Footwear with a 3D printed midsole

Abstract

A sole for a footwear article having a three-dimensional grid, the three-dimensional grid having a bottom surface at least partially defined by a plurality of nodes, the nodes having platforms, the platforms having a top platform surface connected to a bottom platform surface, the bottom platform surface having side surfaces, and a plurality of struts of the three-dimensional grid for directly connecting to the top platform surface. In some embodiments, the side surfaces of two directly adjacent nodes defining the bottom surface do not connect to each other at the bottom surface. In some embodiments, the bottom platform surfaces of two or more adjacent nodes may be merged to form a continuous integrally formed surface at the bottom surface of the three-dimensional grid.

Description

Technical Field

[0001] The described embodiments generally relate to soles for footwear. In particular, the described embodiments relate to 3D printed midsoles for footwear. Background Art

[0002] The human foot is a complex and remarkable machine that is capable of withstanding and dissipating many impact forces. The natural padding of fat at the heel and forefoot, as well as the flexibility of the arch, help cushion the foot. Although the human foot has natural shock absorption and rebound characteristics, the foot alone cannot effectively overcome many of the forces encountered during daily activities. Unless people wear shoes that provide appropriate cushioning and support, the pain and fatigue associated with daily activities will be more severe and may worsen. The discomfort experienced by the wearer will reduce the motivation for further activity. Equally importantly, inadequately cushioned shoes can cause injuries such as blisters; damage to muscles, tendons, and ligaments; and stress fractures of bones. Improper footwear can also lead to other diseases, including back pain.

[0003] People often focus on the amount of cushioning provided by footwear. This is true for footwear worn for non-competitive activities (such as casual walking) and competitive activities (such as running) because during the average day, an individual's feet and legs experience significant impact forces. When the footwear contacts a surface, a considerable amount of force acts on the footwear and correspondingly on the wearer's foot. The function of the sole of the footwear is to provide cushioning for the wearer's foot to some extent and protect it from these forces.

[0004] Proper footwear should be durable, comfortable, and provide other beneficial characteristics for the individual. Therefore, there is a continuing need for innovation in footwear. Summary of the Invention

[0005] A first aspect (1) of the present application relates to a sole for a footwear product, the sole comprising a three-dimensional grid, the three-dimensional grid comprising: a plurality of interconnected cells, each interconnected cell comprising a plurality of struts defining a three-dimensional shape and a plurality of nodes at which one or more struts are connected; a top surface; and a bottom surface opposite the top surface, the bottom surface being at least partially defined by the plurality of nodes, wherein each node of the plurality of nodes defining the bottom surface comprises a platform, the platform comprising: a top platform surface, a bottom platform surface, side surfaces connecting the top platform surface and the bottom platform surface, and a plurality of struts directly connected to the top platform surface.

[0006] In a second aspect (2), side surfaces of two directly adjacent nodes defining the bottom surface according to the first aspect (1) are not connected by a strut at the bottom surface.

[0007] In a third aspect (3), the side surfaces of two directly adjacent nodes that define the bottom surface according to the first aspect (1) or the second aspect (2) are not connected to each other at the bottom surface.

[0008] In a fourth aspect (4), the plurality of nodes that define the bottom surface according to any one of aspects (1)-(3) do not include struts connected to the side surface of the platform.

[0009] In a fifth aspect (5), the plurality of struts directly connected to the top platform surface according to any one of aspects (1)-(4) do not define a part of the side surface of the platform.

[0010] In a sixth aspect (6), the top platform surface according to any one of aspects (1)-(5) includes a top peripheral edge, the bottom platform surface includes a bottom peripheral edge, and the side surface connects the top peripheral edge and the bottom peripheral edge.

[0011] In a seventh aspect (7), the top platform surface according to any one of aspects (1)-(6) includes a central region and a peripheral region disposed around the central region, and in the central region, a plurality of struts are directly connected to the top platform surface.

[0012] In an eighth aspect (8), the plurality of nodes that define the bottom surface according to any one of aspects (1)-(7) include: a first node including a first platform having a first bottom platform surface, the first bottom platform surface having a first surface area, a second node directly adjacent to the first node and including a second platform having a second bottom platform surface, the second bottom platform surface having a second surface area that is 10% or more larger than the first surface area.

[0013] In a ninth aspect (9), the sole according to the eighth aspect (8) further includes a third node, the third node being directly adjacent to the second node and including a third platform having a third bottom platform surface, the third bottom platform surface having a third surface area that is 10% or more larger than the second surface area.

[0014] In a tenth aspect (10), the plurality of nodes that define the bottom surface according to any one of aspects (1)-(7) include: a first node including a first platform having a first bottom platform surface, a second node directly adjacent to the first node and including a second platform having a second bottom platform surface, and a third node directly adjacent to the second node and including a third platform having a third bottom platform surface, wherein the third bottom platform surface and the second bottom platform surface form a continuous integrally formed surface.

