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 includes an upper and a sole structure with a sole member. The sole member can be manufactured using a customized cushioning sole system. A user's foot morphology and/or preferences may be used to design the sole member. The sole member can include a set of pinpoint apertures that are formed along the outer surface of the sole member to form at least a first distribution of apertures associated with a first density and a second distribution of apertures associated with a second density, wherein the first density is greater than the second density.

A method of method of manufacturing customized inserts for a boot, such as a skate boot, that is at least partially thermoformable includes receiving numerical data corresponding to a tridimensional shape of a wearer’s foot, and manufacturing a medial side insert and a lateral side insert based on the tridimensional shape of the wearer’s foot. The medial side insert and the lateral side insert are shaped to be insertable into the boot with a core that is dimensioned to generally correspond to a foot size of the boot, with a medial internal surface of the medial side insert and a lateral internal surface of the lateral side insert abutting respective outer surfaces of the core.

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. The articles may include one or more reinforcements configured to provide added durability to various regions of the articles. In addition, the articles may be formed from two or more materials in a single rapid manufacturing process. The rapid manufacturing additive fabrication technique may also include using of varying intensities of the laser to fuse material to form the articles.

The invention relates to devices and methods for designing and manufacturing customized footwear, and components thereof. An example method includes a method of designing at least a portion of a sole of an article of footwear customized for a user. The method includes the steps of determining at least one input parameter related to a user, analyzing the at least one input parameter to determine at least one performance metric of a foot of the user, and determining at least one customized structural characteristic of at least a portion of a sole of an article of footwear for the user based on the performance metric.

A method and corresponding apparatus is disclosed for generating a digital last for the manufacture of a shoe for a person. The method comprises obtaining a predefined digital last, the predefined digital last comprising an axis relating to the shape of the last; obtaining data of a foot of the person; and modifying the obtained predefined digital last based on the obtained data, wherein modifying comprises at least one of translation and rotation of the axis.

The present invention is a system and method for identifying certain physical properties of human feet. The system uses electronic and optical elements to perform before and after pronation test and before and after arch tests (meaning before and after use of an orthotic), and develop a 360 degree, three-dimensional view of the foot.

An apparatus and method for determining contours of a patient's foot ankle and lower leg. The apparatus includes an alignment structure that orientates the foot for imaging. The alignment structure includes at least one support member that engages the plantar surface of the foot substantially only in the immediate area of the lateral metatarsal heads of the foot, preferably the fifth metatarsal head. The support generates a dorsally-directed force that locks the midtarsal joint. The alignment structure further includes a saddle that engages the rearfoot and a laser beam for aligning the second metatarsal head with the distal one-third of the lower leg to place the subtalar joint in a neutral condition. The foot is thus suspended in space such that imaging is able to produce an accurate measurement of the subject areas of the foot, ankle and lower leg without distortion of the soft tissues or bone structure.

Method and system of virtual fitting a foot with a shoe by obtaining a first and second 3D model associated with the surface of the foot and interior cavity of the shoe, respectively, each 3D model comprising a point cloud; aligning the point clouds such that the heel extreme point of the two point clouds align and the ankle back extreme point of the first point cloud aligns with the top back point of the second point cloud; calculating for at least one point p in the first point cloud a value of at least one fit indicator determined based on a distance between p and a corresponding point q in the aligned second point cloud; and outputting, to a display device, a graphical representation of the first 3D model colored in accordance with the fit calculated at p.

A method is provided for making footwear utilizing a spray-on material. The method can include spraying a spray-on fabric onto surfaces of a three dimensional last. The last can be produced using additive manufacturing techniques, such as 3D printing, based on data corresponding to dimensions and contours of a consumer's foot, and/or preselected aesthetic footwear designs. The spray-on fabric is sprayed onto the surfaces of the last and allowed to cure to form a flexible, non-woven fabric upper. The upper can be removed from the last and turned inside out. With the upper turned inside out, a sole can be joined to the fabric upper to form the footwear.