A sole for an article of footwear includes a continuous dispensed component forming a first layer and a second layer. The first layer is disposed directly on top of the second layer. The continuous dispensed component forms a medial sidewall and a lateral sidewall. The first layer includes a starting point where the continuous dispensed component is first dispensed. The continuous dispensed component continuously transitions from the first layer to the second layer at the starting point.

A thermoforming system for forming a cushioning pod structure that includes a first and a second thermoforming station with each comprised of a film holder and a thermoforming mold holder. The system implements a thermal source that is moveable between the first thermoforming station and the second thermoforming station such that the film holders are between the thermal source and the respective thermoforming mold holder. The system also relies on intentional application of a vacuum source fluidly coupled to thermoforming stations and a movement mechanism configured to move the thermal source between the first thermoforming station and the second thermoforming station. Additional aspects contemplate the implementation of a positive pressure source to aid in the dislodgment of the formed portion, a cooling system to adjust mold temperatures, and/or a fan to efficiently thermoform the component.

Methods for manufacturing articles of footwear are provided. In various aspects, the methods comprise utilizing additive manufacturing methods with foam particles. In some aspects, the additive manufacturing methods comprise increasing the temperature of a plurality of foam particles with actinic radiation under conditions effective to fuse a portion of the plurality of foam particles comprising one or more thermoplastic elastomers. Increasing the temperature of the foam particles can be carried out for one or multiple iterations. The disclosed methods can be used to manufacturer articles with sub-regions that exhibit differing degrees of fusion between the foam particles, thereby resulting in sub-regions with different properties such as density, resilience, and/or flexural modulus. This abstract is intended as a scanning tool for purposes of searching in the particular art and is not intended to be limiting of the present disclosure.

A shoe having a sole connected with a shoe upper part. The sole includes: a first sole part having a ground plate, wherein a plurality of first damping elements which extend in a direction of loading are integrally shaped at the ground plate, a second sole part having a cover plate, wherein a plurality of second damping elements which extend in the direction of loading are integrally shaped at the cover plate, a connection part which includes a plurality of interconnected plugin connections. Each plug-in connection has a first plug connector extending downwards in the direction of loading and a second plug connector extending upwards in the direction of loading. The first plug connection frictionally engages into the hollow-cylindrical section of the first damping element and wherein the second plug connection frictionally engages into the hollow-cylindrical section of the second damping element.

A sole structure for an article of footwear may have a midsole system that includes a sole plate having a forefoot region and a midfoot region. The sole plate may have a foot-facing surface and a ground-facing surface opposite to the foot-facing surface. The sole plate may define a through hole extending from the foot-facing surface to the ground-facing surface in the forefoot region. The through hole may be closer to a medial edge of the sole plate than to a lateral edge of the sole plate. The sole plate may have ridges extending longitudinally in the midfoot region and in the forefoot region. The ridges may have crests at least some of which may extend non-parallel with one another in a longitudinal direction of the sole plate.

A midsole for an article of footwear including a three dimensional mesh including interconnected unit cells and methods of making the same. The interconnected unit cells each include a plurality of struts defining a three dimensional shape. The interconnected unit cells are connected at nodes having a valence number defined by the number of struts connected at that node. The valence number of the nodes may vary to provide customized characteristics to zones or portions of the midsole. The plurality of interconnected unit cells may be organized in a warped cubic lattice structure. The warped cubic lattice structure and the size/shape of interconnected unit cells may vary to provide customized characteristics to zones or portions of the midsole. The three dimensional mesh may be customized based on a biometric data profile for an individual, or group of individuals. The midsole may be manufactured using an additive manufacturing process.

Provided is a shoe sole member partially or entirely made of a resin composite in which a plurality of resin foam particles, and one or a plurality of non-foamed elastic bodies having an initial elastic modulus at 23 C. being smaller than that of the resin foam particles are integrated together. Also provided is a shoe including the shoe sole member.

A puncture resistant material is made from high modulus continuous filament polypropylene yarns which are twisted and woven into a tight weave. Batting materials are placed adjacent the woven layer (which may comprise one or more individual woven layers) to form a stack and the stack is needlepunched to form a consolidated material. The material is heat treated and calendared and the finished product may be used in applications where puncture resistance is required, such as in a shoe insole material.

A sole structure for an article of footwear comprises a midsole having four stacked polymeric sheets bonded to one another to define a first cushioning layer, a second cushioning layer, and a third cushioning layer. Each cushioning layer comprises a sealed chamber retaining gas in isolation from each other sealed chamber. Bonds between adjacent ones of the sheets are arranged such that the third cushioning layer is stacked directly above the first cushioning layer with the second cushioning layer bordering both the first cushioning layer and the third cushioning layer, and the sealed chamber of the second cushioning layer includes a plurality of elongated segments each extending lengthwise across a longitudinal midline of the midsole at a respective acute angle to the longitudinal midline.

Orthotic sole devices, systems, methods, and computer readable media are for use with footwear. Three-dimensional scans are used to shape the devices to match the user's feet with the footwear. Each of the devices includes a sunken heel portion, a stopper portion, an arch portion, metatarsal pads, a bunion-cut out shape, and a built-in toe crest portion, all to help redistribute the user's weight away from their forefoot. The devices are infused with eucalyptus oils and silver ions. The devices are automatically manufactured via computer numerical control (CNC) software on a computer readable medium. Milling machines and 3D printers can be used in association with the systems, methods, and computer readable media.