Methods and Systems for Creating Custom Hard Shelled Footwear

Abstract

Methods for creating a piece of hard shelled footwear are provided. The method may include determining a first set of data, where the first set of data represents a three-dimensional shape of a foot. The method may also include determining a second set of data based at least in part on the first set of data, where the second set of data represents at least a portion of an exterior shape of a piece of hard shelled footwear. The method may further include fabricating a mold shape based at least in part on the second set of data. The method may moreover include fabricating the piece of hard shelled footwear in the mold shape.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims priority to Provisional U.S. Patent Application No. 60 / 828,712 filed Oct. 9, 2006, entitled “METHODS AND SYSTEMS FOR CREATING CUSTOM HARD SHELLED FOOTWEAR,” the entire disclosure of which is hereby incorporated by reference, for all purposes, as if fully set forth herein.BACKGROUND OF THE INVENTION [0002] This invention relates generally to methods of creating footwear. More specifically the invention relates to creating custom shaped hard shelled footwear. [0003] Typical hard shelled footwear known in the art (referred generally to as “boots” hereinafter) is made in various sizes, where each size is made to accommodate feet (hereinafter understood to also include at least some portion of the lower leg) within a range of certain sizes and shapes through the use of a compressible foam liner. The compressible foam liner usually has outer dimensions to match the inner dimension of the boot and inner dimensions which...

AI Technical Summary

Problems solved by technology

This design has multiple problems.

First, smaller feet may not fill all portions of a liner, leaving voids between the foot and the liner.

This may result in lack of responsiveness, feel and power transfer in the boot during movement, in addition to lack of comfort.

This may result in a lack of responsiveness, feel and power transfer in the boot during movement, as the liner compresses before motion is transferred between boot and foot.

Third, a foot may overfill portions of the liner, causing extreme compression of the liner where the foot is as large, or nearly as large, as the corresponding interior volume of the boot.

This may result in pressure on the foot causing discomfort.

However, standard sized non-custom boots are still used in this process, so some portions of the liner will remain thicker than others where the interior of the boot is much larger than the foot, degrading performance.

This method may be suitable where skilled craftsmen are available, but is unsuitable to mass production methods.

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