Abstract: A last assembly includes a plurality of retractable pins and a plurality of vacuum holes, both acting to hold footwear segments to the last assembly to facilitate manufacturing of, or modification to, an article of footwear. A method of making or modifying an article of footwear includes placing footwear segments on the last assembly by associating an extension portion of at least one footwear segment with the retractable pins, modifying the footwear segments and then removing the extension portion.

Abstract: A flexible manufacturing system can be used to fuse different layers of material together for forming an article of footwear. The system includes a base portion, an intermediate member and an upper member. The intermediate member includes a flexible membrane. The intermediate member can be sealed with the base portion and a vacuum can be provided to pull the flexible membrane over layers of material placed on the base portion. The upper member can be sealed against the intermediate member so that external pressure can be applied to the flexible membrane. The intermediate member and the upper member can be moved independently.

Abstract: Articles of footwear, including athletic footwear, include cleat structures, strapping systems, sole structures, and/or improved natural motion characteristics are described. Also, methods for making such articles of footwear (and particularly sole structures for articles of footwear) are described.

Abstract: A flexible manufacturing system can be used to fuse different layers of material together for forming an article of footwear. The system includes a base portion, an intermediate member and an upper member. The intermediate member includes a flexible membrane. The intermediate member can be sealed with the base portion and a vacuum can be provided to pull the flexible membrane over layers of material placed on the base portion. The upper member can be sealed against the intermediate member so that external pressure can be applied to the flexible membrane. The intermediate member and the upper member can be moved independently.

Abstract: A method for producing a regionalized-firmness midsole utilizing a heat press, and a description of the resultant product, are provided. Initially, the method involves providing a plurality of pre-formed phylon biscuits. Typically, the plurality of biscuits includes at least a first biscuit that has a first density and a second biscuit that has a second density. The method may further include the steps of arranging the biscuits into a receiving area of the heat press, and integrating the plurality of biscuits to form the midsole by activating the heat press. Integrating the biscuits includes raising the biscuits above a threshold temperature, and causing the biscuits to expand such that each of the plurality of biscuits couples with another of the biscuits to form a midsole with two or more degrees of firmness located at distributed regions thereon.

Abstract: A shoe having a shoe upper including multiple unwelded flex zones in selected locations on the shoe upper. The flex zones may be selectively located on the upper to flex when the shoe is in use.

Abstract: A method for producing a regionalized-firmness midsole utilizing a heat press, and a description of the resultant product, are provided. Initially, the method involves providing a plurality of pre-formed phylon biscuits. Typically, the plurality of biscuits includes at least a first biscuit that has a first density and a second biscuit that has a second density. The method may further include the steps of arranging the biscuits into a receiving area of the heat press, and integrating the plurality of biscuits to form the midsole by activating the heat press. Integrating the biscuits includes raising the biscuits above a threshold temperature, and causing the biscuits to expand such that each of the plurality of biscuits couples with another of the biscuits to form a midsole with two or more degrees of firmness located at distributed regions thereon.

Abstract: A method for producing a regionalized-firmness midsole utilizing a heat press, and a description of the resultant product, are provided. Initially, the method involves providing a plurality of pre-formed phylon biscuits. Typically, the plurality of biscuits includes at least a first biscuit that has a first density and a second biscuit that has a second density. The method may further include the steps of arranging the biscuits into a receiving area of the heat press, and integrating the plurality of biscuits to form the midsole by activating the heat press. Integrating the biscuits includes raising the biscuits above a threshold temperature, and causing the biscuits to expand such that each of the plurality of biscuits couples with another of the biscuits to form a midsole with two or more degrees of firmness located at distributed regions thereon.

Abstract: An article of footwear is disclosed that includes an upper and a midsole. A first midsole impact force attenuation structure or system is arranged at least within the toe region of the midsole. A second midsole impact force attenuation structure or system is arranged at least within the heel region of the midsole, such that the second midsole impact force attenuation structure or system includes a molded heel region member extending from a lateral side of the article of footwear to a medial side; the heel region member having a hollow central region defined by a first radius of curvature in a direction toward the toe region and a second radius of curvature in a direction toward the heel region. The first radius of curvature is different from the second radius of curvature. The heel region member may be in an asymmetrical stiffness construction.

