An article of footwear includes a sole structure including a polymeric bladder element enclosing a fluid-filled interior cavity. The bladder element has a surface with a groove that extends generally parallel with a transverse edge from a lateral side to a medial side, and has a reduced thickness at the groove. A first length along a longitudinal midline of the bladder element from a longitudinal extremity of the bladder element to the groove corresponds with a first footwear size, and a second length along the longitudinal midline of the bladder element from the longitudinal extremity to the transverse edge corresponds with a second footwear size larger than the first footwear size. The sole structure is used in a method of manufacturing an article of footwear.

Aspects hereof relate to a multi-part mold assembly for use in manufacturing articles. The mold assembly provides for contouring, shaping and cutting materials to form articles via a continuous single processing operation. The mold assembly includes an upper mold portion with a three-dimensional contouring/shaping portion and a first cutting edge, a lower mold portion with a three-dimensional contouring/shaping portion and a second cutting edge, and a base portion into which the lower mold portion may retract during use. Upon application of a first force, the upper and lower mold portions cooperate to contour/shape a material from which an article is to be formed. Upon application of a second force greater than the first, the first cutting edge and the second cutting edge interact to shear the material that extends beyond the respective cutting edges. The result is an article that is contoured, shaped and cut/trimmed utilizing a single processing operation.

A sockliner for a shoe may be formed to include an integral fabric skirt. The fabric skirt may remain loose from the sockliner along at least a portion of the periphery of the sockliner. The loose periphery of the fabric skirt may be used to join the sockliner to other shoe components, as in a strobel-type seam.

A sole structure of an article of footwear is provided and includes a first midsole portion including a first sidewall and a second midsole portion including a second sidewall. The sole structure also includes a first sheet disposed between the first midsole portion and the second midsole portion and including a first surface and a second surface formed on an opposite side of the first sheet than the first surface. The first sheet includes one or more apertures extending through the first sheet from the first surface to the second surface. The first midsole portion and the second midsole portion are operably connected through the one or more apertures of the first sheet.

Footwear may comprise customizable support plates. Methods for customizing footwear comprising a support plate may comprise applying heat to the footwear article to raise a temperature of the support plate to less than the melt temperature of the composition of the support plate such that the support plate becomes non-rigid in a first state, applying force to the support plate in the first state to customize a shape of the support plate, allowing the footwear to cool such that the support plate is at a second state having a higher rigidity than the first state.

Footwear articles are disclosed herein. Footwear articles may be formed using a method comprising disposing uncured resin adjacent a mold, disposing a lattice structure in at least a portion of the uncured resin disposed adjacent the mold, closing the mold using a lasted upper, and injecting foam into the closed mold such that the foam operates to couple the lasted upper and the lattice structure together.

A method includes positioning a first polymer sheet on a substantially first flat surface of a tool, positioning a second polymer sheet on the first polymer sheet, and moving a second substantially flat surface of the tool into contact with the second polymer sheet. The method also includes maintaining a gap between the first polymer sheet and the second polymer sheet at a predetermined area and heating one of the two substantially flat surfaces of the tool to heat one of the first polymer sheet and the second polymer sheet. The method further includes joining the first polymer sheet and the second polymer sheet together at locations outside of the predetermined area to define a peripheral bond of the chamber.

The disclosed embodiments relate to portions of an article of footwear formed from an extruded member. In certain embodiments, a sole or portion of a sole can be formed from one or more extruded members. In certain embodiments, the extruded member can be a single, continuous piece of solid material. In certain embodiments, a sole for an article of footwear can be fashioned from an extruded member formed in a controlled geometric pattern. In certain embodiments, the sole can include one or more layers.

A sole structure for an article of footwear comprises a midsole including a polymeric bladder element enclosing a fluid-filled interior cavity, a first outsole component secured to a bottom surface and to a side surface of the polymeric bladder element, and a second outsole component. The first outsole component includes a first base, and a wall integral with the first base. The second outsole component includes a second base secured to the first base, and a wall integral with the second base and secured to the outer surface of the wall of the first outsole component. A method of manufacturing the article of footwear includes thermoforming the bladder element and the first outsole component, and securing the second outsole component to the first outsole component.

An article of footwear includes a strobel that has a polymeric bladder defining an interior cavity and configured to retain a fluid in the interior cavity. The polymeric bladder has a peripheral flange extending around at least a portion of a perimeter of the interior cavity. A tensile component is disposed in the interior cavity and is secured to opposing inner surfaces of the polymeric bladder. The peripheral flange defines a groove extending along the peripheral flange. The strobel also includes a lasting component configured to extend along the peripheral flange around the at least a portion of the perimeter of the interior cavity. The lasting component is secured to the peripheral flange. A method of manufacturing footwear that includes the strobel is disclosed.