A method of manufacturing an article of footwear from a flat pattern is provided. The method includes cutting a first cut in a first material through the top surface (502) and the bottom surface of the first material. The method continues with coupling an overlay (500) on the first material top surface (502) such that the overlay (500) extends over the first cut and obscures the first material top surface (502). The method continues with forming the flat pattern having the first material with the first cut and the overlay (500) into a dimensional article of footwear configured to receive a foot. The first material bottom surface is more interior to the dimensional article of footwear than the top surface (502).

A skate (e.g., an ice skate) or other footwear for a user. The skate or other footwear comprises a skate boot or other foot-receiving structure for receiving a foot of the user and possibly one or more other components, such as a skating device (e.g., a blade and a blade holder) disposed beneath the skate boot to engage a skating surface (e.g., ice). In some cases, at least part of the skate boot or other foot-receiving structure and optionally at least part of one or more other components (e.g., the skating device) may be constructed from one or more materials (e.g., foams) molded by flowing in molding equipment during a molding process (e.g., injection molding or casting). This may allow the skate or other footwear to have useful performance characteristics (e.g., reduced weight, proper fit and comfort, etc.) while being more cost-effectively manufactured.

A skate (e.g., an ice skate) or other footwear for a user. The skate or other footwear comprises a skate boot or other foot-receiving structure for receiving a foot of the user and possibly one or more other components, such as a skating device (e.g., a blade and a blade holder) disposed beneath the skate boot to engage a skating surface (e.g., ice). In some cases, at least part of the skate boot or other foot-receiving structure and optionally at least part of one or more other components (e.g., the skating device) may be constructed from one or more materials (e.g., foams) molded by flowing in molding equipment during a molding process (e.g., injection molding or casting). This may allow the skate or other footwear to have useful performance characteristics (e.g., reduced weight, proper fit and comfort, etc.) while being more cost-effectively manufactured.

Embodiments herein disclose a primary sole part (10) having a foot facing surface (11) and a ground facing surface (12). The primary sole part (10) comprises a plurality of through-going holes (14), wherein the plurality of through-going holes extends in a vertical direction from the foot facing surface (11) to the ground facing surface (12). The foot facing surface (11) is configured to receive an injected sole material for attaching the primary sole part to a ground facing surface (12) of an upper (1).

An article of footwear (1) comprising an upper (8) having a first ground facing surface (9); a primary sole part (10) having a first foot facing surface (11), a second ground facing surface (12), the first foot facing surface comprising a plurality of openings (14), each opening defining a volume (14A) extending in a vertical direction from the first foot facing surface (11) towards the second ground facing surface (12) having a closed end; and a secondary sole part (20) having a second foot facing surface (22) and a third ground facing surface (23), wherein the secondary sole part (20) is arranged between the upper (8) and the primary sole part (10) and extends into the plurality of volumes (14A) and/or openings (14) in the first foot facing surface of the primary sole part.

An article of footwear (1) comprising an upper (8) having a first ground facing surface (9); a primary sole part (10) having a first foot facing surface (11), a second ground facing surface (12), the first foot facing surface comprising a plurality of openings (14), each opening defining a volume (14A) extending in a vertical direction from the first foot facing surface (11) towards the second ground facing surface (12) having a closed end; and a secondary sole part (20) having a second foot facing surface (22) and a third ground facing surface (23), wherein the secondary sole part (20) is arranged between the upper (8) and the primary sole part (10) and extends into the plurality of volumes (14A) and/or openings (14) in the first foot facing surface of the primary sole part.

An article of footwear has an upper that is direct attached with the sole. The sole has a film extending up sidewalls of the sole to a film edge that is prior to the sidewall and the upper joining. Method of manufacture of the article of footwear includes steps of positioning a film over a mold cavity and then securing the film to the mold. The film is heated and then drawn into the mold cavity under a vacuum. The film forms a liner of the mold cavity. A foam composition is injected into the lined mold cavity. As the foam composition expands, the foam composition interacts with and mechanically engages with the upper that is positioned at the mold cavity to allow for the mechanical engagement that results in the direct attach of the sole to the upper. The film is then trimmed from the sole sidewalls.

An article of footwear has an upper that is direct attached with the sole. The sole has a film extending up sidewalls of the sole to a film edge that is prior to the sidewall and the upper joining. Method of manufacture of the article of footwear includes steps of positioning a film over a mold cavity and then securing the film to the mold. The film is heated and then drawn into the mold cavity under a vacuum. The film forms a liner of the mold cavity. A foam composition is injected into the lined mold cavity. As the foam composition expands, the foam composition interacts with and mechanically engages with the upper that is positioned at the mold cavity to allow for the mechanical engagement that results in the direct attach of the sole to the upper. The film is then trimmed from the sole sidewalls.

A footwear article forming process, and a device for the same are disclosed. The process includes: providing a forming mold set including an outer modular mold, an inner formation mold, and a footwear-forming space therebetween. The footwear-forming space comprises a footwear lower portion forming space and a footwear main portion forming space. Footwear article forming steps are as follows: injecting a pre-determined amount of a footwear main portion rubber material into a footwear main portion sprue channel, the footwear main portion rubber material being injected from a footwear main portion rubber injection opening into the footwear main portion forming space via a transfer injection channel; and placing a footwear lower portion rubber material into the footwear lower portion forming space.

A footwear article forming process, and a device for the same are disclosed. The process includes: providing a forming mold set including an outer modular mold, an inner formation mold, and a footwear-forming space therebetween. The footwear-forming space comprises a footwear lower portion forming space and a footwear main portion forming space. Footwear article forming steps are as follows: injecting a pre-determined amount of a footwear main portion rubber material into a footwear main portion sprue channel, the footwear main portion rubber material being injected from a footwear main portion rubber injection opening into the footwear main portion forming space via a transfer injection channel; and placing a footwear lower portion rubber material into the footwear lower portion forming space.