The present invention relates to a method for preparing a three-dimensional shaped article, comprising the following steps: a) unfolding the three-dimensional profile of the three-dimensional shaped article with a curved surface via a computer-aided design software; b) dividing the unfolded three-dimensional profile obtained in step a) into several elemental layers via the computer-aided design software; c) cutting a continuous fiber reinforced thermoplastic resin based composite sheet to have the same or similar shape and size with the elemental layers; d) stacking the cut composite sheets in order of size to obtain a stack; and g) forming the stack obtained in step d), followed by demoulding and optionally trimming to obtain the three-dimensional shaped article. With the method of the present invention, a continuous fiber reinforced thermoplastic resin based composite sheet can be processed into a three-dimensional shaped article with uneven thickness and a high degree of curvature. The resulting three-dimensional shaped article features a light weight, good impact resistance and compression resistance.

The present disclosure relates generally to three-dimensionally printed molds, and associated methods, for use in manufacturing articles such as footwear. In some embodiments, for example, a three-dimensionally printed mold may be a master mold that is used to manufacture a secondary mold. The secondary mold may be used, in certain embodiments, to provide a cured material that can be transferred to a substrate, such as a textile, thereby providing the manufactured article. The use of such arrangements can, according to certain embodiments, allow for the production of improved articles of footwear and/or customized articles of footwear.

A method for providing pressure feedback is described herein. The method includes receiving, via a processor, pressure sensor data from a plurality of pressure sensors over a period of time. The method also includes receiving, via the processor, movement data from a plurality of sensors over the period of time. The method also further includes sending, via the processor, pressure sensor data and movement data to a data service. The method also includes receiving, via the processor, a feedback from data service.

A custom footwear sole component may have an upper surface conforming to a lower surface of an underfoot component. A method of making the custom sole component includes detecting a shape of a lower surface of the underfoot component. An upper surface of the sole component may be designed that has an upper surface conforming to the detected shape of the lower surface of the underfoot component. The sole-component upper-surface design may conform to three-dimensional geometrical surface data describing an as-worn shape of the lower surface of the underfoot component. Portions of the upper surface of the sole component may extend beyond an upper surface of the underfoot component to form with the underfoot component a combined continuous upper surface. The designed sole component and custom footwear may then be manufactured.

Methods and systems are disclosed for three-dimensional printing directly onto an article of apparel. Disclosed is a method and system for direct three-dimensional printing onto an article of apparel, including positioning at least a portion of the article on a tray in a three-dimensional printing system, the portion being positioned substantially flat on the tray, printing a three-dimensional material directly onto the article using a three-dimensional pattern, curing the printed material, and removing the article from the three-dimensional printing system.

An article of footwear flat pattern upper having an upper portion and a footbed portion is provided. The upper portion and the footbed portion are integrally continuous, such that the upper portion lateral side converges with the footbed lateral side. The flat pattern includes nested same-sided article of footwear with a reduced surplus portion there between. The articles of footwear includes the following continuous portions: the first medial side with a toe end, the toe end with a lateral side, the lateral side with a heel end, and the heel end with the second medial side. The first medial side and the second medial side are joined to form dimensional article of footwear.

Systems, methods, logic, and devices may support shoe design through 2.5-dimensional (2.5D) shoe models. In some examples, a system may include a 2D shoe shell pattern engine configured to access a 2D shoe shell pattern, the 2D shoe shell pattern generated for shoe design. The system may also include a 2.5D shoe model engine configured to generate a 2.5D shoe model by placing shoe design elements provided by a user onto the 2D shoe shell pattern of the shoe, including by adding 2.5D layering data for each shoe design element placed on the 2D shoe shell pattern to form the 2.5D shoe model, and wrap the 2.5D shoe model into a 3D shoe model for construction of a physical shoe from the 3D shoe model.

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.

An article of footwear includes an upper, a midsole connected to the upper, and an outsole connected to the midsole. The midsole includes a platform extending along a perimeter portion of the midsole and a lattice structure integrally formed with the platform, the lattice structure including a network of laths.

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.