The present disclosure encompasses three-dimensional articles comprising flexible-composite materials and methods of manufacturing said three-dimensional articles. More particularly, the present system relates to methods for manufacturing seamless three-dimensional-shaped articles usable for such finished products as airbags/inflatable structures, bags, shoes, and similar three-dimensional products. A preferred manufacturing process combines composite molding methods with specific precursor materials to form fiber-reinforced continuous shaped articles that are flexible and collapsible.

Methods for manufacturing at least a portion of an upper for an article of footwear that include thermo-forming a pattern on the upper. The methods may include disposing a skin for forming an upper over and inflatable bladder and disposing a mold insert between the skin and a surface of a mold cavity. The mold insert may include a mold pattern including surface features formed in the mold insert. The inflatable bladder may be inflated such that the skin is pressed against the mold insert within a heated mold cavity to form a pattern on an exterior surface of the skin and cause the skin to take on the shape of at least a portion of an upper. In some embodiments, the surface features may be disposed in a gradient pattern configured to provide varying degrees of one or more characteristics to different areas of an upper.

In one embodiment, a midsole for an article of footwear is described that includes a first foaming cord made of a first material and a second foaming cord made of a second material. The first material is different than the second material. The first foaming cord and the second foaming cord are embroidered into a shape of the midsole. The first foaming cord and the second foaming cord may be embroidered to a substrate material by thread. A midsole can include multiple layers of foaming cords. Customized midsoles may be formed by selective placement of one or more foaming cords in different locations or layers to provide different properties or characteristics to the midsole.

In one embodiment, a midsole for an article of footwear is described that includes a first foaming cord made of a first material and a second foaming cord made of a second material. The first material is different than the second material. The first foaming cord and the second foaming cord are embroidered into a shape of the midsole. The first foaming cord and the second foaming cord may be embroidered to a substrate material by thread. A midsole can include multiple layers of foaming cords. Customized midsoles may be formed by selective placement of one or more foaming cords in different locations or layers to provide different properties or characteristics to the midsole.

A method of making a midsole for an article of footwear includes forming a plurality of foam layers, arranging the plurality of foam layers in a mold to form the midsole, piercing the plurality of foam layers with pins, and introducing heat with the pins to bond the plurality of layers together.

A rubber sole thermos-molding machine includes a lower mold seat disposed on a hydraulic actuator of the machine seat. The lower mold seat ascends and descends with respect to the upper mold seat according to the hydraulic actuator, allowing the lower upper molds to close and open. The upper mold seat moves between a normal and a tilt positions according to the turning mechanism. The middle plate horizontally moves between the upper and the lower mold seats, and has a push mechanism connected with the middle frame. When the pin of the middle frame and the fasten unit on the push mechanism are separated, the middle frame is stacked on the middle plate or the lower mold to move, facilitating the cleansing and material-feeding operations. The user can cleanse the upper mold without being hindered by the middle frame, assuring the safe and smooth process.

A sole mold for manufacturing a sole from a plurality of particles includes at least one first opening for supplying the particles, and at least two second openings for supplying a gaseous and/or liquid medium to bond and/or fuse the particles together. At least a portion of the sole mold is manufactured by an additive manufacturing method.

The present invention relates to a mold for manufacturing a sole from a plurality of particles.

Embodiments relate generally to a traction surface and methods for forming the traction surface. The traction surface may comprise a compound material comprising glass fibers oriented orthogonal to the surface of the compound material extending from the compound material, wherein when the traction surface contacts an icy surface, the glass fibers are operable to penetrate a liquid-like top layer of the icy surface to provide grip with an ice layer below the liquid-like top layer. The method for forming the traction surface may comprise integrating glass fibers into a compound material; orienting the glass fibers within the compound material such that the glass fibers are oriented approximately orthogonal to the surface of the compound material; splitting the compound material to expose the glass fibers, wherein the glass fibers extend from the surface of the compound material; and forming the split compound material into a traction surface.

Methods for manufacturing at least a portion of an upper for an article of footwear that include thermo-forming a pattern on the upper. The methods may include disposing a skin for forming an upper over and inflatable bladder and disposing a mold insert between the skin and a surface of a mold cavity. The mold insert may include a mold pattern including surface features formed in the mold insert. The inflatable bladder may be inflated such that the skin is pressed against the mold insert within a heated mold cavity to form a pattern on an exterior surface of the skin and cause the skin to take on the shape of at least a portion of an upper. In some embodiments, the surface features may be disposed in a gradient pattern configured to provide varying degrees of one or more characteristics to different areas of an upper.