In at least some embodiments, an orthotic footbed assembly includes a three-dimensional footbed that closely approximates a size and configuration of a particular foot and at least one orthotic feature additively coupled to the three-dimensional footbed. In at least some other embodiments, a method of making the orthotic footbed assembly includes direct printing of orthotic features onto a 3-D footbed. Another method includes indirect printing of orthotic features and applying these features onto to a 3-D footbed. And yet another method includes direct printing of orthotic features onto a 2-D blank footbed and then conducting a three-dimensional forming operation to make the orthotic footbed assembly.

The invention concerns a method of producing an article of footwear comprising: providing an upper; providing a mold and opening the mold; inserting the upper into the open mold; closing the mold; and injecting a pressurized molten resin, wherein, after the injecting, there is a gap filled with the resin between a side wall of the mold and an outer surface of at least a first portion of the upper, wherein the gap is essentially zero at a contacting point, wherein the gap increases gradually from the contacting point in at least a first region of the mold.

The invention concerns a method of producing an article of footwear comprising: providing an upper; providing a mold and opening the mold; inserting the upper into the open mold; closing the mold; and injecting a pressurized molten resin, wherein, after the injecting, there is a gap filled with the resin between a side wall of the mold and an outer surface of at least a first portion of the upper, wherein the gap is essentially zero at a contacting point, wherein the gap increases gradually from the contacting point in at least a first region of the mold.

The waterproof/breathable moisture transfer liner for a running and hiking shoe includes an inner liner selected from technically advanced fabrics which are carefully selected. A series of layers are provided outside the inner liner including foam material layers, breathable membranes, a supportive mesh or a moldable foam, and an outer shell fabric. The applicability of the liner to alpine, snowboard boots, cross country, hiking boots, protective gear and helmets, along with appropriate variations for each application.

A footwear assembly having an upper that comprises a neoprene sock with a foot portion integrally connected to a leg portion. The foot portion has heel, vamp and under-foot portions. The leg portion has front shin, side wall, and rear calf-side portions. The upper has a unitary, outer, injection molded layer molded directly onto the foot and shin portions of the neoprene sock, while the sidewall and rear calf-side portions remain substantially uncovered by the injection molded layer. The injection molded layer encases the foot portion of the neoprene sock. The injection molded layer on the shin portion defines a shin guard portion having a necked down area integrally connected to the injection molded layer at the vamp portion, wherein the shin guard extends upwardly from the necked-down portion in an outwardly diverging shape away from the vamp.

A footwear assembly having an upper that comprises a neoprene sock with a foot portion integrally connected to a leg portion. The foot portion has heel, vamp and under-foot portions. The leg portion has front shin, side wall, and rear calf-side portions. The upper has a unitary, outer, injection molded layer molded directly onto the foot and shin portions of the neoprene sock, while the sidewall and rear calf-side portions remain substantially uncovered by the injection molded layer. The injection molded layer encases the foot portion of the neoprene sock. The injection molded layer on the shin portion defines a shin guard portion having a necked down area integrally connected to the injection molded layer at the vamp portion, wherein the shin guard extends upwardly from the necked-down portion in an outwardly diverging shape away from the vamp.

A footwear cover system and method to prevent unwanted matter from entering a shoe of a wearer. The footwear cover system includes the shoe having a relatively soft and flexible upper portion for surrounding at least part of the wearer's foot and a sole attached to the upper portion of the shoe. The relatively soft and flexible upper portion has a toe-receiving forepart section, a mid-foot receiving section, and a heel-receiving rear part section. A housing surrounds the shoe and fastens to the shoe at an intersection of the sole and the flexible upper portion. A waterproof rain cover is stored within the housing and adapted to being extended from the housing to enclose the flexible upper portion. A structure is used to secure the waterproof rain cover in place after it has enclosed the flexible upper portion of the shoe.

A pressure injected plastic footwear is provided characterized in that comprising double liner made of fabric, one on the inside part and one on the outside part; both liners may be identical or different and provide the footwear with special characteristics such as being fire retardant, antifungal, anti-mold and hermetic to moisture and liquid water as well as thermal insulating.

A pressure injected plastic footwear is provided characterized in that comprising double liner made of fabric, one on the inside part and one on the outside part; both liners may be identical or different and provide the footwear with special characteristics such as being fire retardant, antifungal, anti-mold and hermetic to moisture and liquid water as well as thermal insulating.

Flip flop sandals with a barrier around a perimeter of a sole. The barrier forms a continuous loop, thereby protecting the feet from wind and water in all directions. The flip flops comprise a medial strap, a lateral strap and a toe strap attached to the sole at locations interior to the barrier. The barrier protects the feet from water splashes, puddles, wet grass and wind. The barrier height can be in the range of 0.5-4 inches or 0.7-3 inches. Alternatively, the barrier height can be at least 40% or ½ a length of the toe strap. The barrier can be made of closed cell foam or plastic film. The attachment between the sole and barrier can be water tight.