[0015] In an eleventh aspect (11), the bottom surface of the three-dimensional grid according to the tenth aspect (10) is further defined by a surface layer, the surface layer including: a top surface layer surface, a bottom surface layer surface opposite to the top surface layer surface, and a plurality of struts for directly connecting to a plurality of cells of the top surface layer surface, wherein a continuous integrally formed surface defines a part of the bottom surface layer surface.

[0016] In a twelfth aspect (12), the surface layer and the first node according to the eleventh aspect (11) are not connected to each other at the bottom surface of the three-dimensional grid.

[0017] In a thirteenth aspect (13), the sole according to any one of aspects (1)-(12) further includes an outsole, the outsole being connected to the bottom platform surface of a plurality of nodes defining the bottom surface of the three-dimensional grid.

[0018] In a fourteenth aspect (14), the bottom platform surface according to any one of aspects (1)-(7) includes a flat surface.

[0019] A fifteenth aspect (15) of the present application relates to a sole for a footwear article, the sole including a three-dimensional grid, the three-dimensional grid including: a plurality of interconnected cells, each interconnected cell including a plurality of struts defining a three-dimensional shape and a plurality of nodes at which one or more struts are connected; a top surface; and a bottom surface opposite to the top surface, the bottom surface being defined by a first surface layer, a second surface layer, and a plurality of nodes, wherein the first surface layer includes: a first top surface layer surface, a first bottom surface layer surface opposite to the first top surface layer surface, and a plurality of struts for directly connecting to a plurality of cells of the first top surface layer surface, wherein the second surface layer includes: a second top surface layer surface, a second bottom surface layer surface opposite to the second top surface layer surface, and a plurality of struts for directly connecting to a plurality of cells of the second top surface layer surface, wherein each of the plurality of nodes defining the bottom surface includes a platform, the platform including: a top platform surface and a bottom platform surface opposite to the top platform surface, and wherein the first surface layer, the second surface layer, and the plurality of nodes are not connected to each other at the bottom surface of the three-dimensional grid.

[0020] In a sixteenth aspect (16), the first surface layer according to the fifteenth aspect (15) is located in the forefoot portion of the three-dimensional grid, and the second surface layer according to the fifteenth aspect (15) is located in the heel portion of the three-dimensional grid.

[0021] In a seventeenth aspect (17), the first surface layer according to the fifteenth aspect (15) or the sixteenth aspect (16) is located in a first high-wear area on the bottom surface of the three-dimensional grid, and the second surface layer according to the fifteenth aspect (15) or the sixteenth aspect (16) is located in a second high-wear area on the bottom surface of the three-dimensional grid.

[0022] In an eighteenth aspect (18), the first surface layer according to any one of aspects (15)-(17) includes a portion located outside the bottom surface of the three-dimensional grid, and the second surface layer according to any one of aspects (15)-(17) includes a portion located inside the bottom surface of the three-dimensional grid.

[0023] In a nineteenth aspect (19), the sole according to any one of aspects (15)-(18) further includes an outsole that is coupled to the first bottom surface layer surface, the second bottom surface layer surface, and the bottom platform surface of the platform.

[0024] In a twentieth aspect (20), the sole according to any one of aspects (15)-(18) further includes an outsole that is coupled to the first bottom surface layer surface and the second bottom surface layer surface.

[0025] In a twenty-first aspect (21), the outsole according to the twentieth aspect (20) includes a first outsole member directly coupled to the first bottom surface layer surface and a second outsole member directly coupled to the second bottom surface layer surface.

[0026] A twenty-second aspect (22) of the present application relates to a method of manufacturing a sole for a footwear article, the method including 3D printing a three-dimensional grid for the sole, the three-dimensional grid including a plurality of interconnected cells, each interconnected cell including a plurality of struts defining a three-dimensional shape and a plurality of nodes at which one or more of the struts are connected, wherein 3D printing the three-dimensional grid includes: printing a plurality of the plurality of nodes on a build surface of a build plate, each of the plurality of nodes including a platform that includes: a bottom platform surface in contact with the build surface, a top platform surface opposite the bottom platform surface, and side surfaces connecting the top platform surface and the bottom platform surface; and printing a plurality of the plurality of struts on the top surface, wherein the plurality of struts define a portion of the interconnected cells.

[0027] In a twenty-third aspect (23), the 3D printing of the three-dimensional grid according to the twenty-second embodiment (22) includes a continuous liquid interface production process. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 A side view of a footwear article according to some embodiments.

[0029] Figure 2 A side view of a footwear article according to some embodiments, showing various parts of the footwear article.

[0030] Figure 3 A perspective view of a midsole according to some embodiments.

[0031] Figure 4 isFigure 3 An enlarged view of a portion.

[0032] Figure 5 Illustration of three adjacent nodes according to some embodiments.

[0033] Figure 6 Illustration of the top platform surface of two nodes according to some embodiments.

[0034] Figure 7 Illustration of three adjacent nodes according to some embodiments.

[0035] Figure 8 Illustration of three adjacent nodes according to some embodiments.

[0036] Figure 9 Bottom view of a sole according to some embodiments.

[0037] Figure 10 Shows a plurality of nodes printed on a build plate according to some embodiments.

