Abstract: The present invention relates to a 3D printed sole for footwear that has a plurality of reinforced holes that are useful for securing at least a portion of the sole to a footwear upper without the use of adhesive.

Abstract: A device and method manufacture an object for a user by fused deposition. A screw conveyor conveys a plurality of solid thermoplastic pellets from a hopper to a barrel. A heating element, coupled to the barrel, melts the solid thermoplastic pellets within the barrel, thereby producing a thermoplastic liquid. The thermoplastic liquid is extruded through a nozzle that caps one end of the barrel, the extruded thermoplastic liquid thereafter solidifying into the object. A computerized control system controls both a flow rate of the thermoplastic liquid, by adjusting rotation of a motor coupled to the screw conveyor, and a position of the nozzle above the build surface according to a three-dimensional shape of the object. The device and method are particularly suited for mass production of customized shoes and other objects, whereby thermoplastic material can be easily combined with customized colorants and blowing agents.

Abstract: A device and method manufacture an object for a user by fused deposition. A screw conveyor conveys a plurality of solid thermoplastic pellets from a hopper to a barrel. A heating element, coupled to the barrel, melts the solid thermoplastic pellets within the barrel, thereby producing a thermoplastic liquid. The thermoplastic liquid is extruded through a nozzle that caps one end of the barrel, the extruded thermoplastic liquid thereafter solidifying into the object. A computerized control system controls both a flow rate of the thermoplastic liquid, by adjusting rotation of a motor coupled to the screw conveyor, and a position of the nozzle above the build surface according to a three-dimensional shape of the object. The device and method are particularly suited for mass production of customized shoes and other objects, whereby thermoplastic material can be easily combined with customized colorants and blowing agents.

Abstract: A method is described for manufacturing a U-shaped support unit for use in footwear. A shaft mandrel has a longitudinal axis and a cross-section with at least one U-shape region. An enclosed shape of composite material is formed over the shaft mandrel which includes one or more layers of resin-impregnated reinforcing fibers. One or more cuts are made through the enclosed shape to create U-shaped support units adapted for use as a weight bearing structure in footwear.

Abstract: A foot support includes a foot supporting structure having a lateral side and a medial side. The foot supporting structure is adapted to provide support to the underside of weight-bearing portions of a user's foot. An anchoring structure beneath the foot supporting structure is connected to the lateral side of the foot supporting structure and not connected to the medial side so that the medial side of the foot supporting structure forms a cantilever arm projecting out from the lateral side.

Abstract: A cantilevered shoe construction for preventing knee and hip osteoarthritis. The shoe construction includes a cantilevered foot support with an anchored lateral side and a fully or partially cantilevered medial side. The cantilevered foot support transfers forces, otherwise transmitted through the medial aspect of the shoe and foot, to the lateral side of the shoe and foot, thereby reducing the knee varus and hip adductor torques to prevent or delay onset of knee and hip osteoarthritis and reducing the ankle joint adductor torque to reduce the risk for ankle sprain injury. The reduction of these joint torques also maintains posture without counterbalancing muscle activity, thereby improving muscle efficiency and performance during weight bearing activities and reducing the tendency for musculoskeletal injury. A spring loading effect of other embodiments enhances the natural coronal foot progression during gait so as to enhance the push off phase of gait.

Abstract: A joint protective shoe construction for preventing knee and hip osteoarthritis is provided. The shoe construction includes a midsole or insole having a body with medial and lateral sides. The height of the lateral side of the body is greater than the height of the medial side, thereby forming a lateral wedge. A cantilevered arch support is also provided for transferring forces from the weight of the body to the lateral side of the shoe and foot. The arch support is adapted to support the medial side of an arch of a wearer's foot at a height above the ground. The lateral wedge and/or the arch support significantly reduce the knee and hip torques during walking, running, standing, or other weight bearing activities including athletic endeavors.

Abstract: A cantilevered shoe construction for preventing knee and hip osteoarthritis. The shoe construction includes a cantilevered foot support with an anchored lateral side and a fully or partially cantilevered medial side. The cantilevered foot support transfers forces, otherwise transmitted through the medial aspect of the shoe and foot, to the lateral side of the shoe and foot, thereby reducing the knee varus and hip adductor torques to prevent or delay onset of knee and hip osteoarthritis and reducing the ankle joint adductor torque to reduce the risk for ankle sprain injury. The reduction of these joint torques also maintains posture without counterbalancing muscle activity, thereby improving muscle efficiency and performance during weight bearing activities and reducing the tendency for musculoskeletal injury. A spring loading effect of other embodiments enhances the natural coronal foot progression during gait so as to enhance the push off phase of gait.

Abstract: A joint protective shoe construction for preventing knee and hip osteoarthritis is provided. The shoe construction includes a midsole or insole having a body with medial and lateral sides. The height of the lateral side of the body is greater than the height of the medial side, thereby forming a lateral wedge. A cantilevered arch support is also provided for transferring forces from the weight of the body to the lateral side of the shoe and foot. The arch support is adapted to support the medial side of an arch of a wearer's foot at a height above the ground. The lateral wedge and/or the arch support significantly reduce the knee and hip torques during walking, running, standing, or other weight bearing activities including athletic endeavors.