An upper may include a plurality of knit elements linked together by a molded thermoplastic polymer element comprising a thermoplastic polymer, each of the knit elements being discrete, where each of the knit elements comprises a border that is at least partially surrounded by the molded thermoplastic polymer element. Further, an article of footwear may include a plurality of knit elements linked together by a molded thermoplastic polymer element comprising a thermoplastic polymer, each of the knit elements being discrete, where each of the knit elements comprises a border that is at least partially surrounded by the molded thermoplastic polymer element.

An article of footwear can include a sole structure, an upper, and a printed layer. The upper can be coupled to the sole structure. The printed layer can be disposed on the upper and include a plurality of printed materials each having a different hardness than an adjacent printed material. The plurality of printed materials can be arranged on the upper such that a stiffness of the upper is gradated from a toe portion of the upper to a heel portion of the upper, and a stiffness of the heel portion is greater than a stiffness of the toe portion.

An article of apparel can include a layer disposed on the article of apparel, where the layer includes a plurality of materials each having a different hardness than an adjacent material. The plurality of materials is arranged on the article of apparel such that a stiffness of the article of apparel is gradated along a length of the article of apparel from a first portion to a second portion of the article of apparel. A stiffness of the second portion is greater than a stiffness of the first portion and the layer has a continuous and even gradation that extends along the entire length of the article of apparel.

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.

A method for manufacturing an upper for an article of footwear includes: forming a foam layer; forming a preliminary upper by laminating an outer layer, an inner layer, and the foam layer intermediate to the outer layer and the inner layer; and molding the preliminary upper to a shape having a contour to substantially fit at least a portion of a foot to provide at least a portion of an upper for an article of footwear.

An article of footwear can include a sole structure, an upper, and a printed layer. The upper can be coupled to the sole structure. The printed layer can be disposed on the upper and include a first printed material and a second printed material. The first printed material can have a plurality of spaced-apart first segments and have a first hardness. The second printed material can have a plurality of spaced-apart second segments and have a second hardness that is less than the first hardness of the first printed material. Each of the second segments can be disposed adjacent to one or more of the first segments.

Systems and processes for thermoforming an article are disclosed. The system can include a first heating station that can include a first heating zone and a second heating zone. The system can further include a first cooling station for reducing the temperature of the heated article to a range of about 50 C. to about 70 C. while exposing the article to atmospheric pressure. The system can also include a second cooling station that can expose an article to a pressure above atmospheric pressure.

Safety footwear, a metatarsal guard for safety footwear, and a method for manufacturing a metatarsal guard comprising: a guard body sized and shaped to cover at least partially a dorsal surface of a wearer's foot, the guard body including: a shielding layer made of a rigid material, the shielding layer further including a first bonding surface; an extension panel extending forwardly from the guard body, the extension panel including a second bonding surface, the extension panel being disposed against the shielding body such that the first and second bonding surfaces are superposed over each other, the extension panel being overmolded over the shielding layer such that the extension panel is bonded with the shielding layer along the superposed first and second bonding surfaces.

An upper for an article of footwear, the upper including a base layer defining a least a portion of the upper and polymer threads stitched to the base layer. The polymer threads may include a core composed of a first material and a coating composed of a second material, where the melting point of the first material is higher than the melting point of the second material. The polymer threads may be bonded to the base layer by the coating of the polymer threads. The polymer threads may include one or more polymer thread sets stitched in pattern(s) on area(s) of an outer surface of the base layer to provide targeted characteristics to area(s) on the upper. In some embodiments, the polymer threads may be bonded to the base layer with heat and/or pressure.

Described are methods for the manufacture of a plurality of shoes, an apparatus to perform such method, as well as shoes manufactured by such method. According to certain examples, the method for the manufacture of a plurality of shoes includes providing a plurality of first shoe components for the manufacture of the plurality of shoes, and moving the plurality of first shoe components with a transport means which is at least partially comprised of the plurality of first shoe components.