[0038] Figure 11A Midsole according to some embodiments.

[0039] Figure 11B Midsole and outsole according to some embodiments.

[0040] Figure 12 Side view of a footwear article according to some embodiments.

[0041] Figure 13 Side view of a footwear article according to some embodiments. Detailed Description

[0042] The present invention will now be described in detail with reference to embodiments of the present invention as shown in the accompanying drawings. References to "an embodiment", "one embodiment", "an exemplary embodiment", etc. indicate that the embodiment may include specific features, structures, or characteristics, but each embodiment may not necessarily include the specific features, structures, or characteristics. Moreover, such phrases do not necessarily refer to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is considered within the knowledge of those skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments, whether or not explicitly described.

[0043] Footwear has many purposes. Among these, footwear can cushion a wearer's foot, support the wearer's foot, protect the wearer's foot (e.g., from injury), and optimize the performance of the wearer's foot. Each of these purposes, alone or in combination, provides a comfortable footwear product suitable for use in a variety of situations (e.g., exercise and daily activities). The characteristics of the footwear (e.g., the shape, components, and materials used to make the footwear) can be varied to produce desired properties such as cushioning, support, stability, ride, propulsion, and weight characteristics.

[0044] The stability provided by footwear can protect the wearer's foot from injury, such as spraining his or her ankle. The propulsion provided by footwear can optimize the performance of the wearer's foot by, for example, maximizing the energy transfer from the individual's foot to the surface (e.g., the ground) contacted by his or her foot via the footwear. Maximizing the energy transfer between the individual's foot and the surface (i.e., reducing the energy lost and / or absorbed by the footwear) can help an athlete, for example, accelerate faster, maintain a higher maximum speed, change direction more quickly, and jump higher. The cushioning and ride characteristics provided by footwear can provide comfort to an individual during exercise or daily activities. Lightweight footwear can be comfortable for an individual and can provide a competitive advantage for an individual competing in a sporting activity such as running or cycling due to the reduced weight the individual bears on his or her feet.

[0045] The midsole described herein includes a three-dimensional grid having a bottom surface that is customized to produce desired properties of the footwear. The structure of the three-dimensional grid defining the bottom surface can be customized to, among other things, minimize the weight of the midsole, facilitate attachment of the outsole to the bottom surface, and enhance the flexibility of the bottom surface. In some cases, the enhanced flexibility of the bottom surface can be beneficial to the cushioning and / or ride characteristics of the footwear.

[0046] The bottom surface of the midsole described herein can minimize the weight of the midsole by efficiently using the surface area on the bottom surface. This efficient use of the surface area can keep the weight of the midsole low while also providing an optimized surface for attaching the outsole. In some embodiments, the efficient use of the surface area can be achieved by using a plurality of bottom surface features that are not connected to each other at the bottom surface. The disconnected nature of the bottom surface of the midsole described herein can enhance the flexibility of the midsole by providing a large degree of freedom of movement for the midsole at the bottom surface. By utilizing various elements that are separated at the bottom surface, these elements can move freely relative to each other at the bottom surface unless connected via another component such as the outsole. Using the separated elements as described herein can also enhance the ability of the bottom surface to provide attachment friction. By providing bottom surface features that can move freely relative to each other at the bottom surface, the bottom surface features can conform to the ground profile and enhance the attachment friction provided by the bottom surface.

[0047] As used herein, the term "three-dimensional grid" refers to a three-dimensional structure that includes interconnected structural members defining a plurality of cells. The structural members and the cells can be connected at nodes. The cells can be arranged in a lattice configuration. For example, the interconnected structural members can be struts that are connected at nodes and define cells arranged in a lattice configuration. Exemplary lattice configurations include, but are not limited to, a primitive cubic lattice, a body-centered cubic lattice, a face-centered cubic lattice, and lattice configurations derived from these lattice types.

[0048] A midsole including a three-dimensional grid as discussed herein can be manufactured using one or more additive manufacturing methods. Additive manufacturing methods can allow for the manufacture of three-dimensional objects without the need for a mold. By reducing or eliminating the need for a mold, additive manufacturing methods can reduce the cost for the manufacturer of a product (e.g., a shoe) and, in turn, reduce the cost for the consumer of the product (e.g., a shoe). The overall manufacture of an additive-manufactured midsole can obviate the need for the assembly of separate elements of the midsole. Similarly, an additive-manufactured midsole can be made from a single material, which can facilitate the easy recycling of the midsole.

