An article of apparel or sporting equipment, such as garments and footwear incorporates a molded component formed of a UV radiation curable material. In the case of an article of footwear, the UV radiation curable material may be formed into an outsole. The method of manufacturing such articles include placing an ultraviolet radiation curable material in contact with a molding surface; conforming the UV radiation curable material to a shape of the molding surface, forming a molded component; and removing the molded component from the molding surface, such that the component maintains the shape of the molding surface. The molded component may be exposed to ultraviolet radiation in an amount and for a duration that is sufficient to partially cure or fully cure the UV radiation curable material.

A method of manufacturing an article that includes providing an element formed of an elastomeric material or composite; placing the surface of the element in contact with a substrate; and affixing the element to the substrate. The element includes an uncured, partially cured, or fully cured UV radiation curable elastomeric material and optionally one or more regions of an adhesive material. The element is affixed to the substrate while the surface of the element is in contact with a surface of the substrate by increasing a temperature of at least a portion of the element, applying pressure to at least a portion of the element, or exposing the uncured or partially cured UV radiation curable material to UV radiation in an amount and for a duration of time that is sufficient to partially cure the uncured material or to fully cure the partially cured material.

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 footwear article is formed according to a process that includes the steps of: forming a sheet including a rubber outsole material; forming an outsole component by passing the sheet through an extruder or calendar machine; applying a vulcanizing accelerant to the outsole component by dipping the outsole component in a liquid bath; forming a plurality of rubber outsoles from the outsole component by cutting the outsole component into the plurality of rubber outsoles; incorporating each of the plurality of rubber outsoles into the footwear article; and vulcanizing the footwear article. The vulcanizing accelerant includes a dithiocarbamate compound. The footwear article includes the rubber outsole, an insole and an upper. The vulcanizing accelerant allows the step of vulcanizing the footwear article to be performed substantially faster as compared to conventional footwear vulcanization methods.

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 sports shoe includes an upper wherein a majority by weight of the upper is made from a thermoplastic base material and a sole wherein a majority by weight of the sole is made from the same thermoplastic base material. The sole and the upper are individually fabricated and joined to each other. The thermoplastic base material includes at least one of the following materials: thermoplastic polyurethane TPU, polyamide PA, polyethylene terephthalate PET, or polybutylene terephthalate PBT.