Abstract: An article of footwear has a sole structure with an extension portion that maintains contact with the ground during a forward stride, extending the time period for deceleration of loads applied to the sole structure. The article of footwear comprises an upper and a sole structure. The upper has a forefoot region with a foremost extent. The sole structure has a forefoot portion underlying the forefoot region, and an extension portion extending forward from the forefoot portion. The extension portion extends forward of the foremost extent of the upper from a forward edge of the forefoot portion to a distal end. A top side of the extension portion is spaced apart from the upper between the forward edge and the distal end. The extension portion establishes a propulsion surface beyond the foremost extent of the upper during a forward stride.

Abstract: A sockliner for a shoe may be formed to include an integral fabric skirt. The fabric skirt may remain loose from the sockliner along at least a portion of the periphery of the sockliner. The loose periphery of the fabric skirt may be used to join the sockliner to other shoe components, as in a strobel-type seam.

Abstract: 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.

Abstract: A manufacturing frame comprises 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 flexible material in a known position and orientation relative to the frame, allowing the manufacturing station to infer the position and orientation of the flexible material on the frame from the interaction of the alignment elements on the frame and the manufacturing station.

Abstract: An article of footwear has a sole with a forefoot portion, a midfoot portion, and a heel portion. The sole has a ground-facing side and a foot-facing side opposite the ground-facing side. The article of footwear includes a support system that has one or more rods spaced from the sole and extending longitudinally from the forefoot portion to the heel portion on the foot-facing side. The rod is operatively connected to the sole at the forefoot portion and at the heel portion. A sling is suspended from the rod over the midfoot portion. The rod bends when the sole is flexed to thereby lift the sling away from the sole.

Abstract: An article of footwear formed from a flat pattern to include a side seam and/or utilizing aperture alignment of multiple flat pattern pieces is disclosed. In aspects, an article of footwear, such as an upper, is formed from a flat pattern and modified into a dimensional article of footwear that includes a side closing. The side closing may comprise adjoined side edges of the flat pattern upper that are secured to each other with a securing element to maintain the dimensional article of footwear in its shape. Alignment of the parts may be provided through at least partial alignment of apertures in the flat pattern upper and apertures in a securing element and/or other flat pattern pieces, including using multi-purpose apertures, allowing streamlined processing and manufacturing of footwear.

Abstract: A method of making an article of footwear is disclosed. The method includes the steps of designing an article of footwear via a website, converting a footwear representation into a set of two-dimensional portions, printing the two dimensional portions onto a sheet material, cutting and assembling the two dimensional portions into a finalized article of footwear. The method further includes a step of shipping the article of footwear to a pre-designated shipping address. Systems for receiving an order for a customized article of footwear are also disclosed.

Abstract: An article of footwear is disclosed that includes upper and a sole structure. The upper defines an interior void that is configured to receive the sole structure and a foot. A lower surface of the upper defines a plurality of apertures, and the sole structure includes a plurality of projections that extend through the apertures to form a ground-engaging surface. The projections are connected to a foot-supporting member that remains within the upper. A locking system is incorporated into the upper and sole structure to secure the sole structure to the upper.

Abstract: In one aspect of the present disclosure, a knitted component may include a knitted layer at least partially formed with a plurality of first yarns and a retention system formed in the knitted layer. The retention system may include a plurality of floating portions of the first yarns, and may be movable from a first state to a second state. In the first state, the plurality of floating portions of the first yarns may assume a slack state, where a float length of the first yarns may be greater than a dimension of the retention system.

Abstract: Footwear components are made from lightweight textile structures (e.g., including circular knitted structures made from natural or synthetic fibers, such as socks or sock-type structures). The textile structures are selectively supported at various areas to provide desired local characteristics. Methods are provided for making such components, precursors to such components, and articles of footwear containing such components.

Abstract: 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.

Abstract: Stitching is applied to a shoe or shoe component and then printed. The stitching may be formed from a continuous thread. After printing, a portion of the continuous thread may have a different color or appearance from other portion(s) of the continuous thread.