[0049] In addition, since a mold may not be required, additive manufacturing methods facilitate product customization. Additive manufacturing methods can be utilized to provide customized and affordable footwear for individuals. Exemplary additive manufacturing techniques, which may also be referred to as 3D printing techniques, include, for example, selective laser sintering, selective laser melting, thermal selective sintering, stereolithography, or fused deposition modeling. Various additive manufacturing techniques related to footwear articles are described, for example, in US 2009 / 0126225, WO 2010 / 126708, US 2014 / 0300676, US 2014 / 0300675, US 2014 / 0299009, US 2014 / 0026773, US 2014 / 0029030, WO 2014 / 008331, WO 2014 / 015037, US2014 / 0020191, EP 2564719, EP 2424398, and US 2012 / 0117825. In some embodiments, the additive manufacturing process can include a continuous liquid interface production process. For example, the additive manufacturing process can include a continuous liquid interface production process as described in U.S. Patent No. 9,453,142, which was issued on September 27, 2016, and is hereby incorporated by reference in its entirety. In some embodiments, 3D printing a three-dimensional grid can include 3D printing a grid in a green state, shaping the grid in the green state, and curing the green grid into its final shape.

[0050] Techniques for producing intermediates from resins by additive manufacturing are known. Suitable techniques include bottom-up and top-down additive manufacturing commonly referred to as stereolithography. These methods are known and are described, for example, in U.S. Patent No. 5,236,637 to Hull, U.S. Patent Nos. 5,391,072 and 5,529,473 to Lawton, U.S. Patent No. 7,438,846 to John, U.S. Patent No. 7,892,474 to Shkolnik, U.S. Patent No. 8,110,135 to El-Siblani, U.S. Patent Application Publication No. 2013 / 0292862 to Joyce, and U.S. Patent Application Publication No. 2013 / 0295212 to Chen et al. The disclosures of these patents and applications are hereby incorporated by reference in their entirety.

[0051] In some embodiments, the additive manufacturing step is performed by one of a family of methods sometimes referred to as continuous liquid interface production (CLIP). CLIP is known and is described, for example, in U.S. Patent Nos. 9,211,678; 9,205,601; 9,216,546; and others; J. Tumbleston et al., Continuous liquid interface production of 3D Objects, Science 347, 1349 - 1352 (2015); and R. Janusziewcz et al., Layerless fabrication with continuous liquid interface production, Proc. Natl. Acad. Sci. USA 113, 11703 - 11708 (October 18, 2016). Other examples of methods and apparatuses for performing specific embodiments of CLIP include, but are not limited to: U.S. Patent Application Publication No. US2017 / 0129169 to Batchelder et al. (May 11, 2017); U.S. Patent Application Publication No. US 2016 / 0288376 to Sun and Lichkus (October 6, 2016); U.S. Patent Application Publication No. US 2015 / 0360419 to Willis et al. (December 17, 2015); U.S. Patent Application Publication No. US 2015 / 0331402 to Lin et al. (November 19, 2015); U.S. Patent Application Publication No. US 2017 / 0129167 to D. Castanon (May 11, 2017); U.S. Patent Application Publication No. US2018 / 0243976 to B. Feller (published August 30, 2018); U.S. Patent Application Publication No. US2018 / 0126630 to M. Panzer and J. Tumbleston (published May 10, 2018); U.S. Patent Application Publication No. US2018 / 0290374 to K. Willis and B. Adzima (October 11, 2018); PCT Patent Publication No. WO 2015 / 164234 to L. Robeson et al. (see also U.S. Patent Nos. 10,259,171 and 10,434,706); and PCT Patent Publication No. WO 2017 / 210298 to C. Mirkin et al. (see also U.S. Patent No. US 2019 / 0160733). The disclosures of these patents and applications are hereby incorporated by reference in their entirety.

[0052] Although vat photopolymerization such as CLIP is preferred, it should be understood that other additive manufacturing techniques such as inkjet printing (see, e.g., U.S. Patent 6,259,962 to Gothait and U.S. Patent Application Serial Number US 2020 / 0156308 to Ramos et al.) may also be used.

[0053] The bottom surface of the three-dimensional mesh described herein can facilitate the ease of manufacturing the midsole using an additive manufacturing process. In particular, the surface area of the bottom surface can facilitate additive manufacturing by providing an optimized surface on which the three-dimensional mesh can be printed. The surface area of the bottom surface can reduce the chance of printing errors and other manufacturing defects, e.g., detachment between the bottom surface and the build surface of the build plate.

[0054] For some additive manufacturing processes, e.g., continuous liquid interface production processes, detachment between the bottom surface of the 3D printed part and the build surface of the build plate can be problematic unless the bottom surface is designed to avoid detachment. Direct attachment between the cured resin and the build surface holds the 3D printed part on the build surface and prevents the 3D printed part from detaching during printing. The amount of bottom surface area that is attached and directly connected to the build surface, as well as other printing variables, such as printing speed, the mass of the 3D printed part, and the mass distribution of the 3D printed part, determine the detachment probability. The midsole described herein can include a three-dimensional mesh having a bottom surface that is customized to avoid detachment during a continuous liquid interface production process. Nodes having a platform with a bottom platform surface as described herein and / or a skin having a bottom skin surface as described herein provide a bottom surface that resists detachment during a continuous liquid interface production process. This, in turn, can increase the efficiency and repeatability of the continuous liquid interface production process for manufacturing 3D printed midsoles.

