A method includes compressing a non-dielectric, elastically-deformable component, a wire mesh component, and a dielectric, contoured object between first and second forming tools. Once the components are compressed, radio frequency energy is supplied to the first forming tool, thereby causing a radio frequency electromagnetic field to be generated between the first forming tool and the wire mesh component that results in a contoured weld of the contoured object. A tooling assembly is configured to carry out the method.

In some embodiments, a method of forming a bonded assembly includes: providing a first object comprising a first surface having a plurality of locking orifices formed therein, each of the plurality of locking orifices including an opening on the surface of the object and a cavity extending in the first object; positioning an adhesive on at least one of the first surface of the first object and a second surface on a second object; positioning the first surface of the first object on the second surface of the second object with the adhesive between the first and second surfaces; and curing the adhesive to form the bonded assembly.

Various articles, such as footwear, apparel, athletic equipment, watchbands, and the like, and methods of forming those articles are presented. The articles are generally formed, in whole or in part, using rapid manufacturing techniques, such as laser sintering, stereolithography, solid deposition modeling, and the like. The use of rapid manufacturing allows for relatively economical and time efficient manufacture of customized articles. Portions of the articles may be manufactured using rapid manufacturing and those portions may be joined with portions formed using conventional, non-rapid manufacturing techniques. The methods may also include performing a scan of an appropriate body part of a user, such as a foot, in order to create a customized article of footwear for the user.

Manufacturing and assembly of a shoe or a portion of a shoe is enhanced by automated placement and assembly of shoe parts. For example, a part-recognition system analyzes an image of a shoe part to identify the part and determine a location of the part. Once the part is identified and located, the part can be manipulated by an automated manufacturing tool.

Cutting of a material, such as a textile or film, can damage the material. A tool is provided that utilizes vacuum pressure near a knife edge to increase a result of the cut. The vacuum pressure passes through a base portion of the tool that has a recessed portion effective to distribute vacuum pressure to one or more apertures extending around an insert of a core portion. The one or more apertures align with a void between the knife edge and the insert allowing for the void to transmit the vacuum pressure through the tool to the knife edge. A machine horn may then cut the material at the knife edge and couple the material with another material.

Aspects relate to systems, methods, and apparatus for a manufacturing tool. The manufacturing tool is comprised of a vacuum tool and an ultrasonic welder as a unified manufacturing tool. The manufacturing tool may be used to pick and position a manufacturing part that is then welded with the associated ultrasonic welder.

A method of forming a printed structure is disclosed. The method may include printing layers of a printed structure and incorporating an element within the printed structure. The element may be removed in order to form tunnels within the printed structure. In some embodiments the element may be removed and reused in the formation of additional printed structures. The element may also be retained to form a composite printed structure.

Methods and systems are provided for color printing. A three-dimensional object can be printed onto an article using the methods and systems. The three-dimensional object can include a lower color graphic layer printed onto an article, one or more transparent structural layers printed onto the lower color graphic layer, and an upper color graphic layer printed onto an uppermost layer of the one or more transparent structural layers. The upper color graphic layer and the lower color graphic layer collectively visually depict a color graphic image.

Various articles, such as footwear, apparel, athletic equipment, watchbands, and the like, and methods of forming those articles are presented. The articles are generally formed, in whole or in part, using rapid manufacturing techniques, such as laser sintering, stereolithography, solid deposition modeling, and the like. The use of rapid manufacturing allows for relatively economical and time efficient manufacture of customized articles. Portions of the articles may be manufactured using rapid manufacturing and those portions may be joined with portions formed using conventional, non-rapid manufacturing techniques. The methods may also include performing a scan of an appropriate body part of a user, such as a foot, in order to create a customized article of footwear for the user.

Manufacturing and assembly of a shoe or a portion of a shoe is enhanced by automated placement and assembly of shoe parts. For example, a part-recognition system analyzes an image of a shoe part to identify the part and determine a location of the part. Once the part is identified and located, the part can be manipulated by an automated manufacturing tool.