Abstract: A method and system for making uppers for articles of footwear is disclosed. The system comprises a last assembly as well as a pressing system for forming uppers with the last assembly. The last assembly includes a last member and a base member. The last member is inverted so that the bottom surface of the last member is oriented away from the base member.

Abstract: A flexible manufacturing system can be used to fuse different layers of material together for forming an article of footwear. The system includes a base portion, an intermediate member and an upper member. The intermediate member includes a flexible membrane. The intermediate member can be sealed with the base portion and a vacuum can be provided to pull the flexible membrane over layers of material placed on the base portion. The upper member can be sealed against the intermediate member so that external pressure can be applied to the flexible membrane. The intermediate member and the upper member can be moved independently.

Abstract: A shoe having a shoe upper including multiple unwelded flex zones in selected locations on the shoe upper. The flex zones may be selectively located on the upper to flex when the shoe is in use.

Abstract: A last assembly includes a plurality of retractable pins and a plurality of vacuum holes, both acting to hold footwear segments to the last assembly to facilitate manufacturing of, or modification to, an article of footwear. A method of making or modifying an article of footwear includes placing footwear segments on the last assembly by associating an extension portion of at least one footwear segment with the retractable pins, modifying the footwear segments and then removing the extension portion.

Abstract: A shoe having a shoe upper including multiple welds in selected locations on the shoe upper. The welds may be selectively located on the upper to provide structure and support to the specific portions of a shoe upper.

Abstract: Footwear including removable and replaceable outsole members may include: (a) an upper member; (b) a midsole member, having an exterior surface not designed for performance use in direct contact with the ground, fixedly engaged with the upper member; and (c) an outsole member designed for performance use in contact with the ground removably attached over at least a major portion of the midsole member. The outsole member may attach to the midsole member and/or upper member in a variety of different ways. In use, the wearer may select a specific set of outsole members to use at a given time depending, for example, on the type of play surface, temperature, and/or other conditions. Worn outsole members may be replaced without the expense involved in also replacing the remainder of the footwear.

Abstract: Cleat structures, e.g., for football shoes, may include: (a) a cleat base; (b) a cleat free end; and (c) a concave side edge and at least two additional side edges extending between the cleat base and the cleat free end. Such cleats may be incorporated into sole structures (e.g., outsole components) that have one or more of: a base plate having a V-shaped support structure with lateral and medial support members extending forward from a base support area located in a heel or rear midfoot area of the outsole component; a base plate having a matrix structure with recesses or openings formed between rib elements that make up the matrix structure; and/or a base plate having a rear heel support. The cleats and base plates may be made, at least in part, as unitary, one-piece constructions, using selective laser sintering or other three-dimensional printing and/or rapid manufacturing additive fabrication techniques.

Abstract: An article of footwear may include an upper, including a skin layer forming at least a portion of an external surface of the upper. The upper may also include a reinforcing material selectively located internal and adjacent to portions of the skin layer, thereby defining reinforced portions of the skin layer and unreinforced portions of the skin layer. The reinforcing material may be selectively joined with the skin layer at a bonded area by welding, the bonded area having an externally exposed surface that defines a portion of the external surface of the upper. In addition, the skin layer may have a first color and the externally exposed surface of the bonded area may have a second color that is different from the first color.

Abstract: Customized articles of footwear are produced by defining options that can be selected by a customer when submitting a custom order. These options typically include model options, functional options, and aesthetic options. These options are created by a design source, such as a shoe designer within a particular market, and presented to the customer when making the order. Upon a customer selecting one or more of the options at a user interface, the selected options are converted to specifications associated with the order. A work-load engine is employed to generate, based on the specifications, a work order that includes a dataflow for selecting appropriate stations on a manufacturing floor to participate in a manufacturing process, and a workflow for instructing each of the appropriate stations to perform a sequence of operations, within the manufacturing process, that result in fabricating individual components of the article of footwear according to the order.

Abstract: An article of footwear includes an upper and a midsole secured to the upper. A support plate assembly includes a support member extending along a portion of the upper. A plate extends inwardly from the support member, the plate being positioned between the outsole and the midsole. A groove is formed in an exterior surface of the support member, and is positioned outwardly of the plate and extends longitudinally along the exterior surface of the support member.