[0055] Figure 1 and 2 FIG. 12 shows a footwear article 100 according to some embodiments. The footwear article 100 can include an upper 120 coupled to a midsole 130. The footwear article 100 includes a forefoot end 102, a heel end 104, a medial side 106, and a lateral side 108 opposite the medial side 106. Similarly, for example, as Figure 2 shown, the footwear article 100 includes a forefoot portion 110, a midfoot portion 112, and a heel portion 114. The portions 110, 112, and 114 are not intended to precisely demarcate regions of the footwear article 100. Instead, the portions 110, 112, and 114 are intended to denote approximate regions of the footwear article 100 that provide a frame of reference. Although the portions 110, 112, and 114 generally apply to the footwear article 100, references to the portions 110, 112, and 114 can also specifically apply to the upper 120 or the midsole 130, or to individual components of the upper 120 or the midsole 130.

[0056] AsFigure 1 As shown in the example of , the midsole 130 may include a three-dimensional grid 132 composed of a plurality of interconnected cells 134. In some embodiments, the footwear article 100 may include an outsole 140 coupled to the midsole 130. The midsole 130 and the outsole 140 together may define a sole 150 of the footwear article 100. In some embodiments, the outsole 140 may be directly manufactured (e.g., 3D printed) on the bottom side of the midsole 130. In some embodiments, the outsole 140 and the midsole 130 may be manufactured in one manufacturing process (e.g., one 3D printing process) and may not require bonding, such as via an adhesive. In some embodiments, the outsole 140 may include a plurality of protrusions 142 to provide traction friction for the footwear article 100. The protrusions 142 may be referred to as tread. The midsole 130 may be any midsole described herein, e.g., midsole 300 or 1100. The outsole 140 may be any outsole described herein, e.g., outsole 900 or 1190.

[0057] The upper 120 and the sole 150 may be configured for a particular type of footwear, including but not limited to running shoes, hiking shoes, water shoes, training shoes, fitness shoes, dance shoes, cycling shoes, tennis shoes, cleats (e.g., baseball cleats, soccer cleats, or football cleats), basketball shoes, boots, walking shoes, casual shoes, or dress shoes. Additionally, the size and shape of the sole 150 may be designed to provide a desired combination of cushioning, stability, propulsion, and smoothness characteristics to the footwear article 100. The term "smoothness" may be used herein to describe the smooth or fluid sensation generated during a gait cycle, including heel strike, mid-stance, toe-off, and the transitions between these phases. In some embodiments, the sole 150 may provide particular smoothness characteristics, including (but not limited to) appropriately controlling pronation and supination, supporting natural movement, supporting unconstrained or less constrained movement, appropriately managing the rate of change and transition, and combinations thereof.

[0058] The sole 150 and its parts (e.g., the midsole 130 and the outsole 140) may include materials for providing desired cushioning, ride, propulsion, support, and stability. Suitable materials for the sole 150 (e.g., the midsole 130 and / or the outsole 140) include, but are not limited to, foams, rubbers, ethylene vinyl acetate (EVA), thermoplastic polyurethane (TPU), expanded thermoplastic polyurethane (eTPU), polyether block amide (PEBA), expanded polyether block amide (ePEBA), thermoplastic rubber (TPR), and thermoplastic polyurethane (PU). In some embodiments, the foam may include, for example, EVA-based foam or PU-based foam, and the foam may be open-cell foam or closed-cell foam. In some embodiments, the midsole 130 and / or the outsole 140 may include elastomers, thermoplastic elastomers (TPE), foam-like plastics, and gel-like plastics and combinations thereof. In some embodiments, the midsole 130 and / or the outsole 140 may include polyolefins, such as polyethylene (PE), polystyrene (PS), and / or polypropylene (PP). In some embodiments, the sole 150 may include a sockliner or a torsion bar. In such embodiments, the sockliner or the torsion bar may be made of a nylon polymer.

[0059] The sole 150 and its parts (e.g., the midsole 130 and the outsole 140) may be formed using an additive manufacturing process, including but not limited to selective laser sintering, selective laser melting, thermal selective sintering, stereolithography, or fused deposition modeling. In some embodiments, the midsole 130 and / or the outsole 140 may be formed using an additive manufacturing process that includes a continuous liquid interface production process. For example, the additive manufacturing process may include a continuous liquid interface production process as described in U.S. Patent No. 9,453,142, which was issued on September 27, 2016, and is hereby incorporated by reference in its entirety. In some embodiments, the midsole 130 and the outsole 140 may be formed as a single piece by an additive manufacturing process. In such embodiments, the midsole 130 and the outsole 140 may be a single integrally formed component.

[0060] In some embodiments, the outsole 140 may be formed by injection molding, blow molding, compression molding, rotational molding, or dip molding. In such embodiments, the midsole 130 and the outsole 140 may be separate components that are formed separately and attached. In some embodiments, the midsole 130 may be attached to the outsole 140 via, for example but not limited to, adhesive bonding, stitching, welding, or combinations thereof. In some embodiments, the midsole 130 may be attached to the outsole 140 via an adhesive disposed between the midsole 130 and the outsole 140. Similarly, the midsole 130 may be attached to the upper 120 via, for example but not limited to, adhesive bonding, stitching, welding, or combinations thereof.

