Abstract: A method of making functional orthotics from a multiplicity of uniquely designed injection molds which have been constructed by studying large numbers of replicas produced from uncorrected replicas that replicate the contour of the feet of a multiplicity of patients. In one form of the method of the invention, following a careful dimensional study of the corrected replicas, they are grouped into families, the members of which exhibit lower surface contours that are substantially identical. An injection mold is then made for each of the identified families, in a manner such that the mold will produce an orthotic having an upper surface that corresponds to the lower surface of the corrected orthotic that make up the group. Companion data is then developed which correlates the corrected replicas of each identified family with the uncorrected replicas from which they were made. A study of the uncorrected replicas then provides data as to the contour of the patient's feet which they replicate.

Abstract: A method of manufacturing a last for a first article of footwear. The last comprising a cast shaped and dimensioned to customize, in use, one end of the first article of footwear for one end of an individual's foot, and an end piece adapted to engage, in use, the opposite end of the first article of footwear. The method comprising the steps of customizing the cast and fixing the cast.

Abstract: A stitched waterproof joint can be formed between the vamp and top plug of a shoe by applying waterproof coatings to the interior facing surfaces of the vamp and plug, stitching the vamp and plug together to merge the waterproof coatings, heating the vamp and plug to eliminate voids in the merged film, and applying an additional waterproofing layer to the interior edge of the stitched joint between the vamp and the plug.

Abstract: A method of making functional orthotics from a multiplicity of uniquely designed injection molds which have been constructed by studying large numbers of replicas produced from uncorrected replicas that replicate the contour of the feet of a multiplicity of patients. In one form of the method of the invention, following a careful dimensional study of the corrected replicas, they are grouped into families, the members of which exhibit lower surface contours that are substantially identical. An injection mold is then made for each of the identified families, in a manner such that the mold will produce an orthotic having an upper surface that corresponds to the lower surface of the corrected orthotic that make up the group. Companion data is then developed which correlates the corrected replicas of each identified family with the uncorrected replicas from which they were made. A study of the uncorrected replicas then provides data as to the contour of the patient's feet which they replicate.

Abstract: A footwear last usable in the mass production of footwear comprises a solid body having a top, bottom, toe and heel portion with a smooth contoured sole surface connecting the toe and heel portion including an inner longitudinal arch formed on the sole surface and on an inner side of the last, an outer longitudinal arch formed on the sole surface on an outer side of the last. A first transverse arch formed proximate the toe portion. A second transverse arch formed forward of the heel portion. The smooth upper surface transitions to the smooth sole surface in a continuous curve free from a sharply angled last bottom featherline and the contoured sole surface defines three separate and distinct contact areas. The sole surface projects cross-sections of varying percentages with respect to the total cross-sectional area onto a base plane at different heights above the base plane in accordance with the unique contours of the sole surface.

Abstract: An improved last, and article of footwear derived therefrom, for providing improved function, fit, and comfort for use in various athletic activities, and in particular for running. The last has dimensions defined by a plurality of cross-sectional contours extending from proximate a proximal end of the heel portion to proximate a distal end of the forefoot portion. The last dimensions are in accordance with or proportional to the plurality of cross-sectional contours shown in FIGS. 13-97. The last is characterized by a natural shape to the top of the cone or island and an enlarged toe box.

Abstract: A system is provided for integrated foot measurement and last manufacture which comprises a foot sizing device for determining foot sizing data by empirically measuring a foot to determine proper fit of a predetermined footwear style, a data processing device for receiving the foot sizing data from the foot sizing device and for transmitting the foot sizing and footwear style data, and a computer automated design mechanism for receiving the data from the data processing device and deriving machine readable data in a form suitable for transmission to footwear last production machinery for manufacture of a footwear last. The system also may include footwear last production machinery configured to utilize the machine readable data in the manufacturing of a footwear last. The foot sizing device preferably includes an electro-optical scanner which is capable of accurately determining foot sizing data of a foot covered by stocking as well as a foot of light or dark skin tones.

Abstract: A last having an outer footwear shaping surface is provided wherein the outer footwear shaping surface is constructed and arranged to have a foot length component corresponding to the length measurement of the foot, a width component corresponding to the width line, and curvature angles corresponding to the curvature angles of the foot. An arch-line component, a heel width component, and a foot volume component may also be provided to correspond with the foot.

Abstract: A kit for use in preparing a last, i.e., an anatomical model of the human foot for use in the contruction of custom footwear, as well as a method of preparing lasts, the lasts prepared by such a method, and the custom footwear constructed by the use of such lasts. The kit includes a hardenable, shell-forming fabric that can be conformed to the shape of the foot, hardened in its conformed shape, and removed from the foot in a manner that does not substantially destroy its conformed shape. The resultant shell, being sufficiently smooth and being of substantially the same size and shape as the foot, can be used directly as a positive model of the foot.

