A method for generating foot shape specification data includes obtaining foot shape 3D data (FS3D) by measuring the three-dimensional shape of a bare foot (BF) of a subject (P) of measurement; generating a virtual insole (VIS) for measurement based on the obtained foot shape 3D data (FS3D); generating corrected foot shape 3D data (CFSD) by adding the data of the virtual insole (VIS) to a sole portion of the obtained foot shape 3D data; and obtaining foot shape specification data (FSSD) by measuring a predefined dimension of the corrected foot shape 3D data (CFSD) to determine a foot shape.

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.

A system of manufacturing equipment including molds for a direct injection production of footwear. The system includes a design facility that provides a design. A mold manufacturing facility manufactures a mold for the design for molding a sole of the footwear. A last manufacturing facility manufactures a last of the design. A footwear manufacturing facility manufactures footwear according to the design. The last corresponds to the footwear design and the mold corresponds to the footwear design. The mold is a basic direct injection mold and at least partly channels injection material to a mold cavity and further accommodates direct injection mold inserts. Mold descriptive data of the mold inserts is communicated to the footwear manufacturing facility to manufacture the mold inserts, or the mold inserts are manufactured at the mold manufacturing facility based on the mold descriptive data and transported to the footwear manufacturing facility.

A system for manufacturing equipment for a direct injection production of footwear. The equipment includes molds for direct injection production of footwear. The system includes a design facility that provides a footwear design. A mold manufacturing facility located manufactures a mold corresponding to the footwear design. The mold is for direct injection molding of a sole part of the footwear. At least one footwear manufacturing facility manufactures footwear according to the footwear design, utilizing a last corresponding to the footwear design and the mold corresponding to the footwear design. Last descriptive data relating to said last corresponding to said footwear design is provided. The last descriptive data is communicated to the footwear manufacturing facility for manufacturing the last at the footwear manufacturing location or the last is manufactured at a last manufacturing facility, based on last descriptive data, and transported to the footwear manufacturing facility.

A system for manufacturing equipment for a direct injection production of footwear. The equipment includes molds for direct injection production of footwear. The system includes a design facility that provides a footwear design. A mold manufacturing facility located manufactures a mold corresponding to the footwear design. The mold is for direct injection molding of a sole part of the footwear. At least one footwear manufacturing facility manufactures footwear according to the footwear design, utilizing a last corresponding to the footwear design and the mold corresponding to the footwear design. Last descriptive data relating to said last corresponding to said footwear design is provided. The last descriptive data is communicated to the footwear manufacturing facility for manufacturing the last at the footwear manufacturing location or the last is manufactured at a last manufacturing facility, based on last descriptive data, and transported to the footwear manufacturing facility.

A last system and a method of making the last system are disclosed. The last system includes a last member and an exterior layer. The exterior layer becomes deformable when heated above a characteristic temperature. The method can include forming a braided footwear component on the last system. The exterior layer may be joined with the braided footwear component by heating the last system above the characteristic temperature.

A last system and a method of making the last system are disclosed. The last system includes a last member and an exterior layer. The exterior layer becomes deformable when heated above a characteristic temperature. The method can include forming a braided footwear component on the last system. The exterior layer may be joined with the braided footwear component by heating the last system above the characteristic temperature.

A bonded mesh composite panel can be used to form a three-dimensional upper shell that includes extensions used for double-lasting and/or to otherwise provide a shelf to support foam padding. The foam padding may be, e.g., a foam midsole. The extensions of the upper shell may be located in a lower portion of the shell and may be bonded to the foam midsole in a heel, midfoot and/or forefoot regions.

A bonded mesh composite panel can be used to form a three-dimensional upper shell that includes extensions used for double-lasting and/or to otherwise provide a shelf to support foam padding. The foam padding may be, e.g., a foam midsole. The extensions of the upper shell may be located in a lower portion of the shell and may be bonded to the foam midsole in a heel, midfoot and/or forefoot regions.

A method of producing a customized shoe last for individual fitting and shaping of the inner surface of the shoe includes production of a shoe last based on a precise shape and size of the digital foot model. The actual physical shape of the foot is converted into a foot model using 3D scanning. The digital foot model is divided into parts required for insertion and functioning of a mechanism, and simulation of the bend in the metatarsophalangeal and ankle joints. The parts of the foot obtained by dividing the digital model are then manufactured. An extendable mechanism to move the parts of the shoe last against each other in three axes of coordinates is developed, based the produced parts, an individual shoe last is manufactured in the form of a physical foot model, configured for personal fitting and shaping of an inner surface of the shoe.