[0061] Figure 3Illustrated is a midsole 300 according to some embodiments. The midsole 300 includes a forefoot end 302, a heel end 304, a medial side 306, a lateral side 308, a top surface 310, and a bottom surface 312 opposite the top surface 310. A longitudinal direction 390 of the midsole 300 extends between the forefoot end 302 and the heel end 304. The longitudinal direction 390 includes a forward longitudinal direction (“forward direction”) extending from the heel end 304 to the forefoot end 302 and a backward longitudinal direction (“backward direction”) extending from the forefoot end 302 to the heel end 304. A transverse direction 392 of the midsole 300 extends between the medial side 306 and the lateral side 308 of the midsole 300. The transverse direction 392 includes an inward transverse direction (“inward direction”) extending from the lateral side 308 to the medial side 306 and an outward transverse direction (“outward direction”) extending from the medial side 306 to the lateral side 308. A vertical direction 394 of the midsole 300 extends between the top surface 310 and the bottom surface 312 of the midsole 300. The vertical direction 394 includes an upward vertical direction (“upward direction”) extending from the bottom surface 312 to the top surface 310 and a downward vertical direction (“downward direction”) extending from the top surface 310 to the bottom surface 312. The top surface 310 can be considered a “surface facing upward,” and the bottom surface 312 can be considered a “surface facing the ground.”

[0062] The midsole 300 can be defined, in whole or in part, by a three-dimensional mesh 320. For example, in some embodiments, the three-dimensional mesh 320 can define one or more of a forefoot portion 110 of the midsole 300, a midfoot portion 112 of the midsole 300, and / or a heel portion 114 of the midsole. In some embodiments, the three-dimensional mesh 320 can define all or a part of the forefoot portion 110 of the midsole 300. In some embodiments, the three-dimensional mesh 320 can define all or a part of the midfoot portion 112 of the midsole 300. In some embodiments, the three-dimensional mesh 320 can define all or a part of the heel portion 114 of the midsole 300.

[0063] Similar to the midsole 300, the three-dimensional mesh 320 can be described as having a forefoot end 302, a heel end 304, a medial side 306, a lateral side 308, a top surface 310, and a bottom surface 312. Unless specified, the forefoot end 302, heel end 304, medial side 306, lateral side 308, top surface 310, and bottom surface 312 of the three-dimensional mesh 320 do not necessarily correspond to the forefoot end 302, heel end 304, medial side 306, lateral side 308, top surface 310, or bottom surface 312 of the midsole 300. The forefoot end 302 of the three-dimensional mesh 320 refers to the foremost end of the three-dimensional mesh 320, and the heel end 304 of the three-dimensional mesh 320 refers to the rearmost end of the three-dimensional mesh 320. The medial side 306 of the three-dimensional mesh 320 refers to the innermost side of the three-dimensional mesh 320, and the lateral side 308 of the three-dimensional mesh 320 refers to the outermost side of the three-dimensional mesh 320. The top surface 310 of the three-dimensional mesh 320 refers to the uppermost surface of the three-dimensional mesh 320, and the bottom surface 312 of the three-dimensional mesh 320 refers to the lowermost surface of the three-dimensional mesh 320. The bottom surface 312 of the three-dimensional mesh 320 can be defined by the bottom surface of the three-dimensional mesh 320, which would directly contact a plane if the three-dimensional mesh 320 were placed on the plane in a flat configuration.

[0064] In some embodiments, such as as Figure 13 shown, the midsole 300 can include an edge 314 disposed around all or a portion of the perimeter of the top surface 310 of the midsole 300. In some embodiments, the edge 314 can be disposed around all or a portion of the perimeter of the medial and lateral sides 306 / 308 of the midsole 300. In embodiments that include the edge 314, the edge 314 can provide stability to the perimeter of the midsole 300 and / or can facilitate attachment of the midsole 300 to a shoe upper (e.g., shoe upper 120).

[0065] In some embodiments, the edge 314 can include a serrated top line 316 having a plurality of protrusions 317, as Figure 13 shown. The protrusions 317 can extend from the edge 314 such that they are disposed over portions of the shoe upper 1310 of the footwear article 1300. In some embodiments, the protrusions 317 can be coupled to the shoe upper 1310 via, for example but not limited to, adhesive bonding, stitching, or a combination thereof. In some embodiments, the protrusions 317 can be in the form of V-shaped spikes that extend from the edge 314 and are disposed over portions of the shoe upper 1310.

[0066] In some embodiments, the three-dimensional grid 320 may include struts 330 that define a serrated top line 316. In such embodiments, the struts 330 that define the serrated top line 316 may define upwardly extending protrusions 317 such that they are disposed over portions of the upper 1310. In such embodiments, the protrusions 317 defined by the struts 330 may be coupled to the upper 1310 via, for example but not limited to, adhesive bonding, stitching, or a combination thereof. In some embodiments, the struts 330 that define the protrusions 317 may include a plurality of struts 330 that define V-shaped spikes that extend upwardly and are disposed over portions of the upper 1310. In embodiments that include struts 330 that define protrusions 317, the three-dimensional grid 320 may or may not include an edge 314 disposed around all or a portion of the perimeter of the top surface 310 of the midsole 300.

