Abstract: Embodiments are directed to manufacturing footwear. A first outer mold shell and a second outer mold shell may be provided. A first inner mold body and a second inner mold body may be manufactured. The first and second inner mold bodies may have respective first and second inner mold surfaces. The second inner mold surface, together with the first inner mold surface, may define an internal mold volume. The first and second inner mold bodies may be removably coupled to the respective first and second outer mold shells to form first and second hybrid side rings. The first hybrid side ring and the second hybrid side ring may be installed in an automated injection molding machine. The installed first hybrid side ring may be moved toward the installed second hybrid side ring to provide the internal mold volume. One or more liquids may be injected into the internal mold volume.

Abstract: Embodiments are directed towards recommending a shoe and insole combination for a consumer. A variety of shoe information, insole information, and consumer foot information may be determined, which may include heel width, a width or shape, a length, a height, and arch characteristics. The foot information, the shoe information for a plurality of shoes, and the insole information for a plurality of insoles may be compared to determine at least one combination of shoe and insole that is compatible with the consumer's foot. Based on this comparison of foot information, shoe information, and insole information, a recommendation of at least one shoe and insole combination may be determined and provided to a user and/or the consumer.

Abstract: Embodiments are directed to an insole for footwear. The insole preferably includes a bottom surface, a peripheral sidewall, and a relief. The bottom surface has a perimeter, and the peripheral sidewall preferably extends upward from the perimeter of the bottom surface. The relief is preferably disposed in the peripheral sidewall.

Abstract: An apparatus to assist in making an orthotic, insole or other footwear insert that is customized to a plantar surface of an individual's foot is provided. The apparatus includes a portable housing; a heater unit to selectively heat the orthotic or a heel cap of the footwear insert to increase its pliability; at least one alignment device to assist in positioning and orientating the individual's foot prior to conforming the orthotic or the heel cap to the plantar surface of the individual's foot; and a vacuum system to selectively apply a vacuum around the individual's foot to bring the orthotic or the heel cap into conformance with the plantar surface of the individual's foot prior to setting of the orthotic or the heel cap. Related methods of making custom orthotics, insoles and other footwear inserts are also provided.

Abstract: A footwear item includes an insole, an outsole, and a midsole. The insole includes an insole top surface, an insole bottom surface, and an insole sidewall. The outsole includes an outsole top surface and an outsole bottom surface. The midsole is positioned between the insole and the outsole. The midsole is configured to nest onto the top surface of the outsole. In at least the heel region, the midsole includes a strobel upper surface and a strobel sidewall configured to nestingly receive a heel region of the insole. In addition, an interface between the strobel upper surface and the strobel sidewall includes a fillet region configured to support and reduce lateral-medial movement of the insole relative to the midsole.

Abstract: A midsole of footwear with an incorporated orthotic support. The midsole includes a soft and flexible member and a more rigid orthotic support. The orthotic support includes a heel cup and an arch support portion that extends forwardly from the heel cup. Embodiments produce the midsole by positioning the orthotic insert between an upper portion of the footwear and an outsole. Then, soft and flexible material is injected into the space surrounding the orthotic. The soft and flexible material subsequently cures forming the multi-part unitary midsole.

Abstract: A footwear item includes an insole, an outsole, and a midsole. The insole includes an insole top surface, an insole bottom surface, and an insole sidewall. The outsole includes an outsole top surface and an outsole bottom surface. The midsole is positioned between the insole and the outsole. The midsole is configured to nest onto the top surface of the outsole. In at least the heel region, the midsole includes a strobel upper surface and a strobel sidewall configured to nestingly receive a heel region of the insole. In addition, an interface between the strobel upper surface and the strobel sidewall includes a fillet region configured to support and reduce lateral-medial movement of the insole relative to the midsole.

