The soft boot and liner include a moisture transfer system that includes an inner fabric layer carefully selected from technically advanced fabrics. A series of layers are provided outside the inner liner including foam material layers, spacer fabrics and breathable membranes, in various orders. Encapsulation technology and waterproofing are used as well. The outer fabric layer is also capable of working with the other layers to promote the transfer of moisture. Frothed foams and flocking with fibers are further characteristics of the present invention. The moisture transfer system is incorporated into a soft boot or skate or as a removable liner for a shell boot. Numerous other modifications and applications are disclosed.

A midsole for an article of footwear including a three-dimensional mesh including interconnected unit cells and methods of making the same. The interconnected unit cells each include a plurality of struts defining a three-dimensional shape. The interconnected unit cells are connected at nodes having a valence number defined by the number of struts connected at that node. The valence number of the nodes may vary to provide customized characteristics to zones or portions of the midsole. The plurality of interconnected unit cells may be organized in a warped cubic lattice structure. The warped cubic lattice structure and the size/shape of interconnected unit cells may vary to provide customized characteristics to zones or portions of the midsole. The three-dimensional mesh may be customized based on a biometric data profile for an individual, or group of individuals. The midsole may be manufactured using an additive manufacturing process.

A footwear assembly having an upper configured to receive a foot and a sole assembly integrally connected to the upper. The sole assembly includes an outsole and a midsole coupled between the upper and the outsole. The sole assembly also includes a footwear insert coupled to the midsole having anisotropic and anti-puncture properties so as to provide protection, support, and stability to the foot of a wearer of the footwear assembly while still allowing for flexibility. The footwear insert is formed from a soft, dorsal layer having woven fabric, a hard, plantar layer formed from a fiber reinforced composite material bonded to the dorsal layer, and an interfacing polymer layer interposed between the dorsal and plantar layers and used to bond the two layers together. The layered arrangement has a high resistance to bending in a first direction and a low resistance to bending in an opposing second direction.

An article of footwear with a dynamic support system that controls arrays of tiles in the upper of the footwear to adjust the level of support provided in different regions of the upper. Sensors in the sole of the footwear, in the upper of the footwear and/or in an article worn by the wearer of the footwear measure the level of stress or other characteristics and provide input to one or more microprocessors that control motors located in the sole or in the upper of the footwear. When the motors are activated, they may compress or loosen arrays of tiles to adjust the stiffness of the upper in one or more regions of the upper.

A method and kit are provided for the customization of footwear comprising an upper which is partially or totally made of thermoformable material. The method provides for selectively heating the portions made of thermoformable material of the footwear, while leaving the remaining portions of the footwear at a substantially unchanged temperature, and for applying to the thermoformable material portions a pressure sufficient to adapt their shape to the specific morphology of the user's foot. This allows to customize even footwear comprising delicate portions, which would be damaged if subjected to high temperatures. The method may provide for customizing a footbed, partially or totally made of thermoformable material, to the specific morphology of the user's foot sole. The kit is compact, preferably transportable and capable of autonomously carrying out all the steps of the method.

A performance footwear, apparel or medical accessory product for hot, cold, and all-weather conditions, the performance footwear, apparel or medical accessory product comprised of a series of material layers having: a first layer of a breathable, moisture transfer, antimicrobial inner lining, fabric or nonwoven material or a combination of fabric or nonwoven material; a second layer comprising a breathable, moisture transfer, absorbent, antimicrobial, mechanically bonded, antimicrobial, nonwoven material comprised of shaped, channeled, grooved and lobed synthetic polymer fibers, antimicrobial silver polymer fibers and natural and synthetic, thermal and cooling fibers wherein the fiber combinations naturally provide adjustable thermal regulation; and a third exterior layer comprised of a breathable, antimicrobial woven fabric, knitted fabric, spacer fabric, nonwoven material, leather material or a combination thereof.

An article of footwear can include provisions for facilitating the installation of various components such as a lighting apparatus. During manufacture of the article of footwear, the upper and/or sole structure can include a chamber designed to receive the lighting apparatus. The lighting apparatus can be installed in the chamber after manufacture of the article of footwear. In some cases, the lighting apparatus can include provisions for facilitating the installation of the lighting apparatus in the chamber, including a removable handle portion that can help guide the lighting apparatus within the chamber.

An article of footwear may include an upper configured to receive a foot and a sole component fixedly attached to a bottom portion of the upper. The sole component may include a baseplate having a bottom surface. The sole component may also include an arrangement of ground engaging members extending downward from the bottom surface of the baseplate. The baseplate may further include a reinforcing shank arrangement including a plurality of reinforcing strips formed of a different material than portions of the baseplate adjacent the reinforcing strips, wherein at least one of the reinforcing strips forms at least a portion of a base platform from which at least one of the ground engaging members extends.

A midsole for an article of footwear including a three dimensional mesh including interconnected unit cells and methods of making the same. The interconnected unit cells each include a plurality of struts defining a three dimensional shape. The interconnected unit cells are connected at nodes having a valence number defined by the number of struts connected at that node. The valence number of the nodes may vary to provide customized characteristics to zones or portions of the midsole. The plurality of interconnected unit cells may be organized in a warped cubic lattice structure. The warped cubic lattice structure and the size/shape of interconnected unit cells may vary to provide customized characteristics to zones or portions of the midsole. The three dimensional mesh may be customized based on a biometric data profile for an individual, or group of individuals. The midsole may be manufactured using an additive manufacturing process.

A protective plate for footwear provides protection that is flexible. A protective plate may include a forefoot plate having a ball, middle and lateral section that are configured to move and flex to enable a better feel on uneven terrain. A protective plate may extend from the forefoot to the heel and include a midfoot protective plate and a heel protective plate. Sections of the protective plate are hinged or separated to allow for a greater degree of independent movement of the three main groups of muscles and bones in the forefoot in response to walking, hiking and running on various terrain. A separate insole is described that incorporates the forefoot protection plate and that can be inserted into and removed from footwear in order to provide additional protection as needed. A shoe including outer-sole, midsole and upper, are also described having a flexible protective plate.