A method of making a foamed article, for example a foamed component for an article or footwear, comprises forming a structure of interconnected, unfoamed, thermoplastic polymeric members spaced to define openings between the thermoplastic polymeric members. The structure may be made by printing a thermoplastic polymeric material with a three-dimensional printer. The thermoplastic polymeric members are heated to a first temperature to soften the thermoplastic polymeric members and the softened thermoplastic polymeric members are infused with at least one inert gas at a first pressure greater than atmospheric pressure. The first pressure is sufficient to cause the at least one inert gas to permeate into the softened thermoplastic polymeric members. After being infused with the inert gas, the pressure is reduced to at least partially foam the thermoplastic polymeric members.

The disclosed systems provide ways to manufacture a style of an article of footwear in bulk, while providing customization for heel stability for individual customers. Moreover, the disclosed systems provide ways to customize articles of footwear for a customer on an ongoing basis, such that the heel stability of the articles of footwear is refined until a tailored fit is achieved for the same customer. Generally, the process may include providing a user/customer with an article of footwear, getting evaluation information about the stability of the article of footwear from a survey (e.g., asking the user to rate the stability of the article of footwear in a smartphone app), modifying the next article of footwear provided to the user/customer according to the evaluation information, and iterating through this process to give the user an article optimized for stability.

A footbed comprises a cushion comprising a heel portion, a forefoot portion, and a lower surface. The heel and forefoot portions each comprise resilient balls located in a resilient matrix material. The balls have a first hardness measure, and the matrix material has a second hardness measure that is different than the first hardness measure. The balls in the forefoot portion are of a first diameter and the balls in the heel portion are of a second diameter, the first diameter being smaller than the second diameter. The heel portion is separated from the forefoot portion by a midfoot portion. Each of the balls in the cushion may be interconnected with adjacent respective balls by spacing pins, the spacing pins creating gaps between adjacent respective balls, the matrix material being located in the gaps. The matrix material substantially surrounds each of the balls in the cushion.

A sole structure for an article of footwear includes a component including a first bundle of fibers affixed to a substrate, a ground-engaging assembly including a first traction element, a second traction element, and a connecting member extending between and connecting the first traction element and the second traction element, and a resin consolidating the first bundle of fibers and entrapping the connecting member to fix a position of the first traction element, the second traction element, and the connecting member relative to the substrate.

An apparatus is provided that includes a sole cover. The sole cover is configured to be removably attached to a sole of a shoe to cover the sole of the shoe. The sole cover includes a first covering section and a second covering section, where the first covering section is configured to cover the sole of the shoe at a toe box portion of the shoe. The second covering section is configured to cover the sole of the shoe at a waist portion of the shoe. The first covering section angles upwardly and away from the second covering section at an angle relative to the second covering section at an angle relative to the second covering section when the second covering section lies flat on a horizontal plane in an undeformed state. The sole cover is of a sufficient elasticity that enables the first covering section to bend downwardly when the sole cover is attached to the sole of the shoe. The angle and elasticity are of sufficient values to urge the sole cover against a bottom of the sole of the shoe to help secure the sole cover to the sole of the shoe when the sole cover is attached to the sole of the shoe.

An apparatus is provided that includes a sole cover. The sole cover is configured to be removably attached to a sole of a shoe to cover the sole of the shoe. The sole cover includes a first covering section and a second covering section, where the first covering section is configured to cover the sole of the shoe at a toe box portion of the shoe. The second covering section is configured to cover the sole of the shoe at a waist portion of the shoe. The first covering section angles upwardly and away from the second covering section at an angle relative to the second covering section at an angle relative to the second covering section when the second covering section lies flat on a horizontal plane in an undeformed state. The sole cover is of a sufficient elasticity that enables the first covering section to bend downwardly when the sole cover is attached to the sole of the shoe. The angle and elasticity are of sufficient values to urge the sole cover against a bottom of the sole of the shoe to help secure the sole cover to the sole of the shoe when the sole cover is attached to the sole of the shoe.

A sole for an article of footwear includes a continuous dispensed component forming a first layer and a second layer. The first layer is disposed directly on top of the second layer. The continuous dispensed component forms a medial sidewall and a lateral sidewall. The first layer includes a starting point where the continuous dispensed component is first dispensed. The continuous dispensed component continuously transitions from the first layer to the second layer at the starting point.

A plate for an article of footwear includes a substrate, a first strand portion attached to the substrate via first stitching, and a second strand portion disposed on the first layer. The first strand portion includes first segments that each extend between two different locations along the substrate to form a first layer on the substrate. The second strand portion includes second segments that each extend between two different locations along the substrate to form a second layer on the first layer.

An article of footwear has an upper that is direct attached with the sole. The sole has a film extending up sidewalls of the sole to a film edge that is prior to the sidewall and the upper joining. Method of manufacture of the article of footwear includes steps of positioning a film over a mold cavity and then securing the film to the mold. The film is heated and then drawn into the mold cavity under a vacuum. The film forms a liner of the mold cavity. A foam composition is injected into the lined mold cavity. As the foam composition expands, the foam composition interacts with and mechanically engages with the upper that is positioned at the mold cavity to allow for the mechanical engagement that results in the direct attach of the sole to the upper. The film is then trimmed from the sole sidewalls.

An article of footwear has an upper that is direct attached with the sole. The sole has a film extending up sidewalls of the sole to a film edge that is prior to the sidewall and the upper joining. Method of manufacture of the article of footwear includes steps of positioning a film over a mold cavity and then securing the film to the mold. The film is heated and then drawn into the mold cavity under a vacuum. The film forms a liner of the mold cavity. A foam composition is injected into the lined mold cavity. As the foam composition expands, the foam composition interacts with and mechanically engages with the upper that is positioned at the mold cavity to allow for the mechanical engagement that results in the direct attach of the sole to the upper. The film is then trimmed from the sole sidewalls.