Abstract: One aspect of the present disclosure provides a knitted component forming an overfoot portion and an underfoot portion of an article of footwear. The knitted component may include a first layer defining a void and a second layer second layer at least partially surrounding the first layer. The second layer may form an outer surface on the overfoot portion and the underfoot portion, and a portion of the first layer may be continuous with a portion of the second layer in an ankle region of the knitted component. An interstitial space may be formed between the first layer and the second layer, and a component may be disposed between the first layer and the second layer.

Abstract: An article of footwear flat pattern upper (126, 300, 302) portion (216) is provided. The upper portion (302) has a midline reference line (415, 416) extending between the toe end apex (316) and a midpoint on the heel end (314). The upper portion (302) also is comprised of an origin (344) aperture that is located within 10 millimeters of the midline reference line (415, 416) between the toe end (306) and the heel end (314) of the upper portion (302). The upper portion (302) is also formed with an overlay (500) that is coupled with the upper portion (302) between the toe end (306) and the heel end (314) and between the medial side (315) and the lateral side (317). The overlay (500) has an alignment aperture (345) that is aligned with the origin (344) aperture.

Abstract: An article of footwear flat pattern with an integrated collar liner is provided. The flat pattern has a flat upper with a top surface forming an exterior of a dimensionally formed article of footwear and a bottom surface facing an internal cavity of the dimensionally formed article of footwear. The flat pattern also includes a collar liner that is coupled with the flat upper at an ankle opening. The collar liner has an interior surface and an opposite exterior surface. The exterior surface forms an exposed surface of the internal cavity of the dimensionally formed article and the interior surface faces the flat upper bottom surface within the internal cavity of the dimensionally formed article. However, the collar liner external surface faces the flat upper top surface at an ankle opening coupling location.

Abstract: An article of footwear flat pattern upper (126, 300, 302) having an upper portion (302) and a footbed portion (304) is provided. The upper portion (302) and the footbed portion (304) are integrally coextensive such that the upper portion (302) lateral side (317) converges with the footbed lateral side (317). The footbed portion (304) includes a concave edge (319) extending between the footbed toe end (312) and the footbed heel end (314) along the footbed medial side (315) and a plurality of forming apertures along the medial side (315). The upper portion (302) also includes a plurality of forming apertures extending along the medial side (315).

Abstract: A method of manufacturing an article of footwear from a flat pattern is provided. The method includes cutting a first cut in a first material through the top surface (502) and the bottom surface of the first material. The method continues with coupling an overlay (500) on the first material top surface (502) such that the overlay (500) extends over the first cut and obscures the first material top surface (502). The method continues with forming the flat pattern having the first material with the first cut and the overlay (500) into a dimensional article of footwear configured to receive a foot. The first material bottom surface is more interior to the dimensional article of footwear than the top surface (502).

Abstract: A sockliner for a shoe may be formed to include an integral fabric skirt. The fabric skirt may remain loose from the sockliner along at least a portion of the periphery of the sockliner. The loose periphery of the fabric skirt may be used to join the sockliner to other shoe components, as in a strobel-type seam.

Abstract: A sockliner for a shoe or other article of footwear is formed having at least one generally flat, planar surface. At least a portion of the sockliner has a linear width that exceeds the linear distance across a width of the shoe. When the sockliner is placed in the shoe, pressure on the wider portions of the sockliner changes the conformation of the sockliner to conform to the shoe.

Abstract: Aspects hereof relate to a multi-part mold for molding articles of footwear having sole regions of differing materials forming a desired outsole surface material pattern. The multi-part mold includes a carrier mold portion and a tray mold portion. The carrier mold portion provides definition to the lateral surfaces of a resultant co-molded product. The tray mold portion cooperates with the carrier mold portion and provides definition to another (e.g., bottom) surface of the resultant co-molded product. The tray mold portion generally includes at least one pod or cavity for receiving a first material that when cured/catalyzed, defines a patterned other (e.g., bottom) surface of the resultant product. A multi-part mold having the structure as described herein permits interchangeability of multiple tray mold portions with a single carrier mold portion.