Abstract: Computer based systems and methods for designing and manufacturing consumer products, including knit footwear uppers, and the like. The system provides digital controls for the customization of knitted components, including complex multi-structured knitted components. The system simulates deformations of knit structures and allows the user to control and visualize compensations in the structure(s) of the knitted component to better match between an intended knit design and the actual physical knitted component outcome. The system may manufacture/fabricate a knitted component based on the predicted/estimated deformation behavior of the knit.

Abstract: A method and system are disclosed. A method of printing onto a base having an upper surface spaced from a lower surface by a base thickness includes dispensing a yarn from a nozzle of a printing system and selectively attaching the yarn to a first attachment region. The step of dispensing the yarn includes dispensing a heat-moldable material and a melt-resistant material. The step of selectively attaching the yarn to the first attachment region includes moving the nozzle into the first attachment region. The step of moving the nozzle into the first attachment region reduces the base thickness by a prodding distance. The heat-moldable material bonds to the first attachment region.

Abstract: Computer based systems and methods for designing and manufacturing consumer products, including knit footwear uppers, and the like. The system provides digital controls for the customization of knitted components, including complex multi-structured knitted components. The system simulates deformations of knit structures and allows the user to control and visualize compensations in the structure(s) of the knitted component to better match between an intended knit design and the actual physical knitted component outcome. They system may manufacture/fabricate a knitted component based on the predicted/estimated deformation behavior of the knit.

Abstract: A method and system are disclosed. A method of printing onto a base having an upper surface spaced from a lower surface by a base thickness includes dispensing a yarn from a nozzle of a printing system and selectively attaching the yarn to a first attachment region. The step of dispensing the yarn includes dispensing a heat-moldable material and a melt-resistant material. The step of selectively attaching the yarn to the first attachment region includes moving the nozzle into the first attachment region. The step of moving the nozzle into the first attachment region reduces the base thickness by a prodding distance. The heat-moldable material bonds to the first attachment region.

Abstract: A knitting system includes a seamless circular knitting machine. It has a circular set of needles having a particular number of needles (M), in the range of 500 to 2,500 needles, arranged in a circular pattern; and a knit controller to selectively operate each one of the needles on a needle-by-needle basis. The system includes a digital computational design tool, to receive a bitmap image, having a pixel width resolution that is identical to the particular number of needles; and based on analysis of the bitmap image, to generate and to send knitting instructions to the knit controller of the seamless circular knitting machine, based on direct correlation between (I) a particular Nth pixel in a particular Rth row of the bitmap image, and (II) needle activity of a corresponding particular Nth needle needles when said Nth needle knits the Rth row of a knitted product.

Abstract: A method for forming a plate includes attaching a first strand portion to a flexible substrate to form a first layer on the substrate and positioning a second strand portion on the first layer to form a second layer on the first layer in a plurality of discrete regions on the substrate. The method also includes positioning a plurality of traction elements into corresponding cavities formed into a first mold surface and positioning the substrate on the first mold surface to change a shape of the substrate. At least one of heat and pressure is applied to the first strand portion, the second strand portion, the substrate, and the traction elements to conform the substrate to the shape of the first mold surface and form the traction elements into the substrate at each of the discrete regions. The method also includes incorporating the substrate into an article of footwear.

Abstract: An article of footwear has a tubular structure that may conform to various anatomical features of a foot. The tubular structure has a tunnel, and a tensile strand runs through the tunnel. Applying tension along the tensile strand may cause the tubular structure to conform more closely to one or more anatomical features. The geometry, or path, of the tubular structure on the article may be customized.

Abstract: An article of footwear has a tubular structure that may conform to various anatomical features of a foot. The tubular structure has a tunnel, and a tensile strand runs through the tunnel. Applying tension along the tensile strand may cause the tubular structure to conform more closely to one or more anatomical features. The geometry, or path, of the tubular structure on the article may be customized.

Abstract: A method for forming a plate includes attaching a first strand portion to a flexible substrate to form a first layer on the substrate and positioning a second strand portion on the first layer to form a second layer on the first layer in a plurality of discrete regions on the substrate. The method also includes positioning a plurality of traction elements into corresponding cavities formed into a first mold surface and positioning the substrate on the first mold surface to change a shape of the substrate. At least one of heat and pressure is applied to the first strand portion, the second strand portion, the substrate, and the traction elements to conform the substrate to the shape of the first mold surface and form the traction elements into the substrate at each of the discrete regions. The method also includes incorporating the substrate into an article of footwear.

