is then varied such that one of the distal portions is thicker than the other. Finally, an additive manufacturing technique, using a substantially uniform material or materials, is used to create a physical version of the digital representation of the orthotic.

Footwear with enhanced wearing comfortability, stability and orthotic foot support are disclosed. The footwear comprises built-in intrinsic midsole, anatomically shaped footbed having a functional arch concavity on a medial side, and deep heel cup. The built-in intrinsic midsole provides ideal foot support and function. Raised sidewalls accentuate a deep heel cup, which controls and matches the natural anatomic shape of the foot. The midsole is made by direct single density injection with integrated orthotic contour. The direct injection midsole to upper creates a strong bond, and resolves a potential of delaminating soles. Furthermore, it eliminates the need and cost of cementing, and improves instant fit/comfort.

A weight adjustable orthotic insert system includes an orthotic insert and a weight adjusting leaf. The orthotic insert corrects joint misalignment of a user based on a weight plus any additional load, foot flexibility or activity level (e.g., momentum) of the user. The weight adjusting leaf may be attached to the orthotic insert when the user is carrying a payload over a distance (e.g., a heavy pack or body armor) so that the orthotic insert provides the proper degree of correction given the increased weight instead of being collapsed by the additional weight.

An insole is provided. This insole features a front end, a thickness, a top surface, a bottom surface, a heel receiving portion having a first end and a second end, a lateral longitudinal arch support section which has a width, and a medial longitudinal arch support section. Preferably, the medial longitudinal arch support section is made up of a partial spherical cap which has a radius and a height, and the medial longitudinal arch support section runs from the first end of said heel receiving portion to the lateral longitudinal arch support section.

An arch support may include a base plate having a base plate top surface. The arch support may further include a contoured arch plate attached to the base plate at a joint. The arch plate may include an arch plate bottom surface. The arch plate bottom surface may face and be separated from the base plate top surface, with an extent of the separation increasing toward a medial side of the arch support.

An article of footwear includes a dynamic support member that provides support to a foot. The support member is external to the article. The support member provides dynamic support by tightening around the foot when a user applies a strong enough force against a base portion of the support member. The support member includes several lateral gaps that facilitate increased flexibility for some portions of the support member.