Systems and processes for reinforcing components of articles of wear are disclosed. The processes can include applying a thermoplastic powder to a component of an article of wear and levelling at least a portion of the thermoplastic powder. The processes can also include applying thermal energy to the component and the thermoplastic powder. Further, the processes can include compressing the thermoplastic powder and the component.

A method of making an article of footwear is disclosed. The method may generally include placing a first rigid member into a first region of a molding cavity and placing a second rigid member into a second region of the molding cavity. The first rigid member may be spaced from a first cleat and the second rigid member may be spaced from a second cleat. A second material may be injected into the first region and into the second region to form a sole comprising a first plate member and a second plate member.

A method for making a cleated plate member of an article of footwear includes forming a blade cleat assembly having an anchor member associated with a blade member, the blade member having a planar body, the body having a base portion, a head portion opposite the base portion, and a through hole formed in the base portion, a first molding material of the anchor member surrounding the base portion of the blade member and extending through the through hole formed in the base portion of the blade member, and associating the blade cleat assembly with an exposed surface of a plate body to form a cleated plate member. The base portion of the blade member further may include a pair of opposing shoulder flange portions. A blade cleat assembly may be disposed in a cleat assembly receptacle of a mold system configured to form a cleated plate member.

A method for making a cleated plate member of an article of footwear includes forming a blade cleat assembly having an anchor member associated with a blade member, the blade member having a planar body, the body having a base portion, a head portion opposite the base portion, and a through hole formed in the base portion, a first molding material of the anchor member surrounding the base portion of the blade member and extending through the through hole formed in the base portion of the blade member, and associating the blade cleat assembly with an exposed surface of a plate body to form a cleated plate member. The base portion of the blade member further may include a pair of opposing shoulder flange portions. A blade cleat assembly may be disposed in a cleat assembly receptacle of a mold system configured to form a cleated plate member.

An aspect of the disclosure is a footwear article. The footwear article includes a double layer knitted upper having a foot bed, an upper portion continuous with the foot bed, an ankle opening, and an inner void for receiving a foot of a wearer. The double layer knitted upper has an outer knit layer defining an exterior surface of the double layer knitted upper. The double layer knitted upper also has an inner knit layer monolithically knit to the outer knit layer. The inner knit layer has a plurality of inner knit regions that spatially correspond to the plurality of outer knit regions of the outer knit layer. The outer knit layer and the inner knit layer substantially define the foot bed and the upper portion of the double layer knitted upper.

A method is provided for making footwear utilizing a spray-on material. The method can include spraying a spray-on fabric onto surfaces of a three dimensional last. The last can be produced using additive manufacturing techniques, such as 3D printing, based on data corresponding to dimensions and contours of a consumer's foot, and/or preselected aesthetic footwear designs. The spray-on fabric is sprayed onto the surfaces of the last and allowed to cure to form a flexible, non-woven fabric upper. The upper can be removed from the last and turned inside out. With the upper turned inside out, a sole can be joined to the fabric upper to form the footwear.

A method is provided for making footwear utilizing a spray-on material. The method can include spraying a spray-on fabric onto surfaces of a three dimensional last. The last can be produced using additive manufacturing techniques, such as 3D printing, based on data corresponding to dimensions and contours of a consumer's foot, and/or preselected aesthetic footwear designs. The spray-on fabric is sprayed onto the surfaces of the last and allowed to cure to form a flexible, non-woven fabric upper. The upper can be removed from the last and turned inside out. With the upper turned inside out, a sole can be joined to the fabric upper to form the footwear.

A method of forming a sole assembly for footwear construction comprises providing a first polymeric composition having a first density and a second polymeric composition having a second density in a mold to form a pre-expanded midsole. The pre-expanded midsole is expanded using a supercritical fluid to form a midsole. The midsole includes an exterior portion having a third density and an interior portion having a fourth density, which is different than the third density. The midsole defines a first surface and a second surface opposite the first surface. An outsole is joined with the second surface of the midsole.

Articles of wear having one or more textiles that include a low processing temperature polymeric composition and a high processing temperature polymeric composition, and methods of manufacturing the same are disclosed. The low processing temperature polymeric composition and the high processing temperature polymeric composition can be selectively incorporated into a textile to provide one or more structural properties and/or other advantageous properties to the article. The textile can be thermoformed to impart such structural and/or other advantageous properties to the article of wear. This abstract is intended as a scanning tool for purposes of searching in the particular art and is not intended to be limiting of the present disclosure.

Articles of wear having one or more textiles that include a low processing temperature polymeric composition and a high processing temperature polymeric composition, and methods of manufacturing the same are disclosed. The low processing temperature polymeric composition and the high processing temperature polymeric composition can be selectively incorporated into a textile to provide one or more structural properties and/or other advantageous properties to the article. The textile can be thermoformed to impart such structural and/or other advantageous properties to the article of wear. This abstract is intended as a scanning tool for purposes of searching in the particular art and is not intended to be limiting of the present disclosure.