[0067] In embodiments that include the serrated top line 316, the serrated top line 316 may facilitate the shaping of the three-dimensional grid 320 after 3D printing. In some embodiments, the three-dimensional grid 320 may be 3D printed such that after 3D printing, the bottom surface 312 is flat and the bottom surface 312 is shaped into a curved configuration (e.g., as Figure 13 shown). In such embodiments, the serrated top line 316 may facilitate the shaping of the three-dimensional grid 320 after 3D printing by allowing the three-dimensional grid 320 to be shaped and further cured into its final shape without causing buckling or wrinkling at the perimeter of the top surface 310. In particular, the serrated top line 316 may allow for strain relief at the perimeter of the top surface 310 to prevent buckling or wrinkling at the perimeter during shaping and curing.

[0068] The three-dimensional grid 320 includes a plurality of interconnected cells 322. The interconnected cells 322 include a plurality of struts 330 that define the three-dimensional shape of each cell 322. Each cell 322 may have a basic geometry defined by the struts 330 of the cell 322. As used herein, "basic geometry" refers to the basic three-dimensional shape, connection, and arrangement of the struts 330 that define the cell 322. The basic geometry of the cell 322 may be, but is not limited to, a dodecahedron (e.g., rhombic), tetrahedron, icosahedron, cube, cuboid, prism, or parallelepiped.

[0069] The multiple struts 330 of the three-dimensional grid 320 are connected at nodes 340. The number of struts 330 connected at a node 340 is the "valence" of the node 340. For example, if four struts 330 are connected at a node 340, then the node 340 has a valence of four. In some embodiments, the node 340 may have a valence in the range of two to twelve. For example, the node 340 may have a valence of two, three, four, five, six, seven, eight, nine, ten, eleven, or twelve, or a valence of a number within the range defined by any two of these values. In some embodiments, the node 340 may have a valence of three or more, or four or more. In some embodiments, the valence of the node 340 may be in the range of three to twelve or four to twelve.

[0070] For example, as Figure 3 and 4 shown, the bottom surface 312 of the three-dimensional grid 320 may be defined by a plurality of nodes 340 and one or more surface layers, such as a first surface layer 350, a second surface layer 352, and a third surface layer 354. In some embodiments, the bottom surface 312 of the three-dimensional grid 320 may be at least partially defined by a plurality of nodes 340. In some embodiments, most of the bottom surface 312 may be defined by a plurality of nodes 340. In some embodiments, the entire bottom surface 312 may be defined by a plurality of nodes 340. In some embodiments, the entire bottom surface 312 may be defined by a plurality of surface layers.

[0071] In some embodiments, the bottom surface 312 defined by a plurality of nodes 340, one or more surface layers, or both a plurality of nodes 340 and one or more surface layers may have a surface area equal to 33% to 66% of the full bottom gauge of the midsole 300. The full bottom gauge of the midsole 300 is the touchdown area defined by the peripheral shape 313 of the bottom surface 312. Wherein, the plurality of nodes 340 and / or one or more surface layers having a surface area equal to 33% to 66% of the full bottom gauge of the midsole 300 can contribute to effective 3D printing of the midsole 300 using a continuous liquid level manufacturing process, provide sufficient surface area for the attachment of the outsole, and / or provide desired flexural characteristics for the bottom surface. In some embodiments, the bottom surface 312 defined by a plurality of nodes 340, one or more surface layers, or both a plurality of nodes 340 and one or more surface layers may have a surface area equal to 40% to 60% of the full bottom gauge of the midsole 300. In some embodiments, the bottom surface 312 defined by a plurality of nodes 340, one or more surface layers, or both a plurality of nodes 340 and one or more surface layers may have a surface area equal to 45% to 55% of the full bottom gauge of the midsole 300.

[0072] The arrangement and structure of the platform 400 for node 340 at the bottom surface 312 can be adjusted to produce the desired characteristics of the bottom surface 312 of the three-dimensional grid 320. In a particular embodiment, the arrangement and structure of the platform 400 for directly adjacent nodes 340 at the bottom surface 312 can be adjusted to produce the desired characteristics of the bottom surface 312 of the three-dimensional grid 320. Figure 5 Shows Figure 4 Three directly adjacent nodes 340 in region "5" on the bottom surface 312 in Figure 7 Shows Figure 4 Three directly adjacent nodes 340 in region "7" on the bottom surface 312 in Figure 8 Shows Figure 4 Three directly adjacent nodes 340 in region "8" on the bottom surface 312 in

[0073] For example, as Figures 5 - 8 shown, the nodes 340 defining the bottom surface 312 of the three-dimensional grid 320 may include a plurality of struts 330 connected to the platform 400. The platform 400 of the nodes 340 defining the bottom surface 312 includes a top platform surface 410, a bottom platform surface 420 opposite the top platform surface 410, and side surfaces 430 connecting the top platform surface 410 and the bottom platform surface 420. In some embodiments, the top platform surface 410 of the platform 400 may have a top peripheral edge 412, the bottom platform surface 420 of the platform 400 may have a bottom peripheral edge 422, and the side surfaces 430 of the platform 400 connect the top peripheral edge 412 and the bottom peripheral edge 422. In some embodiments, the thickness of the side surfaces 430 may be in the range of 0.1 mm (millimeters) to 0.8 mm. In some embodiments, the thickness of the side surfaces 430 may be in the range of 0.1 mm to 0.4 mm.

