Abstract: A footwear construction is provided including a waterproof gasket formed between components of the footwear. The footwear can include an upper including a first layer and a waterproof functional second layer adjacent the first layer. A waterproof functional insole includes a perimeter that is disposed adjacent the first layer and/or the second layer. A thread extends through the first layer, sewn through it, and is located between the insole and the second layer, and adjacent the perimeter. The thread is melted to form a waterproof gasket between the second layer and the insole, along the perimeter. Alternatively, the first layer is surrounded with a hot melt flange stitched to an insole. A waterproof functional second layer seals the first layer and flange. A gasket panel can be disposed over the hot melt flange and insole, which can include insole stitching joining the same. Related methods also are provided.

Abstract: Footwear is provided including a protective toe element in the form of a rigid protective toe guard nested in a recess defined by a sole component so that the toe guard is of a low profile and has an at least partially closed bottom which cleanly transitions to an upper surface of the sole component. The footwear and its components provide impact and crushing force resistance, yet the footwear is low profiled and flexible enough to provide enhanced mobility and comfort to a wearer.

Abstract: 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.

Abstract: A method for making a footwear upper assembly, including knitting a tube to form first and second sock portions integrally joined at an intermediate portion; defining a first sock void and a first opening in the first sock portion; turning the second sock portion inside out, folding relative to the intermediate portion, and moving the second sock portion into the first sock void; inserting a footbed through the first opening into a footbed void formed between first and second lower panels of respective first and second sock portions; and closing the first opening to trap the footbed between the first and second lower panels. Alternatively, the method includes placing the knit tube on a last, placing a footbed adjacent the first lower panel, turning the second sock portion right-side out and moving it around an exterior of the first sock portion, and trapping the footbed within the footbed void.

Abstract: A footwear construction is provided including a primary footwear component and a secondary footwear component removably disposed in the primary footwear component. The primary footwear component can include an inward facing wall, and the secondary footwear component can include an outward facing wall surrounding a secondary sole of the secondary footwear component. The inward facing wall is configured to releasably interlock with the outward facing wall, such that the secondary sole is secured within the primary footwear component, yet can be manually pulled upward, whereby the inward facing wall releases from the outward facing wall to enable the secondary footwear component to be removed completely from the primary footwear component.

Abstract: Footwear is provided including a protective toe element in the form of a rigid protective toe guard nested in a recess defined by a sole component so that the toe guard is of a low profile and has an at least partially closed bottom which cleanly transitions to an upper surface of the sole component. The footwear and its components provide impact and crushing force resistance, yet the footwear is low profiled and flexible enough to provide enhanced mobility and comfort to a wearer.

Abstract: A footwear construction including a support cage that wraps an upper to provide an adaptive fit to accommodate a variety of foot shapes and to adapt to changes in foot shape during a gait cycle, while providing exceptional stability and support. The footwear can include an upper, a support cage and a sole assembly. The upper can be joined with the sole assembly and can include an exterior. The sole assembly can define a recess extending across a width of the sole assembly from a medial side to a lateral side. The support cage can be constructed from a semi-rigid but flexible polymeric material, disposed over the exterior of the upper and free floating relative to the exterior of the upper. The support cage can include a sole bridge that extends transverse to a longitudinal axis of the footwear, through the recess defined by the sole assembly.

Abstract: A method for making a footwear upper assembly, including knitting a tube to form first and second sock portions integrally joined at an intermediate portion; defining a first sock void and a first opening in the first sock portion; turning the second sock portion inside out, folding relative to the intermediate portion, and moving the second sock portion into the first sock void; inserting a footbed through the first opening into a footbed void formed between first and second lower panels of respective first and second sock portions; and closing the first opening to trap the footbed between the first and second lower panels. Alternatively, the method includes placing the knit tube on a last, placing a footbed adjacent the first lower panel, turning the second sock portion right-side out and moving it around an exterior of the first sock portion, and trapping the footbed within the footbed void.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: A footwear construction including a support cage that wraps an upper to provide an adaptive fit to accommodate a variety of foot shapes and to adapt to changes in foot shape during a gait cycle, while providing exceptional stability and support. The footwear can include an upper, a support cage and a sole assembly. The upper can be joined with the sole assembly and can include an exterior. The sole assembly can define a recess extending across a width of the sole assembly from a medial side to a lateral side. The support cage can be constructed from a semi-rigid but flexible polymeric material, disposed over the exterior of the upper and free floating relative to the exterior of the upper. The support cage can include a sole bridge that extends transverse to a longitudinal axis of the footwear, through the recess defined by the sole assembly.

Abstract: A method for manufacturing footwear including injection molding a polymeric material on a sheet of material in preselected locations and/or in a preselected pattern so that the polymeric material bonds to the sheet and forms a structural exoskeleton of an upper of the footwear. The upper can be joined with a sole. The polymeric material can be injection molded on the sheet while the sheet is in a planar or flat configuration, and subsequently, the sheet and bonded exoskeleton can be conformed to a three-dimensional configuration of an upper. Additional polymeric materials can be injected on the exoskeleton to reinforce certain areas of the same. The exoskeleton can define one or more holes through which the sheet is visible to form one or more aesthetic regions on the upper. An article of footwear constructed with the method is also provided.

Abstract: A method for manufacturing footwear including injection molding a polymeric material on a sheet of material in preselected locations and/or in a preselected pattern so that the polymeric material bonds to the sheet and forms a structural exoskeleton of an upper of the footwear. The upper can be joined with a sole. The polymeric material can be injection molded on the sheet while the sheet is in a planar or flat configuration, and subsequently, the sheet and bonded exoskeleton can be conformed to a three-dimensional configuration of an upper. Additional polymeric materials can be injected on the exoskeleton to reinforce certain areas of the same. The exoskeleton can define one or more holes through which the sheet is visible to form one or more aesthetic regions on the upper. An article of footwear constructed with the method is also provided.