Systems and processes for thermoforming an article and for preparing an article for thermoforming are disclosed. The system for thermoforming can include one or more heating stations and a cooling station. The system for thermoforming can further include an article movement mechanism that can couple to an article and rotate the article inside a heating chamber, inside a cooling chamber, or both. The system for preparing an article for thermoforming can include a vessel that comprises a port, and a negative pressure generation system coupled to the port. The system for preparing an article for thermoforming can further include a compression material that forms an interior portion for receiving an article. The negative pressure generation system can cause the compression material to expand to allow for insertion of the article into the interior portion of the compression material.

A shoe includes a knit upper and a sole secured to the knit upper. The knit upper is formed with a first type of knit structure knitted with a thermoplastic yarn in a first area. The first area is in at least the toe region of the knit upper. In a second area including at least the medial and lateral metatarsal regions of the knit upper, the knit upper is formed with a second type of knit structure knitted with a second yarn having a higher melting temperature than the thermoplastic yarn. A rear boundary line of the first area and a forward boundary line of the second area define a boundary line between the first and second areas.

An article of footwear and method of manufacturing an article of footwear comprises an upper, a sole structure adjacent the upper and a thermoplastic material sheet attached to the upper to fixedly secure one or more components to the upper or fixedly secure the upper to a sole structure where the thermoplastic material sheet provides the primary or only means for securing the components to the upper and the upper to the sole structure.

A multi-layer decorating element includes a base and a plurality of plates forming decorative elements. The base has a length between the first and second ends thereof and an increased width from the first end to the second end. The first end of the base is curved. The second end of the base is divided by a gap into two segments. The gap has a closed end and an open end. The open end is disposed at the second end of the base. The closed end has a smaller width than the open end. The plurality of plates includes a side with a hot melt glue layer and is hot pressed on a side of the base. The plurality of plates is disposed within peripheral edges of the base and includes a plurality of overlapped sections. The plurality of plates has different shapes.

Upper components for footwear include: (a) a first upper component that includes a first layer having a first material as a first filament including first plural, non-intersecting, spaced apart path segments (wherein the first filament has a width dimension of less than 3 mm wide (and in some examples, less than 2 mm wide, less than 1.5 mm wide, less than 1 mm wide, or even less than 0.75 mm wide)); and (b) a second upper component including a fabric element formed at least in part of a fusible material, wherein the fusible material of the second upper component is fused to the first material of the first upper component (e.g., in an adhesive-free manner). Additional layers of material, including additional layers including filament and/or fabric elements, e.g., of the types described above, may be included in the upper.

A shoe including a sole and an upper. The upper is coupled to the sole. The upper includes an outer layer and an inner layer. The outer layer has an outer surface and an inner surface. The inner surface of the outer layer is in direct contact with the inner layer. The outer layer is a hot melt thermoplastic material, and the inner layer is a material different from that of the outer layer. At least a portion of the outer layer is adhered to the inner layer, and the inner layer including a portion not covered by the outer layer.

A three-dimensional flexing resistance waterproof and moisture-permeable shoe upper, including fabric, waterproof and moisture-permeable membrane, and eco-friendly adhesive is provided. The waterproof and moisture-permeable membrane is closely bonded with an inner layer of the fabric. The outer layer and inner layer of the fabric are closely bonded together through eco-friendly adhesive, which is bonded with the fabric in a mesh structure. The eco-friendly adhesive includes liquid adhesive or powder adhesive. The shoe upper is shaped by the heating method which includes vacuum heating, electric heating or steam heating. The outer layer of the fabric is closely bonded with the inner layer, so that the defects of the accumulation of sludge, dust and water droplets between the outer layer and the inner layer of the existing shoe upper is overcome, making the shoe upper waterproof and moisture permeable. The three-dimensional shoe upper is formed through vacuum forming method.

A manufacturing process involving a series of discrete operations can be modified by adding, removing, or reordering operations, without design changes to the equipment. The manufacturing process uses a frame comprising one or more alignment tabs. Each alignment tab comprises an alignment element. The alignment element interacts with a corresponding alignment element at a manufacturing station to identify to the manufacturing station the position and orientation of the frame. The frame supports a material in a known position and orientation relative to the frame, allowing the manufacturing station to infer the position and orientation of the pliable material on the frame from the interaction of the alignment elements on the frame and the manufacturing station. The operations at any particular manufacturing station can therefore be positioned independent of what operations, if any, have come before, or in what order.

An article of footwear and a method of manufacturing the same is provided. The article comprises an upper having an inner layer and an outer layer coupled to the inner layer, such that the inner layer and the outer layer define a closed pocket therebetween. An insert is disposed in the closed pocket. The outer layer is formed of an at least partially transparent material, such that the insert is at least partially visible through the outer layer. The method comprises placing the insert in a recess defined by the outer layer of the upper, such that the insert abuts an inner surface of the outer layer and positioning the inner layer on the inner surface of the outer layer over the recess and the insert, such that the inner layer and outer layer form the closed pocket at the recess with the insert disposed within the closed pocket.

A shoe having a shoe upper including multiple welds in selected locations on the shoe upper. The welds may be selectively located on the upper to provide structure and support to the specific portions of a shoe upper.