The present invention relates to a shoe insert that is inflatable or otherwise conformable to the interior of a shoe and provides protection against the shoe collapsing or otherwise becoming deformed during transport, shipment or handling. The shoe insert is capable of being inflated in a left or right orientation and can be provided with branding and other merchandising information.

A method for assembling shoe components includes the steps of: providing at least two shoe components, a shoe last and a film unit; placing the at least two shoe components on an outer surface of the shoe last; removably covering an assembly of the at least two shoe components and the shoe last with the film unit such that the film unit and the shoe last cooperatively define a confining space therebetween; and pumping air out of the confining space and heating the at least two shoe components to shrink and deform the film unit so as to press the at least two shoe components to adhere tightly to each other.

A method for assembling shoe components includes the steps of: providing at least two shoe components, a shoe last and a film unit; placing the at least two shoe components on an outer surface of the shoe last; removably covering an assembly of the at least two shoe components and the shoe last with the film unit such that the film unit and the shoe last cooperatively define a confining space therebetween; and pumping air out of the confining space and heating the at least two shoe components to shrink and deform the film unit so as to press the at least two shoe components to adhere tightly to each other.

An example physical last includes a body having a bottom region. The physical last also includes a fitting attachable to the bottom region to define a component of a shoe. The fitting is manufactured based on three dimensional (3D) scan data of a foot of a customer and pressure data associated with the foot of the customer.

Methods for manufacturing uppers for articles footwear that include thermo-forming an upper composed of one or more low melting point thermoplastic polymers. The methods may include disposing a skin for forming an upper over and inflatable bladder. The skin may include at least one of a base layer composed of a low melting point thermoplastic polymer and a grid layer including a yarn composed of a low melting point thermoplastic polymer. The skin and inflatable bladder may be placed into a mold cavity and the mold may be heated to a predetermined temperature. The inflatable bladder may be inflated such that the skin is pressed against an interior surface of the heated mold cavity to cause the skin to take on the shape of the internal surface of the mold cavity, thereby forming an upper for an article of footwear.

Methods for manufacturing uppers for articles footwear that include thermo-forming an upper composed of one or more low melting point thermoplastic polymers. The methods may include disposing a skin for forming an upper over and inflatable bladder. The skin may include at least one of a base layer composed of a low melting point thermoplastic polymer and a grid layer including a yarn composed of a low melting point thermoplastic polymer. The skin and inflatable bladder may be placed into a mold cavity and the mold may be heated to a predetermined temperature. The inflatable bladder may be inflated such that the skin is pressed against an interior surface of the heated mold cavity to cause the skin to take on the shape of the internal surface of the mold cavity, thereby forming an upper for an article of footwear.

A method and a system are provided to re-create an internal shape of a shoe using a pneumatically-powered inflatable sock. For example, a shoe last used to manufacture a shoe product based on a selected shoe identifier may be identified. A description of the dimensions of the shoe last may be accessed. The description of the dimensions of the shoe last may be expressed as a set of fills per chamber of a sock having a plurality of fillable chambers. The set of fills per chamber may be determined based on the displacement of an inner wall of the sock when the fillable chambers are in an inflated state. Further, an instruction to cause the plurality of fillable chambers to inflate according to the accessed description may be transmitted.

A method and a system are provided to re-create an internal shape of a shoe using a pneumatically-powered inflatable sock. For example, a shoe last used to manufacture a shoe product based on a selected shoe identifier may be identified. A description of the dimensions of the shoe last may be accessed. The description of the dimensions of the shoe last may be expressed as a set of fills per chamber of a sock having a plurality of fillable chambers. The set of fills per chamber may be determined based on the displacement of an inner wall of the sock when the fillable chambers are in an inflated state. Further, an instruction to cause the plurality of fillable chambers to inflate according to the accessed description may be transmitted.

Embodiments provide a lamination machine and lamination process for laminating a membrane to a three-dimensional (3D) target surface of an article, such as a footwear article, glove, clothing article, backpack, or other article. The lamination machine may include an inflatable former that is permeable to air. The inflatable former may have a shape that generally corresponds to a shape of the target surface. The membrane and target surface may be arranged on the former, with a heat-activated adhesive disposed between the membrane and the target surface. The lamination machine may further include a pump to pump heated compressed air into the former. The heated compressed air may inflate the former to press the membrane against the target surface and to activate the adhesive to bond the membrane to the target surface.

Embodiments provide a lamination machine and lamination process for laminating a membrane to a three-dimensional (3D) target surface of an article, such as a footwear article, glove, clothing article, backpack, or other article. The lamination machine may include an inflatable former that is permeable to air. The inflatable former may have a shape that generally corresponds to a shape of the target surface. The membrane and target surface may be arranged on the former, with a heat-activated adhesive disposed between the membrane and the target surface. The lamination machine may further include a pump to pump heated compressed air into the former. The heated compressed air may inflate the former to press the membrane against the target surface and to activate the adhesive to bond the membrane to the target surface.