An article of footwear includes a sole and an upper at least partially formed of a textile element. The textile element includes a yarn matrix having a plurality of interlocked strands oriented in predetermined directions. A structural element may be captured within the matrix at selected locations. In operation, the matrix is stitched onto a temporary substrate. The substrate is removed and the article coupled to a sole structure to form the article of footwear.

The invention relates to footwear and portions thereof having structural features and decorative designs thereon, and related systems and methods for manufacturing same. An exemplary method for providing a feature on a surface of an object includes positioning a laser proximate the surface of the object, directing a laser beam from the laser to the surface of the object to mark or engrave at least a portion of the surface of the object, and moving at least one of the laser and the object to create a pattern on the surface of the object, the pattern providing at least one of an aesthetic and a structural feature on the surface of the object.

A footwear article includes a tongue and a tongue reinforcer, which helps the tongue maintain a shape and position when the tongue is subjected to forces or adjustments, such as from other footwear-article elements or from a wearer. For example, the tongue reinforcer may help the tongue maintain a shape and position when a wearer is inserting his or her foot into the footwear article or when medial and/or lateral quarters press inward on the tongue.

A shoe insole includes a semi-rigid shell for providing a wearer with extended comfort. The semi-rigid shell includes a notch which is located on the outward side of the wearer's foot and accommodates pronation of the foot during use. Additionally, the semi-rigid shell includes an extended side portion which is located opposite of the notch side on an inner side of the wearer's foot. The semi-rigid shell is shorter in length than the length of a shoe sole and slightly shorter in width and may be combined with an insole comfort cover to provide cushion between the wearer's foot and the semi-rigid shell.

Systems and methods are disclosed including a tri-layer orthotic system having a heel portion and a forefoot portion to support respective heel and forefoot portions of a foot through at least a portion of a gait cycle. The tri-layer orthotic system can include an upper layer suspended over a mid-layer and a base layer to create a rear spring section, a mid-spring section, and a front spring section. A distal toe portion of the mid-layer can form the forefoot portion of the tri-layer orthotic system and a heel upper layer portion of the upper layer can form the heel portion of tri-layer orthotic system.

Systems and methods are disclosed including a tri-layer orthotic system having a heel portion and a forefoot portion to support respective heel and forefoot portions of a foot through at least a portion of a gait cycle. The tri-layer orthotic system can include an upper layer suspended over a mid-layer and a base layer to create a rear spring section, a mid-spring section, and a front spring section. A distal toe portion of the mid-layer can form the forefoot portion of the tri-layer orthotic system and a heel upper layer portion of the upper layer can form the heel portion of tri-layer orthotic system.

A shoe insole and a shoe with an insole structure, which are capable of, concerning the foot arch structure, preventing fallen arches, restoring and correcting the arches, as well as allowing the wearers to maintain the sense of balance. The shoe insole comprises an insole main body having a substantially foot shape; a lower cushioning portion provided on the insole main body in a front portion thereof for supporting a part from the tiptoe to the position of the metatarsal head part; an upper cushioning portion having a substantially U shape provided on the lower cushioning portion for supporting a part corresponding to the positions of the toe, the first toe ball, and the fifth toe ball; and a heel supporting portion provided on the insole main body in a back portion thereof for supporting a portion corresponding to the position of the heel.

A shoe insole and a shoe with an insole structure, which are capable of, concerning the foot arch structure, preventing fallen arches, restoring and correcting the arches, as well as allowing the wearers to maintain the sense of balance. The shoe insole comprises an insole main body having a substantially foot shape; a lower cushioning portion provided on the insole main body in a front portion thereof for supporting a part from the tiptoe to the position of the metatarsal head part; an upper cushioning portion having a substantially U shape provided on the lower cushioning portion for supporting a part corresponding to the positions of the toe, the first toe ball, and the fifth toe ball; and a heel supporting portion provided on the insole main body in a back portion thereof for supporting a portion corresponding to the position of the heel.

A boot includes a rigid outer shell including a base portion adjacent to a portion of a foot of a subject, a leg portion adjacent to a portion of a leg of the subject, and an ankle support portion integral with and coupling the base portion of the main body with the leg portion of the main body, the ankle portion of the main body being adjacent to two opposing sides of an ankle of the subject, the ankle support portion of the main body having one or more removable elements. A first one of the one or more removable elements, adjacent to a first one of the two opposing sides of the ankle, is configured to be removed from the rigid outer shell to aid in preventing contact between an incision area on the first side of the ankle of the subject and the rigid outer shell.

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.