Abstract: An article of footwear has a tubular structure. The tubular structure may include tab portions that extend away from a tunnel portion of the tubular structure. The tab portions may engage parts of the article of footwear. The tab portions may engage an upper or sole structure along a bite line. The tab portions may be attached to a heel counter, eyestay, or other structure on the article of footwear.

Abstract: A method of forming a traced element is disclosed. The method may include printing layers of a traced element and incorporating a textile strand in overlapping polymer layers of the traced element. In some embodiments, the traced element may be formed on a base layer. The traced element may be incorporated into an upper for an article of footwear.

Abstract: Computer based systems and methods for designing and manufacturing consumer products, including knit footwear uppers, and the like. The system provides digital controls for the customization of knitted components, including complex multi-structured knitted components. The system simulates deformations of knit structures and allows the user to control and visualize compensations in the structure(s) of the knitted component to better match between an intended knit design and the actual physical knitted component outcome. They system may manufacture/fabricate a knitted component based on the predicted/estimated deformation behavior of the knit.

Abstract: A method and apparatus for bonding a yarn to a wearable article includes bonding the yarn to the wearable article at a first portion and a second portion. A first bonding location and a second bonding location are spaced apart from one another on a surface of the wearable article and an intermediate portion of the yarn extends contiguously between the first bonding location and the second bonding location and is not bonded to the wearable article.

Abstract: A method of forming a traced element is disclosed. The method may include printing layers of a traced element and incorporating a textile strand in overlapping polymer layers of the traced element. In some embodiments, the traced element may be formed on a base layer. The traced element may be incorporated into an upper for an article of footwear.

Abstract: Computer based systems and methods for designing and manufacturing consumer products, including knit footwear uppers, and the like. The system provides digital controls for the customization of knitted components, including complex multi-structured knitted components. The system simulates deformations of knit structures and allows the user to control and visualize compensations in the structure(s) of the knitted component to better match between an intended knit design and the actual physical knitted component outcome. They system may manufacture/fabricate a knitted component based on the predicted/estimated deformation behavior of the knit.

Abstract: An arch support may include a base plate having a base plate top surface. The arch support may further include a contoured arch plate attached to the base plate at a joint. The arch plate may include an arch plate bottom surface. The arch plate bottom surface may face and be separated from the base plate top surface, with an extent of the separation increasing toward a medial side of the arch support.

Abstract: A method and apparatus are disclosed. A method of printing onto a base includes providing a yarn from a material source disposed in a printing system. The yarn is an elongated continuous piece including a tagging segment and a reel segment. The reel segment is disposed proximate the material source. The tagging segment extends from a nozzle of the printing system. The method further includes attaching the tagging segment to the base and moving the nozzle away from the tagging segment after the attaching the tagging segment to the base. The nozzle is moved by an actuating system of the printing system. The moving the nozzle along the base increases a tension between the tagging segment and the material source. The tension in the yarn pulls the reel segment from the material source.

Abstract: A system and method for forming 3D printed structures on a base component includes extruding material through a nozzle while moving the nozzle vertically. Extruded material flows from the nozzle and spreads outwardly upon contact with an underlying portion of material. The outward spread of material is controlled to form a desired geometry for the 3D printed structure. An optical sensing device may provide feedback for controlling the outward spread of material. Using a molding component, structures with anchored portions extending through openings in the base component can be formed.

Abstract: A system and method for forming 3D printed structures includes one or more anchor portions on a base component. Additional materials can be printed on or adjacent to the anchor portions to provide additional structural components bonded to the anchor portions. These structures can be printed on, and can be a part of, a base component of an article of apparel.

Abstract: A method and apparatus for printing onto a curved surface of an article are disclosed. An embodiment of a method may include receiving the article and extruding a composite yarn from a nozzle. A method may include attaching the composite yarn to the curved surface by moving the nozzle in a direction aligned with a first axis and a direction aligned with second axis along the curved surface. The first axis may be approximately normal to the print surface and the second axis may be approximately normal to the first direction. The article may be repositioned during printing to accommodate nozzle movement.