Various articles, such as footwear, apparel, athletic equipment, watchbands, and the like, and methods of forming those articles are presented. The articles are generally formed, in whole or in part, using rapid manufacturing techniques, such as laser sintering, stereolithography, solid deposition modeling, and the like. The use of rapid manufacturing allows for relatively economical and time efficient manufacture of customized articles. Portions of the articles may be manufactured using rapid manufacturing and those portions may be joined with portions formed using conventional, non-rapid manufacturing techniques. The methods may also include performing a scan of an appropriate body part of a user, such as a foot, in order to create a customized article of footwear for the user.

Various articles, such as footwear, apparel, athletic equipment, watchbands, and the like, and methods of forming those articles are presented. The articles are generally formed, in whole or in part, using rapid manufacturing techniques, such as laser sintering, stereolithography, solid deposition modeling, and the like. The use of rapid manufacturing allows for relatively economical and time efficient manufacture of customized articles. Portions of the articles may be manufactured using rapid manufacturing and those portions may be joined with portions formed using conventional, non-rapid manufacturing techniques. The methods may also include performing a scan of an appropriate body part of a user, such as a foot, in order to create a customized article of footwear for the user.

A method of manufacturing a waterproof bootie comprises cutting a membrane to result in at least a first bootie portion and a second bootie portion; coupling the first bootie portion to the second bootie portion to form a bootie; arranging a knit upper adjacent the bootie; and activating the heat-activated adhesive to couple the knit upper to the bootie.

The manufacturing of articles relies on the bonding of two or more components to form some forms of the articles, such as a shoe sole bonded with a shoe upper. The bonding may be achieved with an adhesive particulate that is applied to a surface of a substrate. The adhesive particulate is selectively fused to the substrate with a controlled energy source, such as a laser. The selective application of laser energy allows for specific geometric structures of adhesive particulate to be formed on the substrate. The substrate having the fused adhesive particulate is mated with another component allowing the fused adhesive particulate to bond the first substrate and the second component.

The manufacturing of articles relies on the bonding of two or more components to form some forms of the articles, such as a shoe sole bonded with a shoe upper. The bonding may be achieved with an adhesive particulate that is applied to a surface of a substrate. The adhesive particulate is selectively fused to the substrate with a controlled energy source, such as a laser. The selective application of laser energy allows for specific geometric structures of adhesive particulate to be formed on the substrate. The substrate having the fused adhesive particulate is mated with another component allowing the fused adhesive particulate to bond the first substrate and the second component.

A cushioning article comprises a first and a second polymeric sheet bonded to one another and enclosing an interior cavity. The polymeric sheets retain a gas in the interior cavity. A tensile component disposed in the interior cavity includes a first tensile layer, a second tensile layer, and a plurality of tethers spanning the interior cavity and connecting the first tensile layer to the second tensile layer. An inwardly-protruding bond joins the first polymeric sheet to the first tensile layer, protrudes inward from the first polymeric sheet toward the second polymeric sheet, and partially traverses the plurality of tethers. The first polymeric sheet is displaced from the first tensile layer adjacent to the inwardly-protruding bond by the gas. A method of manufacturing a cushioning article is disclosed.

A cushioning article comprises a first and a second polymeric sheet bonded to one another and enclosing an interior cavity. The polymeric sheets retain a gas in the interior cavity. A tensile component disposed in the interior cavity includes a first tensile layer, a second tensile layer, and a plurality of tethers spanning the interior cavity and connecting the first tensile layer to the second tensile layer. An inwardly-protruding bond joins the first polymeric sheet to the first tensile layer, protrudes inward from the first polymeric sheet toward the second polymeric sheet, and partially traverses the plurality of tethers. The first polymeric sheet is displaced from the first tensile layer adjacent to the inwardly-protruding bond by the gas. A method of manufacturing a cushioning article is disclosed.

Various articles, such as footwear, apparel, athletic equipment, watchbands, and the like, and methods of forming those articles are presented. The articles are generally formed, in whole or in part, using rapid manufacturing techniques, such as laser sintering, stereolithography, solid deposition modeling, and the like. The use of rapid manufacturing allows for relatively economical and time efficient manufacture of customized articles. Portions of the articles may be manufactured using rapid manufacturing and those portions may be joined with portions formed using conventional, non-rapid manufacturing techniques. The methods may also include performing a scan of an appropriate body part of a user, such as a foot, in order to create a customized article of footwear for the user.

Various articles, such as footwear, apparel, athletic equipment, watchbands, and the like, and methods of forming those articles are presented. The articles are generally formed, in whole or in part, using rapid manufacturing techniques, such as laser sintering, stereolithography, solid deposition modeling, and the like. The use of rapid manufacturing allows for relatively economical and time efficient manufacture of customized articles. Portions of the articles may be manufactured using rapid manufacturing and those portions may be joined with portions formed using conventional, non-rapid manufacturing techniques. The methods may also include performing a scan of an appropriate body part of a user, such as a foot, in order to create a customized article of footwear for the user.

Systems and methods of the present invention provide for one or more server computers communicatively coupled to a network and configured to make and use an article of manufacture, and the associated method steps for making and using a soft-shelled foot covering.