A foam article, such as a cushioning element for an article of footwear, apparel or sporting equipment is provided that comprises a foam component, such as a midsole, having a number of beneficial physical characteristics. The cushioning element is a low-density foamed component with a surface skin that encases the remaining foam volume. The cushioning element has a number of foam volumes, arranged to achieve a more consistent foam component. Additionally, the cushioning element includes a series of concentric ridges extending radially outwardly from injection gate vestige locations, and a number of striation bands near the perimeter of the cushioning element. The location of the gate vestiges can be beneficially arranged to produce intersecting flow boundaries that are located away from key strain areas of the cushioning element. The cushioning element is more environmentally-friendly, requiring less energy to produce while still providing acceptable energy return and low density.

The present disclosure describes molded footwear including a sole integrally connected to an upper. For example, a sole structure may include an insole and a strobel board. The insole may include a spacing structure that rests on a top surface of the strobel board to form a cavity between the insole and the strobel board. Further, the upper and/or strobel board may include perforations at least partially aligned with the cavity. Accordingly, the sole structure may be connected to the upper via injection molding material into the cavity formed between the insole, the strobel board, and the upper. The molding material may flow through the specifically located perforations in the shoe's upper and/or the shoe's strobel board such that the material bonds internally within the cavity, internally within the perforations, and externally to the shoe's upper and strobel board but within the mold cavity.

The invention relates to a mould (1) for manufacturing three-dimensional items, comprising a body (2); a lid (4) configured to close said body (2); and incorporated closing and opening means (5) configured to keep the body (2) and the lid (4) joined during the movement thereof. A machine (M1) for manufacturing three-dimensional items, comprising a receiving module (M2) configured to receive the mould (1); a conditioning module (M3) configured to receive the mould (1) from the receiving module (M2) and act on the incorporated closing and opening means (5) in order to separate the lid (4) from the body (2); and a handling module (M4) configured to receive the body (2) from the conditioning module (M3) and enable the placement of the components of the item to be manufactured. A method for manufacturing three-dimensional items and manufacturing plant associated with said machine (M1).

The invention relates to a method for manufacturing a shoe part by injection molding a material into a mold where an insert is placed. The insert comprises at least two separable insert parts, an upper insert part and a lower insert part, providing an injection channel in the region of the separation area between the two parts. The insert is placed in the chamber and the injection material is injected through a sprue channel in the mold into the injection channel and into a cavity, whereby the shoe part is formed. The mold is opened after the injection material has cured and the insert is separated into the upper and lower insert parts, thereby exposing the cured material in the injection channel.

Embodiments herein disclose a primary sole part (10) having a foot facing surface (11) and a ground facing surface (12). The primary sole part (10) comprises a plurality of through-going holes (14), wherein the plurality of through-going holes extends in a vertical direction from the foot facing surface (11) to the ground facing surface (12). The foot facing surface (11) is configured to receive an injected sole material for attaching the primary sole part to a ground facing surface (12) of an upper (1).

Footwear articles are disclosed herein. Footwear articles may be formed using a method comprising disposing uncured resin adjacent a mold, disposing a lattice structure in at least a portion of the uncured resin disposed adjacent the mold, closing the mold using a lasted upper, and injecting foam into the closed mold such that the foam operates to couple the lasted upper and the lattice structure together.

Physical foaming a footwear component with a single-phase solution of a polymeric composition and a supercritical fluid is provided. The method include temperature conditioning a mold and then engaging the mold with a robot that conveys the mold to a press. At the press a gas counter pressure is applied to a cavity of the mold before injecting a single-phase solution of a polymeric composition and a supercritical fluid into the cavity of the mold. The process continues with releasing the gas counter pressure from the cavity of the mold and then removing the footwear component from the cavity of the mold. The parameters of the method are configured for the formation of the footwear component in an automated manner.

A system including an injector, a press, and a robotic conveyance is used to form a physically foamed article of footwear component from a single-phase solution of a polymeric composition and a supercritical fluid. The parameters and features of the system are configured for the formation of the footwear component in an automated manner with enhanced throughput by the system.

The present disclosure describes molded footwear including a sole integrally connected to an upper. For example, a sole structure may include an insole and a strobel board. The insole may include a spacing structure that rests on a top surface of the strobel board to form a cavity between the insole and the strobel board. Further, the upper and/or strobel board may include perforations at least partially aligned with the cavity. Accordingly, the sole structure may be connected to the upper via injection molding material into the cavity formed between the insole, the strobel board, and the upper. The molding material may flow through the specifically located perforations in the shoe's upper and/or the shoe's strobel board such that the material bonds internally within the cavity, internally within the perforations, and externally to the shoe's upper and strobel board but within the mold cavity.

Physical foaming a footwear component with a single-phase solution of a polymeric composition and a supercritical fluid is provided. The method include temperature conditioning a mold and then engaging the mold with a robot that conveys the mold to a press. At the press a gas counter pressure is applied to a cavity of the mold before injecting a single-phase solution of a polymeric composition and a supercritical fluid into the cavity of the mold. The process continues with releasing the gas counter pressure from the cavity of the mold and then removing the footwear component from the cavity of the mold. The parameters of the method are configured for the formation of the footwear component in an automated manner.