A method of forming a printed structure is disclosed. The method may include printing layers of a printed structure and incorporating an element within the printed structure. The element may be removed in order to form tunnels within the printed structure. In some embodiments the element may be removed and reused in the formation of additional printed structures. The element may also be retained to form a composite printed structure.

An article of footwear includes an upper and a sole structure with a sole member. The sole member can be manufactured using a system that modifies the forefoot cushioning of the sole member over a series of footwear purchases. The modifications can be configured to correspond to a customer's evaluation of the forefoot cushioning previously purchased. The sole member can include a set of apertures or incisions that are formed along various surfaces of the sole member to adjust the cushioning characteristics of the sole member.

A high heel shoe that contains a sole insert that includes a forward region supporting the forefoot and a reduced thickness or cut out area disposed beneath the first metatarsal head. The reduced thickness or cut out area provides less support to the first metatarsal head than is provided to other areas of the forward region that support the forefoot. The rear region supports the midfoot and the rearfoot including the heel, with the rear region extending from the forefoot to the back of the optional heel. An arch support may also be provided. Also disclosed are the sole insert itself, methods of making the sole insert and methods of making shoes that contain the sole insert.

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.

A method of making an article of footwear is disclosed. The method includes the steps of providing a customer with a pre-selected set of graphics, allowing a customer to choose a set of input graphics, and generating a set of morphed graphics based on a set of input graphics. The user can select a morphed graphic and apply it to an article. The method may further include the step of limiting the number of times a customized graphic may be selected and applied to an article.

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.

Manufacturing of a shoe or a portion of a shoe is enhanced by executing various shoe-manufacturing processes in an automated fashion. For example, information describing a shoe part may be determined, such as an identification, an orientation, a color, a surface topography, an alignment, a size, etc. Based on the information describing the shoe part, automated shoe-manufacturing apparatuses may be instructed to apply various shoe-manufacturing processes to the shoe part, such as a pickup and placement of the shoe part with a pickup tool.

Sole structures for articles of footwear (e.g., outsole components) have one or more of: a base plate having a V-shaped support structure with lateral and medial support members extending forward from a base support area located in a heel or rear midfoot area of the outsole component; a base plate having a matrix structure with recesses or openings formed between rib elements that make up the matrix structure; and/or a base plate having a rear heel support. The base plates may be made, at least in part, as unitary, one-piece constructions, using selective laser sintering or other three-dimensional printing and/or rapid manufacturing additive fabrication techniques.

Disclosed herein are methods, apparatus and computer program products for use in manufacturing an anatomical protective item for one or more users. Embodiments of anatomical protective items may comprise a single layer of energy controlling cells. Input data associated with one or more users is obtained. The obtained input data is processed to identify one or more energy controlling criteria for the anatomical protective item. A packing process is employed to generate each energy controlling cell in the single layer. Each energy controlling cell comprises one or more walls which extend from an upper surface of the single layer to a lower surface of the single layer. The packing process is performed at least on the basis of the identified one or more energy controlling criteria. The anatomical protective item comprising the single layer of energy controlling cells is manufactured.

The ability to capture an undistorted image of the foot or foot and ankle is essential to the production of effective custom orthotics and shoes. This patent solves the problem of providing an accurate three-dimensional measurement of an undistorted foot/ankle by using a system involving the automated and controlled orbit of a point cloud capture device around the foot/ankle with the foot/ankle in a non-weight bearing position so as to capture a three-dimensional image.