An algae-elastomer composite including an elastomer matrix; algae; and a mixing additive sufficient to achieve a desired property. The algae can be present in a milled condition having a particle size value of between about 10 and 120 microns. The algae is mixed with the elastomer matrix in a dry condition having a moisture content of below about 10%. A method of preparing the algae-based elastomer composite is provided that includes the steps of: premixing an elastomer matrix; adding an algae filler; adding a mixing additive that includes a plasticizer; forming an elastomer-algae blend by blending the algae and elastomer to a temperature sufficient to be further mixed, wherein the temperature is about 10° C. higher than the temperature sufficient for the elastomer alone; adding and mixing a curing or vulcanizing agent for the elastomer dispersing the elastomer-algae blend; and heating and curing the elastomer-algae blend into a final form.

Provided are, among other things, systems, methods and techniques for making a shoe outsole and to shoe outsoles made using such techniques. In one such technique, a sheet of composite material is produced by extruding a base material together with a sheet of fabric material. The sheet of composite material is then cut into an outsole component, and a shoe outsole is fabricated using the outsole component.

Provided are, among other things, systems, methods and techniques for making a shoe outsole and to shoe outsoles made using such techniques. In one such technique, a sheet of composite material is produced by extruding a base material together with a sheet of fabric material. The sheet of composite material is then cut into an outsole component, and a shoe outsole is fabricated using the outsole component.

A method of manufacturing a non-woven fabric includes the steps of: (a.) providing a substrate, wherein the substrate is air permeable in at least a portion of its surface; (b.) providing a fiber transfer device adapted to transfer fibers onto the substrate; (c.) transferring a first plurality of fibers onto the substrate; and (d.) applying a pressure differential to the air permeable portion of the substrate, wherein the strength of the pressure differential is varied across the surface of the substrate.

A method of manufacturing a non-woven fabric includes the steps of: (a.) providing a substrate, wherein the substrate is air permeable in at least a portion of its surface; (b.) providing a fiber transfer device adapted to transfer fibers onto the substrate; (c.) transferring a first plurality of fibers onto the substrate; and (d.) applying a pressure differential to the air permeable portion of the substrate, wherein the strength of the pressure differential is varied across the surface of the substrate.

A method of manufacturing an article may include positioning a first textile sheet against a second textile sheet and reciprocating a single needle of an embroidery machine through the first textile sheet and the second textile sheet, the needle forcing fibers of the second textile sheet through the first textile sheet. The fibers may have terminal ends extending outward of an exterior side of the first textile sheet through which the fibers are forced. A method may include forcing fibers from a second side to an opposite side of a single textile sheet to create a pattern of the fibers on the opposite side. Various articles such as footwear uppers may be manufactured according to the method.

Provided is a last for shaping a shoe upper. The last includes at least an outer peripheral portion composed of a plastic material that is reversibly transformed between a solid state where the plastic material has a certain shape when the shoe upper is shaped, and a plasticized state where the plastic material has fluidity and is thereby deformable.

The present disclosure is related to three-dimensionally printed articles for use in footwear and associated systems and methods. In some embodiments, a three-dimensionally printed article may comprise a closed-cell foam. The closed-cell foam may have a gradient in and/or may be a single integrated material. In some embodiments, a three-dimensionally printed article may comprise a sensor. The use of such arrangements can, according to certain embodiments, allow for the production of improved articles of footwear and/or customized articles of footwear.

A strobel for an article of footwear includes a base layer and an upper layer formed of a polymer material covering a portion of the top surface of the base layer, leaving a portion of the top surface of the base layer exposed about an entire periphery of the base layer. The upper layer is directly bonded to the base layer without any fastening members. A method of forming the strobel is also disclosed.

A strobel for an article of footwear includes a base layer and an upper layer formed of a polymer material covering a portion of the top surface of the base layer, leaving a portion of the top surface of the base layer exposed about an entire periphery of the base layer. The upper layer is directly bonded to the base layer without any fastening members. A method of forming the strobel is also disclosed.