Abstract: An optical system and method for digitizing a last or other irregularly shaped article comprises a laser device fixed on a base directing a light beam at a last supported for rotation about an axis, perpendicular to which the light beam is directed. Two cameras are fixed to the base, one at each side of the laser device, and each comprises an array of cells for detecting the point of incidence of the light beam on the last surface. As the last is rotated, the point of incidence varies in relation to a datum, e.g. the axis of rotation, and the point maximum intensity of illumination on the array of cells will vary across the array accordingly. By a correlating technique, the distance of the point of incidence from the datum can be determined according to the point of maximum intensity of the array.

Abstract: A method and apparatus for making shoe lasts, involves digitizing on the fly a large number of sample points on the outer surface of a model last representing a particular shoe style to produce a model last digital file representing the three-dimensional surface contour of the respective model last; grading the model last digital file to produce one or more graded last digital files each representing a different last size of the respective soe style; and utilizing each of the graded last digital files to produce a graded shoe last of the respective shoe style. The invention may also be utilized for making graded components of shoes, and for modifying shoe styles or creating new shoe styles by CAD/CAM techniques.

Abstract: A method and apparatus for making shoe lasts, involves digitizing on the fly a large number of sample points on the outer surface of a model last representing a particular shoe style to produce a model last digital file representing the three-dimensional surface contour of the respective model last; grading the model last digital file to produce one or more graded last digital files each representing a different last size of the respective shoe style; and utilizing each of the graded last digital files to produce a graded shoe last of the respective shoe style. The invention may also be utilized for making graded components of shoes, and for modifying shoe styles or creating new shoe styles by CAD/CAM techniques.

Abstract: The disclosure is directed to a method and apparatus for making a custom shoe based on non-contact measurements of a particular subject's foot. A foot is placed at an inspection position, and a laser beam is directed at the foot, and scanned in a predetermined pattern over the surface of the foot. The light beam reflected from the foot is detected at a position detector. Surface coordinates of the foot are determined as a function of the detector output. The determined surface coordinates are stored and can then be used in making a shoe having a shape which depends on the stored coordinates. In a preferred embodiment, a rotating scanner is disposed above the inspection position and an oscillating reflector is disposed to one side of the inspection position. The beam of light is reflected from the rotating scanner to the oscillating reflector to the foot, and the beam reflected from the foot is thereafter reflected back to the oscillating reflector, the rotating scanner, and then the detector.

Abstract: An automatic system for forming custon-made shoe inserts for a person's feet from a pair of blanks is provided with a foot impression mechanism including a pair of pin arrays for simultaneously forming an impression of the contour of the undersurface of each of the person's feet and for releasably retaining each impression formed. Each of the pin arrays is arranged in orthogonal rows and columns with adjoining pins in each column having asymmetric contacting surfaces.

Abstract: An automatic system for forming custom-made shoe inserts for a person's feet from a pair of blanks is provided with a foot impression mechanism for simultaneously forming an impression of the contour of the undersurface of each of the person's feet and for releasably retaining each impression formed. The system is also provided with a blank holding assembly for holding the blanks in lateral alignment with the impressions, a blank shaping mechanism for successively sensing each impression and for concomitantly successively cutting material away from each blank in conformance with the corresponding sensed impression, and a drive mechanism for automatically driving the blank shaping mechanism both laterally and to-and-fro over the impressions and the blanks in response to a single drive motor so as to automatically form the custom-made shoe inserts from the blanks in conformance with the impressions.

Abstract: A system and method for forming a custom-made resilient insert for a given person's shoe in which the contour of the support surface of the insert conforms to the contour of the undersurface of a person's foot.

Abstract: An automatic system for forming custom-made shoe inserts for a person's feet from a pair of blanks is provided with a foot impression mechanism including a pair of pin arrays for simultaneously forming an impression of the contour of the undersurface of each of the person's feet and for releasably retaining each impression formed. Each of the pin arrays is arranged in orthogonal rows and columns with adjoining pins in each column having asymmetric contacting surfaces.

Abstract: A process for the normalized manufacture of shoes includes defining the measurements of the sole of a last, to determine the transverse contour thereof, by defining an axis transverse to the length of the sole at a position spaced one third of the length from the sole front. Four zones determined by three transverse lines equally spaced at a distance of 1/12 the length are defined forwardly of the transverse axis. The contour of the sole is determined along such lines to be flat at the line nearest to the front, to have an arch height of 1/120 the length at the following line and to have an arch height of 1/96 the length of the last line. Seven transverse lines, equally spaced at a distance 1/12 the length are defined rearwardly of the transverse axis. The contour of the sole is determined by the most forward such line to have an arch height of 1/96 the length, and to have at the remaining such lines arch heights of 1/60 the length.

Abstract: A shoe of natural shape having a flexible material forming the upper part of the shoe, replacing the insole, and extending all over the sole surface to comprise a stocking-like part which extends over the last to envelop the foot on all sides, there being a recess in the heel portion of the footbed with a bearing surface rising from this recess on a forward rising angle to the arch, the bearing surface being cup-shaped with a peripheral edge connected to the stocking-like part.

Abstract: Footwear lasts are molded by preparing an oversized model of the last to be molded; isolating, applying mold release to, and covering with liquid ISP at least first and second surface portions of the model; allowing the ISP cure to form at least first and second mold portions; and using the mold portions to mold plastic lasts.