An article of footwear and a method of manufacturing the same is provided. The article comprises an upper having an inner layer and an outer layer coupled to the inner layer, such that the inner layer and the outer layer define a closed pocket therebetween. An insert is disposed in the closed pocket. The outer layer is formed of an at least partially transparent material, such that the insert is at least partially visible through the outer layer. The method comprises placing the insert in a recess defined by the outer layer of the upper, such that the insert abuts an inner surface of the outer layer and positioning the inner layer on the inner surface of the outer layer over the recess and the insert, such that the inner layer and outer layer form the closed pocket at the recess with the insert disposed within the closed pocket.

The present invention discloses a method for manufacturing an artificial leather shoe upper which comprises steps of preparing plural pieces of artificial leather upper material, setting a thermoforming machine, placing the plural pieces of artificial leather upper material in the thermoforming machine, pumping out excess air of a lower die block of the thermoforming machine, thermoforming the plural pieces of artificial leather upper material to obtain a semi-finished product, and demoulding, image recognition, laser cutting and coloring the semi-finished product to obtain the artificial leather shoe upper.

A last system and a method of making the last system are disclosed. The last system includes a last member and an exterior layer. The exterior layer becomes deformable when heated above a characteristic temperature. The method can include forming a braided footwear component on the last system. The exterior layer may be joined with the braided footwear component by heating the last system above the characteristic temperature.

A last for forming an upper of an article of footwear includes an exterior surface, where the exterior surface includes a plurality of three dimensional structural surface components disposed over at least 50% of the exterior surface of the last.

A method of manufacturing a non-woven fabric includes the steps of: (a.) providing a substrate, wherein the substrate is air permeable in at least a portion of its surface; (b.) providing a fiber transfer device adapted to transfer fibers onto the substrate; (c.) transferring a first plurality of fibers onto the substrate; and (d.) applying a pressure differential to the air permeable portion of the substrate, wherein the strength of the pressure differential is varied across the surface of the substrate.

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.

A footwear assembly having an upper that comprises a neoprene sock with a foot portion integrally connected to a leg portion. The foot portion has heel, vamp and under-foot portions. The leg portion has front shin, side wall, and rear calf-side portions. The upper has a unitary, outer, injection molded layer molded directly onto the foot and shin portions of the neoprene sock, while the sidewall and rear calf-side portions remain substantially uncovered by the injection molded layer. The injection molded layer encases the foot portion of the neoprene sock. The injection molded layer on the shin portion defines a shin guard portion having a necked down area integrally connected to the injection molded layer at the vamp portion, wherein the shin guard extends upwardly from the necked-down portion in an outwardly diverging shape away from the vamp.

A last system and a method of making the last system are disclosed. The last system includes a last member and an exterior layer. The exterior layer becomes deformable when heated above a characteristic temperature. The method can include forming a braided footwear component on the last system. The exterior layer may be joined with the braided footwear component by heating the last system above the characteristic temperature.

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.

A method of manufacturing a shoe component may include injecting a material into a mold cavity to create a thin sheet of molded material formed as a single piece with molded holes extending through the molded material and formed as part of the injection molding process. The thin sheet of molded material may be in a shape that can be secured together to form a shoe upper including a vamp, a medial portion, and a lateral portion. The method may include removing, from the mold cavity, the sheet of molded material, folding the sheet of molded material, optionally cementing a first portion of the sheet of molded material to a second portion of the sheet of molded material, and cementing a third portion of the sheet of molded material to a sole to form a shoe. The completed shoe may also include an insole, a tongue, and laces.