A last for forming an upper of an article of footwear includes an exterior surface, where the exterior surface includes a plurality of three dimensional structural surface components disposed over at least 50% of the exterior surface of the last.

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.

A last for forming an upper of an article of footwear includes a first portion including a lateral side and a medial side that opposes the lateral side, and a second portion connected with and extending upward and transversely outward in an angled manner away from the first portion such that a terminal end of the second portion is distanced from the first portion. An exterior surface of the last can include a plurality of three dimensional structural surface components disposed over at least 50% of the exterior surface of the last.

A method of forming an upper for an article of footwear includes providing a first material layer over a shoe last, providing a second material layer over the first material layer such that the first and second material layers adhere to each other at an interface between the first and second material layers, where one or both of the first material layer and second material layer is provided by spray forming a polymer material onto the last. The material layers are removed from the last and turned inside out such that the first material layer includes an exposed surface that forms an exterior surface of the upper.

A method of forming an upper for an article of footwear includes providing a first material layer over a shoe last, providing a second material layer over the first material layer such that the first and second material layers adhere to each other at an interface between the first and second material layers, where one or both of the first material layer and second material layer is provided by spray forming a polymer material onto the last. The material layers are removed from the last and turned inside out such that the first material layer includes an exposed surface that forms an exterior surface of the upper.

A method for assembling shoe components includes the steps of: providing at least two shoe components, a shoe last and a film unit; placing the at least two shoe components on an outer surface of the shoe last; removably covering an assembly of the at least two shoe components and the shoe last with the film unit such that the film unit and the shoe last cooperatively define a confining space therebetween; and pumping air out of the confining space and heating the at least two shoe components to shrink and deform the film unit so as to press the at least two shoe components to adhere tightly to each other.

An apparatus for making an article of footwear is provided. The apparatus may include a last shaped to resemble a human foot and being formed at least in part from a susceptor material that is thermally reactive to an electromagnetic field. The apparatus may also include an induction coil disposed proximate to the last and configured to produce an electromagnetic field that causes the susceptor material in the last to increase in temperature by induction heating.

A last for forming an upper of an article of footwear includes an exterior surface, where the exterior surface includes a plurality of three dimensional structural surface components disposed over at least 50% of the exterior surface of the last.

A method for assembling shoe components includes the steps of: providing at least two shoe components, a shoe last and a film unit; placing the at least two shoe components on an outer surface of the shoe last; removably covering an assembly of the at least two shoe components and the shoe last with the film unit such that the film unit and the shoe last cooperatively define a confining space therebetween; and pumping air out of the confining space and heating the at least two shoe components to shrink and deform the film unit so as to press the at least two shoe components to adhere tightly to each other.

A method for assembling shoe components includes the steps of: providing at least two shoe components, a shoe last and a film unit; placing the at least two shoe components on an outer surface of the shoe last; removably covering an assembly of the at least two shoe components and the shoe last with the film unit such that the film unit and the shoe last cooperatively define a confining space therebetween; and pumping air out of the confining space and heating the at least two shoe components to shrink and deform the film unit so as to press the at least two shoe components to adhere tightly to each other.