A wearable article such as an article of athletic gear (e.g., a skate, an article of protective athletic equipment such as a helmet, etc.) wearable by a user and comprising an expandable user-engaging structure that is configured to be expanded (e.g., by heat or another stimulus) after manufacturing of the wearable article to conform it to the user or otherwise improve a fit of the wearable article on the user.

A method of forming a castless orthotic for a patient's foot in need thereof. The method comprises preparing an orthotic template for the foot wherein the template extends between a heel end and a toe end. In preparing the template the steps of attaching a three-quarter length or full length upper thermoplastic material to a or three-quarter length lower thermoplastic material, or providing a thermoplastic material having a variable thickness such that said thickness decreases from said heel end to said toe end is provided. Then attaching an outer lower layer to the lower thermoplastic material and attaching an outer upper layer to the upper thermoplastic material, or attaching an outer layer to each face of the variable thickness thermoplastic material and heating the prepared orthotic template for a predetermined period of time at a predetermined temperature to soften the orthotic template. A wrap is then placed on top of the foot foam and the foot of the patient is placed on top of the wrap and foot foam. The patient's foot is lifted and the heated orthotic template is placed on top of the the wrap and then placing the patient's foot on top of the heated orthotic template. The wrap is placed about the longitudinal axis of the foot to retain the heated orthotic template intermediate the sole of the foot and the foot foam whereby the sides of the orthotic template are particularly supported by the wrap. The method further includes ensuring the foot is positioned over a cuboid support and a medial longitudinal arch support wherein the cuboid support is disposed on the outside of the bottom of the foot and the cuboid support is moved to push the foot upwardly until a resistance is felt, and where the foot is also positioned over the medial longitudinal arch support which is then pushed and pulled upwardly until the foot is moved into a neutral position or if it is unable to be translated or rotated due to until it reaches its end range of motion. At this time, the heel of the patient's foot is lifted to place their weight substantially on the front of their foot and a coolant is applied to at least the heel end of the orthotic template.

Disclosed are systems, methods, and devices related to an adjustable arch support system. The adjustable arch support system enables selective adjustment of a component useful in supporting the arch. The system may comprise an insole, an outer shell positioned within the insole, and an inner shell positioned below the outer shell. The inner shell is attached to an adjustment system that controls an area of contact between the inner shell and the outer shell, where the adjustment system includes a gear and track system.

Disclosed are systems, methods, and devices related to an adjustable arch support system. The adjustable arch support system enables selective adjustment of a component useful in supporting the arch. The system may comprise an insole, an outer shell positioned within the insole, and an inner shell positioned below the outer shell. The inner shell is attached to an adjustment system that controls an area of contact between the inner shell and the outer shell, where the adjustment system includes a gear and track system.

A steaming apparatus for an article of footwear includes a steaming chamber adjoined to a plurality of wing portions. The steaming apparatus is configured to accommodate a steam source. The apparatus also includes provisions for securing the article of footwear within the steaming chamber such that a majority of the upper is subjected to steam. Articles of footwear may be placed in the steaming system to help customize the articles of apparel for a user's fit and comfort.

Disclosed embodiments relate to a footwear system. The footwear system includes a shoe, a first insole, and a second insole. The first insole is a fitting insole having a first volume. It is positioned within the shoe during a fitting of a potential wearer of the shoe. The fitting insole is removed after the fitting is completed. The second insole has a volume substantially similar to the first volume. The second insole adapted for positioning within the shoe if the first insole demonstrates an appropriate fit. The second insole is self-customizable and further adapted to conform to the imprint of the sole of the potential wearer.

Disclosed embodiments relate to a footwear system. The footwear system includes a shoe, a first insole, and a second insole. The first insole is a fitting insole having a first volume. It is positioned within the shoe during a fitting of a potential wearer of the shoe. The fitting insole is removed after the fitting is completed. The second insole has a volume substantially similar to the first volume. The second insole adapted for positioning within the shoe if the first insole demonstrates an appropriate fit. The second insole is self-customizable and further adapted to conform to the imprint of the sole of the potential wearer.

A footwear construction including a support cage that wraps an upper to provide an adaptive fit to accommodate a variety of foot shapes and to adapt to changes in foot shape during a gait cycle, while providing exceptional stability and support. The footwear can include an upper, a support cage and a sole assembly. The upper can be joined with the sole assembly and can include an exterior. The sole assembly can define a recess extending across a width of the sole assembly from a medial side to a lateral side. The support cage can be constructed from a semi-rigid but flexible polymeric material, disposed over the exterior of the upper and free floating relative to the exterior of the upper. The support cage can include a sole bridge that extends transverse to a longitudinal axis of the footwear, through the recess defined by the sole assembly.

A footwear construction including a support cage that wraps an upper to provide an adaptive fit to accommodate a variety of foot shapes and to adapt to changes in foot shape during a gait cycle, while providing exceptional stability and support. The footwear can include an upper, a support cage and a sole assembly. The upper can be joined with the sole assembly and can include an exterior. The sole assembly can define a recess extending across a width of the sole assembly from a medial side to a lateral side. The support cage can be constructed from a semi-rigid but flexible polymeric material, disposed over the exterior of the upper and free floating relative to the exterior of the upper. The support cage can include a sole bridge that extends transverse to a longitudinal axis of the footwear, through the recess defined by the sole assembly.

A customizeable footbed, a self-customizing footwear having a customizable footbed, and a method for customizing a footbed to conform to contours of a foot is provided. The customizable footbed may include a plurality of packets, each packet comprising an exterior membrane defining a chamber therein, and an interior filling within the chamber. The interior filling may be selected from a group consisting of two or more components of a curable material that chemically react upon mixing of the components to irreversibly form a solid or semi-solid resin or a gel. The plurality of packets may be configured to burst upon application of a pressure such that the interior fillings of the packets flow into and mix within the intermediate space.