Abstract: An apparatus to assist in making an orthotic, insole or other footwear insert that is customized to a plantar surface of an individual's foot is provided. The apparatus includes a portable housing; a heater unit to selectively heat the orthotic or a heel cap of the footwear insert to increase its pliability; at least one alignment device to assist in positioning and orientating the individual's foot prior to conforming the orthotic or the heel cap to the plantar surface of the individual's foot; and a vacuum system to selectively apply a vacuum around the individual's foot to bring the orthotic or the heel cap into conformance with the plantar surface of the individual's foot prior to setting of the orthotic or the heel cap. Related methods of making custom orthotics, insoles and other footwear inserts are also provided.

Abstract: Embodiments are directed towards recommending a shoe and insole combination for a consumer. A variety of shoe information, insole information, and consumer foot information may be determined, which may include heel width, a width or shape, a length, a height, and arch characteristics. The foot information, the shoe information for a plurality of shoes, and the insole information for a plurality of insoles may be compared to determine at least one combination of shoe and insole that is compatible with the consumer's foot. Based on this comparison of foot information, shoe information, and insole information, a recommendation of at least one shoe and insole combination may be determined and provided to a user and/or the consumer.

Abstract: An insole assembly for use in footwear is provided. The insole assembly generally includes a full-length insole base made of a flexible and resilient material (e.g., resiliently compressible foam), and a heel cap made of a generally rigid material (e.g., a carbon fiber reinforced polymer) which is attached to the insole base and mimics the contours thereof to provide proper biomechanical support of the heel and arch areas of a foot in a particularly lightweight and sleek form factor.

Abstract: Embodiments are directed towards an insole assembly for an article of footwear. The insole includes a cushioning member and a support member. The cushioning member having an upper surface for engaging a plantar surface of a foot and a bottom surface for engaging a sole of the footwear and the support member. The support member engages with a portion of the bottom surface of the cushioning member. The support member has a rearfoot portion which extends around a heel end of the cushioning member, medial and lateral side portions which extend forwardly from the rearfoot portion on opposite sides of a central opening in the support member, and a front-end portion connecting the medial and lateral side portions near a midfoot region of the footwear enclosing the central opening in the support member along a perimeter of the cushioning member.

Abstract: Footwear is provided having a midsole platform, a full length insole and a orthotic midsole in the form of an orthotic shell received between the midsole platform and the insole. The orthotic shell has a heel portion to support a heel of a foot of a wearer and a forefoot portion to support a forefoot of the wearer at least in a region behind and near metatarsal heads of the foot. The orthotic shell is shaped to partially cup the heel and support the forefoot in one of a plurality of determined orientations. The footwear may further include a plurality of support plugs to support the orthotic shell in one of the determined orientations and a shank coupled to the midsole platform to increase torsional rigidity of the footwear with respect to a longitudinal length thereof. Methods of making footwear are also provided.

Abstract: Footwear is provided having a midsole platform, a full length insole and a orthotic midsole in the form of an orthotic shell received between the midsole platform and the insole. The orthotic shell has a heel portion to support a heel of a foot of a wearer and a forefoot portion to support a forefoot of the wearer at least in a region behind and near metatarsal heads of the foot. The orthotic shell is shaped to partially cup the heel and support the forefoot in one of a plurality of determined orientations. The footwear may further include a plurality of support plugs to support the orthotic shell in one of the determined orientations and a shank coupled to the midsole platform to increase torsional rigidity of the footwear with respect to a longitudinal length thereof. Methods of making footwear are also provided.

Abstract: Footwear is provided having a midsole platform, a full length insole and a orthotic midsole in the form of an orthotic shell received between the midsole platform and the insole. The orthotic shell has a heel portion to support a heel of a foot of a wearer and a forefoot portion to support a forefoot of the wearer at least in a region behind and near metatarsal heads of the foot. The orthotic shell is shaped to partially cup the heel and support the forefoot in one of a plurality of determined orientations. The footwear may further include a plurality of support plugs to support the orthotic shell in one of the determined orientations and a shank coupled to the midsole platform to increase torsional rigidity of the footwear with respect to a longitudinal length thereof. Methods of making footwear are also provided.