A method for forming a plate includes attaching a first strand portion to a flexible substrate to form a first layer on the substrate and positioning a second strand portion on the first layer to form a second layer on the first layer in a plurality of discrete regions on the substrate. The method also includes positioning a plurality of traction elements into corresponding cavities formed into a first mold surface and positioning the substrate on the first mold surface to change a shape of the substrate. At least one of heat and pressure is applied to the first strand portion, the second strand portion, the substrate, and the traction elements to conform the substrate to the shape of the first mold surface and form the traction elements into the substrate at each of the discrete regions. The method also includes incorporating the substrate into an article of footwear.

An article of footwear includes an upper and a U-shaped foamed ankle collar. The ankle collar may form the topmost region of the foot receiving shoe opening and the foamed ankle collar may extend at least partially around and over a foot receiving shoe opening. The ankle collar is capable of being compressed by the user's heel during foot insertion and the ankle collar may exert pressure on the user's ankle once the foot is inserted. The ankle collar may have a flattened region along its length forming a downward angle from the topmost region toward the front of the article of footwear. The ankle collar may be located along at least a portion of an inner surface of a heel cup and the heel cup may have a shoe-horn like configuration. The ankle collar may reduce the dimensions of the shoe opening when not compressed.

A method for forming a plate includes attaching a first strand portion to a flexible substrate to form a first layer on the substrate and positioning a second strand portion on the first layer to form a second layer on the first layer in a plurality of discrete regions on the substrate. The method also includes positioning a plurality of traction elements into corresponding cavities formed into a first mold surface and positioning the substrate on the first mold surface to change a shape of the substrate. At least one of heat and pressure is applied to the first strand portion, the second strand portion, the substrate, and the traction elements to conform the substrate to the shape of the first mold surface and form the traction elements into the substrate at each of the discrete regions. The method also includes incorporating the substrate into an article of footwear.

An article of footwear includes a heel counter support situated on the upper and above the sole structure. The heel counter support may have at least two hollow receptacles with backward angles, a compressible component having two ends, and each one of the two hollow receptacles receives one end of the compressible component. The compressible component may have a first configuration and may be capable of distorting into a second configuration under a load of a user's foot when the user is donning the footwear. The compressible component may be capable of automatically returning to the first configuration after the user's foot in fully inserted into the footwear.

An article of footwear includes a heel cup that is attached to the upper and extends from the sole structure to at least a portion of the rear heel collar of the upper. The heel cup may be uniformly molded with an upper portion, midportion, and lower portion and the upper portion has a smaller mediolateral length than the midportion, and the midportion and lower portion form a concave structure that receives the heel. The upper portion has a first configuration and is capable of distorting into a second configuration under a load of a user's foot when the user is donning the footwear. In the second configuration, at least part of the upper portion is lowered and is capable of returning to the first configuration after the load of the user's foot is removed. The midportion includes a peripheral portion that may be thicker than a central portion.

A plate for an article of footwear includes a base layer, a first strand layer, and a second strand layer. The base layer has a peripheral edge defining a medial side and a lateral side extending between a heel region and a forefoot region. The first strand portion is attached to the base layer via first stitching that crosses over the first strand portion and penetrates the base layer at first attachment locations that are spaced apart from the first strand portion. The first strand portion further includes adjacent segments that form a first layer on the base layer. The second strand portion is disposed on the first layer to form a second layer on the first layer and is attached to the base layer via second stitching.

A method of forming a plate for an article of footwear includes applying a first strand portion to a base layer including positioning adjacent segments of the first strand portion to form a first layer on the base layer. The adjacent segments of the first strand portion having a greater density across a width of the plate between a medial side and a lateral side at a midfoot region of the plate than at a forefoot region of the plate and at a heel region of the plate. The method also includes applying at least one of heat and pressure to the first strand portion and to the base layer to conform the first strand portion and the base layer to a predetermined shape.

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.

A method of making an orthotic is disclosed. The method includes the steps of taking measurements relating to a foot and then creating a digital representation of an orthotic on a display device based on said measurements. This digital representation of the orthotic having a heel portion for supporting a heel of a person and a distal portion located in front of the heel portion which can be divided into first and second distal portions. The thickness of the digital representation of the first and second distal portions is then varied such that one of the distal portions is thicker than the other. Finally, an additive manufacturing technique, using a substantially uniform material or materials, is used to create a physical version of the digital representation of the orthotic.

A method of manufacturing a fluid-filled chamber with a tensile element includes manufacturing a tensile element and incorporating the tensile element into a chamber. A first material layer, a second material layer, and a spacing structure having a plurality of support portions and a plurality of gaps may be stacked. The material layers may be located on either side of the spacing structure or on one side of the spacing structure. A strand may be stitched through the gaps to join the material layers and to form the tensile element. The spacing structure may be removed, and the first material layer may be spaced from the second material layer such that segments of the strand extend between the material layers. The tensile element may then be secured to opposite interior surfaces of an outer barrier, and the outer barrier may be pressurized to place the strand in tension.