Various articles, such as footwear, apparel, athletic equipment, watchbands, and the like, and methods of forming those articles are presented. The articles are generally formed, in whole or in part, using rapid manufacturing techniques, such as laser sintering, stereolithography, solid deposition modeling, and the like. The use of rapid manufacturing allows for relatively economical and time efficient manufacture of customized articles. The articles may include one or more reinforcements configured to provide added durability to various regions of the articles. In addition, the articles may be formed from two or more materials in a single rapid manufacturing process. The rapid manufacturing additive fabrication technique may also include using of varying intensities of the laser to fuse material to form the articles.

An article of footwear including an outsole, a fabric upper and at least one connector including a first male member co-molded with the fabric upper and a second female member. The first member includes at least one rib and the second member includes at least one groove, where the at least one connector is secured to the outsole by inserting the second member in the outsole and engaging the at least one rib of the first member with the at least one groove of the second member.

A method of forming a traced element is disclosed. The method may include printing layers of a traced element and incorporating a textile strand in overlapping polymer layers of the traced element. In some embodiments, the traced element may be formed on a base layer. The traced element may be incorporated into an upper for an article of footwear.

A sole structure for an article of footwear may include a chamber for receiving a pressurized fluid, the chamber having a first chamber barrier layer and a second chamber barrier layer bonded to the first chamber barrier layer about peripheral portions of the first chamber barrier layer and the second chamber barrier layer to define an interior void between the first chamber barrier layer and the second chamber barrier layer. The sole structure may also include a tensile member bonded to, and extending between, the first chamber barrier layer and the second chamber barrier layer. The sole structure may include a bond inhibiting material located between the tensile member and the first chamber barrier layer, the tensile member and the first chamber barrier layer being unbonded in an unbonded area in which the bond inhibiting material is disposed. The chamber may include an outwardly extending bulge in the unbonded area.

A hot-molding method using a plastic elastomer to fabricate a vamp comprises steps: fabricating a hot-molding mold according to a pattern design of a vamp; fabricating blanks of different thicknesses, shapes, sizes, colors and materials; placing the blanks in the hot-molding mold; placing the hot-molding mold in a hot-molding machine to undertake a hot-molding process; and taking the hot-molding mold out of the hot-molding machine and then taking out the vamp from the mold after cooling. The method enables a single vamp to simultaneously use blanks of different thicknesses, shapes, colors and materials and diversifies vamp designs. The method fixes blanks securely in the mold and joins blanks of different colors to an identical vamp in a single process. The blanks are hard to peel off the vamp after molding. The method features a short fabrication cycle, high efficiency and high yield.

Systems and methods for providing heat to a three-dimensional article are disclosed. The method can include inserting at least a portion of the article over a form. The method can further include inserting the form and article at least partially within an article container and moving the form and article into engagement with a flexible membrane where the membrane and the article container form an airtight chamber. The method can further include exposing the airtight chamber to a pressure less than atmospheric pressure to pull the membrane against at least a portion of the article and exposing the membrane to a heated deformable media.

A method of manufacturing a shoe includes preparing a flexible shell having an internal space, preparing an upper body in a form of a bag, the upper body being provided with an opening in a portion corresponding to a topline, preparing a sole body, accommodating the upper in the shell, partially fixing the shell and the upper body, and forming the upper body with a last being located in the upper body accommodated in the shell, taking the last out of the formed upper body, and inserting the sole body in the shell.

Methods for manufacturing uppers for articles footwear that include thermo-forming an upper composed of one or more low melting point thermoplastic polymers. The methods may include disposing a skin for forming an upper over and inflatable bladder. The skin may include at least one of a base layer composed of a low melting point thermoplastic polymer and a grid layer including a yarn composed of a low melting point thermoplastic polymer. The skin and inflatable bladder may be placed into a mold cavity and the mold may be heated to a predetermined temperature. The inflatable bladder may be inflated such that the skin is pressed against an interior surface of the heated mold cavity to cause the skin to take on the shape of the internal surface of the mold cavity, thereby forming an upper for an article of footwear.

Described are materials for a shoe upper, in particular for soccer shoes, with a particularly low weight. The material includes an inner polyurethane layer, an outer polyurethane layer, and a textile reinforcing layer. The textile reinforcing layer is arranged between the inner polyurethane layer and the outer polyurethane layer. The inner polyurethane layer and the outer polyurethane layer comprise thermoset polyurethane. The textile reinforcing layer comprises apertures through which the inner polyurethane layer and the outer polyurethane layer are connected to each other.

Aspects herein are directed to braided articles and methods for their manufacture. The braided articles may include articles of footwear having braided uppers. The braided uppers may include a base yarn and a high performance yarn. The high performance yarn may form a braided structure within the braided upper. The braided structure may be continuously braided to provide continuous support to a wearer's foot when the article of footwear is worn as intended, by a wearer. Additionally, the high performance yarn may be configured to exit the braided upper and re-enter the braided upper to form a plurality of arcuate loops along the throat area of the braided article of footwear for accommodating a lace for further adjustment of the fit of the article of footwear on the wearer's foot, when worn.