In at least some embodiments, an orthotic footbed assembly includes a three-dimensional footbed that closely approximates a size and configuration of a particular foot and at least one orthotic feature additively coupled to the three-dimensional footbed. In at least some other embodiments, a method of making the orthotic footbed assembly includes direct printing of orthotic features onto a 3-D footbed. Another method includes indirect printing of orthotic features and applying these features onto to a 3-D footbed. And yet another method includes direct printing of orthotic features onto a 2-D blank footbed and then conducting a three-dimensional forming operation to make the orthotic footbed assembly.

In a method for adapting a thermally deformable item of clothing to a body part, the item is at least partially heated and brought into contact with an abutment region and the appropriate body part. The item of clothing has a side which, in the use position, is directed towards the body and a side which, in the use position, is directed away from the body. At least one pressure-exerting unit subjects that side of the item of clothing which is directed away from the body, at least in part, to a shaping pressure such that the at least partially heated item of clothing is adapted, at least in part, to the shape of the part of the body. The item of clothing is at least partially cooled by a cooling unit such that it is stabilized in the shape adapted to the part of the body.

In a method for adapting a thermally deformable item of clothing to a body part, the item is at least partially heated and brought into contact with an abutment region and the appropriate body part. The item of clothing has a side which, in the use position, is directed towards the body and a side which, in the use position, is directed away from the body. At least one pressure-exerting unit subjects that side of the item of clothing which is directed away from the body, at least in part, to a shaping pressure such that the at least partially heated item of clothing is adapted, at least in part, to the shape of the part of the body. The item of clothing is at least partially cooled by a cooling unit such that it is stabilized in the shape adapted to the part of the body.

A flat foot orthosis has two bodies and a pelvis portion. Each one of the two bodies has a wearing space, a foot portion, an ankle portion, a shank portion, a knee portion, a thigh portion, a toe portion, a hallux valgus region, a substrate, a first elastomer, and a second elastomer. The substrate and the first elastomer are disposed adjacent to each other, and surround the wearing space. The substrate extends from the toe portion to the thigh portion. The first elastomer spirally extends from an instep of the foot portion to the thigh portion through the rest. The two first elastomers surround and fetter where the wearer's pelvis and the wearer's waist meet. The second elastomer extends from the hallux sheath, is connected to the first elastomer, and wraps over the hallux valgus region.

A flat foot orthosis has two bodies and a pelvis portion. Each one of the two bodies has a wearing space, a foot portion, an ankle portion, a shank portion, a knee portion, a thigh portion, a toe portion, a hallux valgus region, a substrate, a first elastomer, and a second elastomer. The substrate and the first elastomer are disposed adjacent to each other, and surround the wearing space. The substrate extends from the toe portion to the thigh portion. The first elastomer spirally extends from an instep of the foot portion to the thigh portion through the rest. The two first elastomers surround and fetter where the wearer's pelvis and the wearer's waist meet. The second elastomer extends from the hallux sheath, is connected to the first elastomer, and wraps over the hallux valgus region.

The present invention describes a shaped footwear device intended to be used as a supportive insole or orthotic and a system and methods for making the same. The footwear device includes a top foam layer, a light-cured composite material layer, and a bottom textile layer. The footwear device is created by conforming a pre-cured insole assembly to the plantar surface of a foot or foot mold and then exposing the pre-cured insole assembly to light to create a shaped footwear device with a light-cured composite material support plate.

In at least some embodiments, an orthotic footbed assembly includes a three-dimensional footbed that closely approximates a size and configuration of a particular foot and at least one orthotic feature additively coupled to the three-dimensional footbed. In at least some other embodiments, a method of making the orthotic footbed assembly includes direct printing of orthotic features onto a 3-D footbed. Another method includes indirect printing of orthotic features and applying these features onto to a 3-D footbed. And yet another method includes direct printing of orthotic features onto a 2-D blank footbed and then conducting a three-dimensional forming operation to make the orthotic footbed assembly.

An article of footwear including an upper, a midsole, a lateral stabilizing rail, and a medial stabilizing rail. The lateral stabilizing rail may be coupled to the upper and the midsole and extend from a forefoot portion of the article of footwear to a heel portion of the article of footwear. The medial stabilizing rail may be coupled to the upper and the midsole and extend from the forefoot portion of the article of footwear to the heel portion of the article of footwear. The lateral stabilizing rail and the medial stabilizing rail may be separate pieces capable deforming independently of each other.

An article of footwear including an upper, a midsole, a lateral stabilizing rail, and a medial stabilizing rail. The lateral stabilizing rail may be coupled to the upper and the midsole and extend from a forefoot portion of the article of footwear to a heel portion of the article of footwear. The medial stabilizing rail may be coupled to the upper and the midsole and extend from the forefoot portion of the article of footwear to the heel portion of the article of footwear. The lateral stabilizing rail and the medial stabilizing rail may be separate pieces capable deforming independently of each other.

Designs and compositions of insoles for footwear are described herein. The insoles may be customized for a given foot. In some examples, the insole (100) includes a base comprising a variable thickness component (205), a directional stiffness component, a stability component, and a reinforcement component. The base may be a single composition that is manufactured using additive manufacturing techniques.