Systems and processes for thermoforming an article and for preparing an article for thermoforming are disclosed. The system for thermoforming can include one or more heating stations and a cooling station. The system for thermoforming can further include an article movement mechanism that can couple to an article and rotate the article inside a heating chamber, inside a cooling chamber, or both. The system for preparing an article for thermoforming can include a vessel that comprises a port, and a negative pressure generation system coupled to the port. The system for preparing an article for thermoforming can further include a compression material that forms an interior portion for receiving an article. The negative pressure generation system can cause the compression material to expand to allow for insertion of the article into the interior portion of the compression material.

Embodiments are directed to manufacturing footwear. A first outer mold shell and a second outer mold shell may be provided. A first inner mold body and a second inner mold body may be manufactured. The first and second inner mold bodies may have respective first and second inner mold surfaces. The second inner mold surface, together with the first inner mold surface, may define an internal mold volume. The first and second inner mold bodies may be removably coupled to the respective first and second outer mold shells to form first and second hybrid side rings. The first hybrid side ring and the second hybrid side ring may be installed in an automated injection molding machine. The installed first hybrid side ring may be moved toward the installed second hybrid side ring to provide the internal mold volume. One or more liquids may be injected into the internal mold volume.

Articles of footwear include an upper and a sole structure having a fluid-filled element in the heel region. The fluid-filled element includes: (a) an upper surface, (b) a lower surface, and (c) an outer peripheral surface extending between the upper surface and lower surface. The fluid-filled element also includes a pair of spaced apart, substantially U-shaped voids that extend through a central region of the fluid-filled element. A first void of the pair of voids is located closer to a forward end of the fluid-filled element than a second void of the pair. Both the first void and the second void have an open portion of its U-shape oriented toward the forward end of the fluid-filled element.

Described is a method of manufacturing a component for a shoe that includes the steps: forming a sheet of material; heating the sheet of material; stretching the heated sheet of material by moving a last into the sheet of material, wherein the last defines the shape of the component; and applying a pressure lower than ambient pressure between the stretched sheet of material and the last to conform the sheet of material to the last; or applying a pressure higher than ambient pressure over the stretched sheet of material to conform the sheet of material to the last.

A method of forming an upper for an article of footwear includes providing a first material layer over a shoe last, providing a second material layer over the first material layer such that the first and second material layers adhere to each other at an interface between the first and second material layers, where one or both of the first material layer and second material layer is provided by spray forming a polymer material onto the last. The material layers are removed from the last and turned inside out such that the first material layer includes an exposed surface that forms an exterior surface of the upper.

This disclosure concerns a master model for the production of a mold, comprising: (a) a first part, a second part comprising a textured surface; wherein the first part and the second part are connected.

A thermoforming system for forming a cushioning pod structure that includes a first and a second thermoforming station with each comprised of a film holder and a thermoforming mold holder. The system implements a thermal source that is moveable between the first thermoforming station and the second thermoforming station such that the film holders are between the thermal source and the respective thermoforming mold holder. The system also relies on intentional application of a vacuum source fluidly coupled to thermoforming stations and a movement mechanism configured to move the thermal source between the first thermoforming station and the second thermoforming station. Additional aspects contemplate the implementation of a positive pressure source to aid in the dislodgment of the formed portion, a cooling system to adjust mold temperatures, and/or a fan to efficiently thermoform the component.

The invention relates to a method of processing a sheet material for use in the manufacture of a product. The method comprises providing a sheet material having a first surface and a second surface; providing a two-dimensional mark on the first surface of the sheet material; arranging one or more strengthening members at one or more of the first surface and the second surface of the sheet material; imposing an indentation on said first surface of the sheet material; wherein at least part of the indentation is arranged with respect to one or more of at least part of the two-dimensional mark and at least part of the one or more strengthening members to create a three-dimensional mark on said first surface. The invention also relates to a blank for at least part of a manufactured product. The blank comprises a sheet material shaped in accordance with the at least part of a manufactured product, the sheet material comprising a two-dimensional mark on a surface of the sheet material; one or more strengthening members arranged at one or more sides of the sheeting material; wherein one or more of at least part of the two-dimensional mark and at least part of the one or more strengthening members are positioned with respect to an indentation formed in the sheet material to thereby provide a three-dimensional mark on said surface.

Methods for manufacturing cushioning elements for sports apparel are described. A method is provided for manufacturing a cushioning element for sports apparel from randomly arranged particles of an expanded material. The method includes positioning a functional element within a mold and loading the mold with the particles of the expanded material, wherein the loading occurs through at least two openings within the mold and/or wherein the loading occurs between different movable parts of the mold.

Embodiments are directed to manufacturing footwear. A first outer mold shell and a second outer mold shell may be provided. A first inner mold body and a second inner mold body may be manufactured. The first and second inner mold bodies may have respective first and second inner mold surfaces. The second inner mold surface, together with the first inner mold surface, may define an internal mold volume. The first and second inner mold bodies may be removably coupled to the respective first and second outer mold shells to form first and second hybrid side rings. The first hybrid side ring and the second hybrid side ring may be installed in an automated injection molding machine. The installed first hybrid side ring may be moved toward the installed second hybrid side ring to provide the internal mold volume. One or more liquids may be injected into the internal mold volume.