In certain aspects, the inventive subject matter is directed to production of constructs of footwear and components thereof by jet extrusion. The inventive subject matter contemplates novel processes for making such constructs using jets or streams of materials that solidify as fibers, and which form into two- or three-dimensional webs as they are collected. The webs may be in the nature of films, membranes, or mats. In some embodiments, the inventive subject matter generally relates to nonwoven textiles consisting of webs of superfine fibers, i.e., fibers with diameters in nanoscale or micronscale ranges.

In certain aspects, the inventive subject matter is directed to production of constructs of footwear and components thereof by jet extrusion. The inventive subject matter contemplates novel processes for making such constructs using jets or streams of materials that solidify as fibers, and which form into two- or three-dimensional webs as they are collected. The webs may be in the nature of films, membranes, or mats. In some embodiments, the inventive subject matter generally relates to nonwoven textiles consisting of webs of superfine fibers, i.e., fibers with diameters in nanoscale or micronscale ranges.

An article of footwear flat pattern upper having an upper portion and a footbed portion is provided. The upper portion and the footbed portion are integrally continuous, such that the upper portion lateral side converges with the footbed lateral side. The flat pattern includes nested same-sided article of footwear with a reduced surplus portion there between. The articles of footwear includes the following continuous portions: the first medial side with a toe end, the toe end with a lateral side, the lateral side with a heel end, and the heel end with the second medial side. The first medial side and the second medial side are joined to form dimensional article of footwear.

An article of footwear flat pattern upper having an upper portion and a footbed portion is provided. The upper portion and the footbed portion are integrally continuous, such that the upper portion lateral side converges with the footbed lateral side. The flat pattern includes nested same-sided article of footwear with a reduced surplus portion there between. The articles of footwear includes the following continuous portions: the first medial side with a toe end, the toe end with a lateral side, the lateral side with a heel end, and the heel end with the second medial side. The first medial side and the second medial side are joined to form dimensional article of footwear.

An article of footwear flat pattern upper having an upper portion and a footbed portion is provided. The upper portion and the footbed portion are integrally continuous, such that the upper portion lateral side converges with the footbed lateral side. The flat pattern includes nested same-sided article of footwear with a reduced surplus portion there between. The articles of footwear includes the following continuous portions: the first medial side with a toe end, the toe end with a lateral side, the lateral side with a heel end, and the heel end with the second medial side. The first medial side and the second medial side are joined to form dimensional article of footwear.

An article of footwear flat pattern upper having an upper portion and a footbed portion is provided. The upper portion and the footbed portion are integrally continuous, such that the upper portion lateral side converges with the footbed lateral side. The flat pattern includes nested same-sided article of footwear with a reduced surplus portion there between. The articles of footwear includes the following continuous portions: the first medial side with a toe end, the toe end with a lateral side, the lateral side with a heel end, and the heel end with the second medial side. The first medial side and the second medial side are joined to form dimensional article of footwear.

Laser siping forms sipes in an article. The laser operates in a scan laser configuration for some sipe patterns and the laser operates in a fixed laser concept for other siping patterns. The article on which the sipes are formed is secured by a part holder. Movement of the part holder may be computer controlled. Movement of the laser may also be computer controlled. A movement of a reflective surface of the laser may be computer controlled. Together, the movement of the part holder, the laser, and the reflective surface is coordinated to achieve the scan laser configuration and the fixed laser configuration when forming sipes.

A process for fabricating shoes having an outer cork sole insert includes processing raw cork into sheets of predetermined thickness, adhering a thin fabric sheet to one side of the intermediate cork sheets, cutting out cork/fabric sole inserts and placing them into an injection mold, and cycling the plastic injection mold so as to form a cork insert into the plastic sole.

An article of footwear flat pattern upper having an upper portion and a footbed portion is provided. The upper portion and the footbed portion are integrally continuous, such that the upper portion lateral side converges with the footbed lateral side. The flat pattern includes nested same-sided article of footwear with a reduced surplus portion there between. The articles of footwear includes the following continuous portions: the first medial side with a toe end, the toe end with a lateral side, the lateral side with a heel end, and the heel end with the second medial side. The first medial side and the second medial side are joined to form dimensional article of footwear.

An article of footwear flat pattern upper having an upper portion and a footbed portion is provided. The upper portion and the footbed portion are integrally continuous, such that the upper portion lateral side converges with the footbed lateral side. The flat pattern includes nested same-sided article of footwear with a reduced surplus portion there between. The articles of footwear includes the following continuous portions: the first medial side with a toe end, the toe end with a lateral side, the lateral side with a heel end, and the heel end with the second medial side. The first medial side and the second medial side are joined to form dimensional article of footwear.