Methods for manufacturing at least a portion of an upper for an article of footwear that include thermo-forming a pattern on the upper. The methods may include disposing a skin for forming an upper over and inflatable bladder and disposing a mold insert between the skin and a surface of a mold cavity. The mold insert may include a mold pattern including surface features formed in the mold insert. The inflatable bladder may be inflated such that the skin is pressed against the mold insert within a heated mold cavity to form a pattern on an exterior surface of the skin and cause the skin to take on the shape of at least a portion of an upper. In some embodiments, the surface features may be disposed in a gradient pattern configured to provide varying degrees of one or more characteristics to different areas of an upper.

Methods for manufacturing at least a portion of an upper for an article of footwear that include thermo-forming a pattern on the upper. The methods may include disposing a skin for forming an upper over and inflatable bladder and disposing a mold insert between the skin and a surface of a mold cavity. The mold insert may include a mold pattern including surface features formed in the mold insert. The inflatable bladder may be inflated such that the skin is pressed against the mold insert within a heated mold cavity to form a pattern on an exterior surface of the skin and cause the skin to take on the shape of at least a portion of an upper. In some embodiments, the surface features may be disposed in a gradient pattern configured to provide varying degrees of one or more characteristics to different areas of an upper.

A machine may be configured to re-create an internal shape of a clothing item using a pneumatically-powered fitting device. For example, the machine, based on a clothing item identifier, identifies a description of an internal shape of a clothing item. The machine transmits an instruction referencing the description to a filling station associated with the fitting device. The machine, based on the transmitting of the instruction, causes the fitting device to adjust according to the description.

A machine may be configured to re-create an internal shape of a clothing item using a pneumatically-powered fitting device. For example, the machine, based on a clothing item identifier, identifies a description of an internal shape of a clothing item. The machine transmits an instruction referencing the description to a filling station associated with the fitting device. The machine, based on the transmitting of the instruction, causes the fitting device to adjust according to the description.

What is disclosed is an object holder for retaining an object in a direct-to-object print system and a direct-to-object print system configured to use various embodiments of the object holder of the present invention. The object holder comprises a shuttle mount configured to slideably traverse a support member positioned parallel to a plane formed by at least one printhead of a direct-to-object print system. An expandable bladder attached to either the shuttle mount or a restraint. The bladder is inserted in a cavity of an object to be printed. A pump then fills the bladder with either a gas or a liquid to cause the bladder to expand. The expanded bladder in the object's cavity enables a surface of the object to be printed. In one embodiment, the filled bladder substantially conforms to a shape of a human foot, and the object being printed is footwear.

A last assembly includes a plurality of retractable pins and a plurality of vacuum holes, both acting to hold footwear segments to the last assembly to facilitate manufacturing of, or modification to, an article of footwear. A method of making or modifying an article of footwear includes placing footwear segments on the last assembly by associating an extension portion of at least one footwear segment with the retractable pins, modifying the footwear segments and then removing the extension portion.

A last assembly includes a plurality of retractable pins and a plurality of vacuum holes, both acting to hold footwear segments to the last assembly to facilitate manufacturing of, or modification to, an article of footwear. A method of making or modifying an article of footwear includes placing footwear segments on the last assembly by associating an extension portion of at least one footwear segment with the retractable pins, modifying the footwear segments and then removing the extension portion.

An apparatus for stretching footwear, wherein an inflatable bladder is inserted into the footwear at a desired location as determined by the user. The various embodiments of the apparatus allow for various areas of the footwear, including the instep, the vamp, the calf area or shaft, and other areas of the footwear to be uniformly expanded without causing damage to the footwear. In one embodiment, a bladder having a rounded peak is inserted into the toe-box of the footwear and inflated to a desired pressure. Alternatively, other embodiments may be inserted into the calf section of a footwear such as a boot to expand the material around the leg and calf of a user. An air valve allows for users to inflate the apparatus while said apparatus is inside of the footwear.

An apparatus for stretching footwear, wherein an inflatable bladder is inserted into the footwear at a desired location as determined by the user. The various embodiments of the apparatus allow for various areas of the footwear, including the instep, the vamp, the calf area or shaft, and other areas of the footwear to be uniformly expanded without causing damage to the footwear. In one embodiment, a bladder having a rounded peak is inserted into the toe-box of the footwear and inflated to a desired pressure. Alternatively, other embodiments may be inserted into the calf section of a footwear such as a boot to expand the material around the leg and calf of a user. An air valve allows for users to inflate the apparatus while said apparatus is inside of the footwear.

An upper for an article of footwear, the upper including a base layer defining a least a portion of the upper and polymer threads stitched to the base layer. The polymer threads may include a core composed of a first material and a coating composed of a second material, where the melting point of the first material is higher than the melting point of the second material. The polymer threads may be bonded to the base layer by the coating of the polymer threads. The polymer threads may include one or more polymer thread sets stitched in pattern(s) on area(s) of an outer surface of the base layer to provide targeted characteristics to area(s) on the upper. In some embodiments, the polymer threads may be bonded to the base layer with heat and/or pressure.