A method of making an article of footwear is disclosed. The method may include the steps of selecting a family of article types, selecting a customized article type, manufacturing an article of footwear with the customized article type and shipping the article of footwear to a pre-designated shipping address. The customized article type can be configured with a user selected characteristic. The method can also include limiting the number of article types displayed to a user at any time.

A biocomposite material and methods and systems for forming a biocomposite material are provided. In one example, a biocomposite material includes a biopolymer material and an internal structure imparting zonal properties to the biocomposite material, where the biopolymer material at least partially surrounds and/or extends through the internal structure. The biopolymer material includes mycelium grown from a fungal strain.

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.

Manufacturing of a shoe or a portion of a shoe is enhanced by executing various shoe-manufacturing processes in an automated manner. For example, shoe parts may be retrieved and temporarily assembled according to preset relative positions to form part stacks. The part stacks may be retrieved with the relative positioning of the shoe parts being maintained and placed at a stitching machine for more permanent attachment via stitching of the parts to form a shoe assembly. Movement during stitching of a conveyance mechanism that transfers the part stack from the stacking surface to the stitching machine and movement of a needle associated with the stitching machine may be controlled by a shared control mechanism such that the movements are synchronized with respect to one another. Vision systems may be leveraged to achieve movement and position information between and at machines and locations.

The manufacturing of articles relies on the bonding of two or more components to form some forms of the articles, such as a shoe sole bonded with a shoe upper. The bonding may be achieved with an adhesive particulate that is applied to a surface of a substrate. The adhesive particulate is selectively fused to the substrate with a controlled energy source, such as a laser. The selective application of laser energy allows for specific geometric structures of adhesive particulate to be formed on the substrate. The substrate having the fused adhesive particulate is mated with another component allowing the fused adhesive particulate to bond the first substrate and the second component.

Disclosed is a method for manufacturing a device for adapting a footwear to the specific deformations of the foot of a user, including creating 3D scans of the foot in weight bearing and non-weight bearing positions, as well as of the footwear; determining rubbing areas between the foot and the footwear by means of superimposing the scanned 3D image of the footwear and the scanned 3D images of the weight bearing and the non-weight bearing foot; obtaining a final out-of-phase 3D image of the non-weight bearing foot, wherein the rubbing areas in this image are moved out of phase until they reach an intermediate position selected between a minimum and a maximum limit; printing the part of the heel and the part of the forefoot from the final out-of-phase 3D image. Finally, fitting a flexible element for joining together the part of the heel and the part of the forefoot.

A midsole for an article of footwear including a three dimensional mesh including interconnected unit cells and methods of making the same. The interconnected unit cells each include a plurality of struts defining a three dimensional shape. The interconnected unit cells are connected at nodes having a valence number defined by the number of struts connected at that node. The valence number of the nodes may vary to provide customized characteristics to zones or portions of the midsole. The plurality of interconnected unit cells may be organized in a warped cubic lattice structure. The warped cubic lattice structure and the size/shape of interconnected unit cells may vary to provide customized characteristics to zones or portions of the midsole. The three dimensional mesh may be customized based on a biometric data profile for an individual, or group of individuals. The midsole may be manufactured using an additive manufacturing process.

Various articles, such as footwear, apparel, athletic equipment, watchbands, and the like, and methods of forming those articles are presented. The articles are generally formed, in whole or in part, using rapid manufacturing techniques, such as laser sintering, stereolithography, solid deposition modeling, and the like. The use of rapid manufacturing allows for relatively economical and time efficient manufacture of customized articles. Portions of the articles may be manufactured using rapid manufacturing and those portions may be joined with portions formed using conventional, non-rapid manufacturing techniques. The methods may also include performing a scan of an appropriate body part of a user, such as a foot, in order to create a customized article of footwear for the user.

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.

An article of footwear includes an upper, a midsole connected to the upper, and an outsole connected to the midsole. The midsole includes a lattice structure comprising a network of laths forming a plurality of cell units, the plurality of cell units arranged in a plurality of layers on the midsole. The cell units in an upper layer are stacked upon the cell units in a lower layer and separated by a set of vertices common to cell units in both the upper layer and the lower layer.