A system including an injector, a press, and a robotic conveyance is used to form a physically foamed article of footwear component from a single-phase solution of a polymeric composition and a supercritical fluid. The parameters and features of the system are configured for the formation of the footwear component in an automated manner with enhanced throughput by the system.

Tooling and components of an injection-molding system may be used to mold a foam article. The tooling and components may include features that control parameters of the injection-molding and foaming process, such as temperature, pressure, shot size, shot placement, and the like.

Tooling and components of an injection-molding system may be used to mold a foam article. The tooling and components may include features that control parameters of the injection-molding and foaming process, such as temperature, pressure, shot size, shot placement, and the like.

Mold including a first shell having a cavity, a second shell having a projection, and an intermediate shell having a projection suitable for being coupled in the cavity of the first shell and a cavity suitable for being coupled with the projection of the second shell. The second shell includes a first injection channel extending from an inlet hole in a side wall of the second shell to an outlet hole in the projection of the second shell. The intermediate shell has a second injection channel extending from an inlet hole in a side wall of the intermediate shell to an outlet hole in the projection of the intermediate shell.

A system including an injector, a press, and a robotic conveyance is used to form a physically foamed article of footwear component from a single-phase solution of a polymeric composition and a supercritical fluid. The parameters and features of the system are configured for the formation of the footwear component in an automated manner with enhanced throughput by the system.

A mould for manufacturing three-dimensional items, comprising a body; a lid configured to close the body; and incorporated closing and openings configured to keep the body and the lid joined during the movement thereof is disclosed. A machine for manufacturing three-dimensional items, comprising a receiving module configured to receive the mould; a conditioning module configured to receive the mould from the receiving module and act on the incorporated closing and openings in order to separate the lid from the body; and a handling module configured to receive the body from the conditioning module and enable the placement of the components of the item to be manufactured. A method for manufacturing three-dimensional items and manufacturing plant associated with the machine.

A foam article, such as a cushioning element for an article of footwear, apparel or sporting equipment is provided that comprises a foam component, such as a midsole, having a number of beneficial physical characteristics. The cushioning element is a low-density foamed component with a surface skin that encases the remaining foam volume. The cushioning element has a number of foam volumes, arranged to achieve a more consistent foam component. Additionally, the cushioning element includes a series of concentric ridges extending radially outwardly from injection gate vestige locations, and a number of striation bands near the perimeter of the cushioning element. The location of the gate vestiges can be beneficially arranged to produce intersecting flow boundaries that are located away from key strain areas of the cushioning element. The cushioning element is more environmentally-friendly, requiring less energy to produce while still providing acceptable energy return and low density.

A mold device includes first and second molds matched and engaged with each other at first and second curved major surfaces thereof to define a cavity between first and second matched portions. The molds respectively have first and second step portions surrounding the matched portions and spaced apart from the major surfaces in a height direction so as to define an air venting channel that is in air communication with the cavity and the ambient air. With such construction, the mold device is easy to fabricate and has a fewer number of components, thereby simplifying the manufacturing process and reducing the manufacturing cost.

Physical foaming a footwear component with a single-phase solution of a polymeric composition and a supercritical fluid is provided. The method include temperature conditioning a mold and then engaging the mold with a robot that conveys the mold to a press. At the press a gas counter pressure is applied to a cavity of the mold before injecting a single-phase solution of a polymeric composition and a supercritical fluid into the cavity of the mold. The process continues with releasing the gas counter pressure from the cavity of the mold and then removing the footwear component from the cavity of the mold. The parameters of the method are configured for the formation of the footwear component in an automated manner.

A foam article, such as a cushioning element for an article of footwear, apparel or sporting equipment is provided that comprises a foam component, such as a midsole, having a number of beneficial physical characteristics. The cushioning element is a low-density foamed component with a surface skin that encases the remaining foam volume. The cushioning element has a number of foam volumes, arranged to achieve a more consistent foam component. Additionally, the cushioning element includes a series of concentric ridges extending radially outwardly from injection gate vestige locations, and a number of striation bands near the perimeter of the cushioning element. The location of the gate vestiges can be beneficially arranged to produce intersecting flow boundaries that are located away from key strain areas of the cushioning element. The cushioning element is more environmentally-friendly, requiring less energy to produce while still providing acceptable energy return and low density.