A sole structure for an article of footwear comprises a midsole system with a plurality of cushioning units, each having multiple cushioning layers configured to work together as a system to absorb a compressive load, such as a dynamic compressive load due to impact with the ground, in stages of progressive cushioning according to the relative stiffness values of the layers. Various midsole systems disclosed include isolated cushioning units, linked cushioning units, sole layers having stanchions interfacing with the midsole system, midsole systems with sole layers having keyed and unkeyed portions overlying a bladder, and midsole systems with vertically-stacked cushioning units disposed in inverted relationship to one another.

An athletic footwear with improved midsole that is having a helical network. The helical network can morph itself under compressive force. The helical network is made from units of an hourglass shape geometry, each unit having an upper member and a lower member. Each unit is of a wireframe geometry that is integrated with adjacent units to form a networked layer. When an external pressure is applied to the networked layer, such as when the feet wearing the footwear land on a ground, the wireframe legs in the upper member and lower member twists for providing cushioning and resiliency.

A footwear includes: a foot bed portion that supports a sole of a foot of a wearer and has a ground contact surface; and a foot cover portion that covers an instep of the foot of the wearer. At least a part of the foot bed portion and at least a part of the foot cover portion are formed of a single additively manufactured product produced by a stereolithography-type three-dimensional additively manufacturing method, and a protruding portion is provided on an outer surface defined by the additively manufactured product of the foot cover portion.

A sole structure for an article of footwear comprises a midsole having four stacked polymeric sheets bonded to one another to define a first cushioning layer, a second cushioning layer, and a third cushioning layer. Each cushioning layer comprises a sealed chamber retaining gas in isolation from each other sealed chamber. Bonds between adjacent ones of the sheets are arranged such that the third cushioning layer is stacked directly above the first cushioning layer with the second cushioning layer bordering both the first cushioning layer and the third cushioning layer, and the sealed chamber of the second cushioning layer includes a plurality of elongated segments each extending lengthwise across a longitudinal midline of the midsole at a respective acute angle to the longitudinal midline.

A method of customizing the sole structure of an article of footwear includes providing a sole structure with a sole component having an inner surface and an opposite-facing outer surface. The sole component includes a plurality of inner recesses extending from the inner surface and a plurality of outer recesses extending from the outer surface, the plurality of inner recesses include a blind-hole inner recess, the plurality of outer recesses include a blind-hole outer recess, and the blind-hole inner recess is generally aligned with the blind hole outer recess along a vertical direction. The method further includes adjusting the flexibility of the sole component by selectively cutting or removing material from one or both of the blind-hole inner recess and the blind-hole outer recess.

Ground-engaging components for articles of footwear include: (a) an outer perimeter boundary rim that at least partially defines an outer perimeter of the ground-engaging component, wherein the outer perimeter boundary rim defines an open space at least at a forefoot support area of the ground-engaging component; and (b) a matrix structure extending at least partially across the open space at least at the forefoot support area to define an open cellular construction with plural open cells in the open space at least at the forefoot support area. A plurality of these open cells of the open cellular construction have openings with curved perimeters and no distinct corners. Additional aspects of this invention relate to ground-engaging components that are very lightweight yet very stiff, particularly in the forefoot support area. Two or more sizes of the ground-engaging components may be provided with substantially constant forefoot stiffness (optionally substantially constant over a size run).

An article of footwear includes a midsole, an upper disposed above the midsole, and an outsole disposed below the midsole. The midsole includes a lattice structure having an upper side and a lower side, wherein the upper side is a user-facing side and the lower side is a ground-facing side. A first platform is integrally formed into the upper side of the lattice structure. A second platform is integrally formed into the lower side of the lattice structure. The lattice structure extends from the first platform to the second platform.

A method of forming a structural honeycomb includes cutting and folding a substrate sheet according to predetermined cutting and folding patterns and fold angles that cause the sheet to form a honeycomb having cells that each have at least one face abutting, or nearly abutting, the face of another cell. The honeycomb is then stabilized by joining abutting, or nearly abutting, faces to hold the honeycomb together. The honeycomb may have a prespecified three-dimensional shape. The folding pattern may include corrugation, canted corrugation, or zig-zag folds. Joining may employ fixed and/or reversible joinery, including slotted cross section, tabbed strip, angled strip, integral skin, sewn, or laced. At least some folds may be partially-closed to create bends and twists in the honeycomb structure. Some surfaces of the honeycomb may be covered with a skin or face sheet. The substrate sheet may have flexible electronic traces.

A footwear sole structure having a fluid-filled chamber including a tensile member is provided. The fluid-filled chamber includes a first barrier sheet, a second barrier sheet and the tensile member. The first barrier sheet is formed from a first thermoplastic material. The second barrier sheet is attached to the first barrier sheet and is formed from a second thermoplastic material. The first barrier sheet and the second barrier sheet cooperate to define an internal cavity. The tensile member is disposed within the internal cavity and is formed from a third thermoplastic material. A first weld attaches the first barrier sheet, the second barrier sheet, and the tensile member together by melding the first thermoplastic material of the first barrier sheet, the second thermoplastic material of second barrier sheet, and the third thermoplastic material of the tensile member.

An article of footwear includes an outsole that has a bottom portion and a medial arch portion extending upward from the bottom portion. The medial arch portion of the outsole has a base and a plurality of protrusions extending outward from the base. The plurality of protrusions are arranged in vertical alignments. In each one of the vertical alignments, at least one protrusion of the plurality of protrusions is closer to the bottom portion and has a larger effective diameter than at least one other protrusion of the plurality of protrusions that is further from the bottom portion.