[0074] The bottom platform surface 420 of each platform 400 includes a flat surface. The flat surface of the bottom platform surface 420 may be perpendicular to the side surfaces 430 connecting the top platform surface 410 and the bottom platform surface 420. In some embodiments, the entire bottom platform surface 420 may be a flat surface. In some embodiments, the flat surface of the bottom platform surface 420 may have a surface area of 2 mm 2 or greater. In some embodiments, the flat surface of the bottom platform surface 420 may have a surface area of 5 mm 2 or greater. In some embodiments, the flat surface of the bottom platform surface 420 may have a surface area of 7 mm 2 or greater. In some embodiments, the flat surface of the bottom platform surface 420 may be parallel to the flat surface of the top platform surface 410.

[0075] A plurality of struts 330 may be directly connected to the top platform surface 410 of the platform 400. As used herein, the term "directly connected" means that a first component is in direct contact with a second component. A first component that is "directly connected" to a second component may be deposited, formed, placed, or otherwise directly applied to the second component. In other words, if a first component is directly connected to a second component, no component or layer is disposed between the first component and the second component. A first component described as "bonded to" a second component means that the components are bonded to each other through direct contact and / or bonding between the two components or via an adhesive layer. If a first component is described as "disposed on" a second component, other layers or components may or may not be present between the first component and the second component.

[0076] In some embodiments, the plurality of struts 330 directly connected to the top platform surface 410 of the platform 400 may be the struts 330 of a single cell 322. In some embodiments, the plurality of struts 330 directly connected to the top platform surface 410 of the platform 400 may be the struts 330 of two or more directly adjacent cells 322. For example, a first strut 330 directly connected to the top platform surface 410 may be a strut that is part of a first cell 322, and a second strut 330 directly connected to the top platform surface 410 may be a strut that is part of a second cell 322 that is directly adjacent to the first cell 322.

[0077] In some embodiments, the plurality of struts 330 directly connected to the top platform surface 410 of the platform 400 may be directly connected to each other at the platform 400. For example, the plurality of struts 330 directly connected to the top platform surface 410 of the platform 400 may be directly connected to each other in a central region 414 on the top platform surface 410.

[0078] In some embodiments, one or more directly adjacent nodes 340 that define the bottom surface 312 may be independent nodes 340 that are capable of moving independently of each other. In such embodiments, the side surfaces 430 of two directly adjacent nodes 340 that define the bottom surface 312 are not connected to each other at the bottom surface 312. In some embodiments, the side surfaces 430 of two directly adjacent nodes 340 that define the bottom surface 312 of the three-dimensional grid 320 are not connected by a strut 330 at the bottom surface 312. In other words, in such embodiments, the side surfaces 430 of two directly adjacent nodes 340 that define the bottom surface 312 of the three-dimensional grid 320 are not directly coupled to each other by a strut 330 that extends from one side surface to the other side surface. This independent nature of the directly adjacent nodes 340 may facilitate the formation of a bottom surface 312 with a high degree of flexibility.

[0079] As used herein, two nodes 340 described as being "directly adjacent" to each other means that no node 340 or surface layer is positioned between the first node 340 and the second node 340 at the bottom surface 312. For two directly adjacent nodes 340 at the bottom surface 312, a straight line can be drawn directly from the first node 340 to the second node 340 without passing through another node 340 or surface layer. Similarly, as used herein, two surface layers described as being "directly adjacent" to each other means that no surface layer or node 340 is positioned between the first surface layer and the second surface layer at the bottom surface 312. For two directly adjacent surface layers at the bottom surface 312, a straight line can be drawn directly from the first surface layer to the second surface layer without intersecting another surface layer or node 340. Additionally, as used herein, two cells described as being "directly adjacent" to each other means that no cell 322 is between the first cell 322 and the second cell 322. Two directly adjacent cells 322 at the bottom surface 312 share at least one node 340 at the bottom surface 312. In contrast, two cells described as being "not directly adjacent" to each other means that there is a cell 322 between the first cell 322 and the second cell 322. Two not directly adjacent cells 322 at the bottom surface 312 do not share a node 340 at the bottom surface 312.

[0080] In some embodiments, the nodes 340 defining the bottom surface 312 of the three-dimensional grid 320 do not include struts 330 that connect to the side surfaces 430 of their respective platforms 400. In some embodiments, the plurality of struts 330 that are directly connected to the top platform surface 410 of the platform 400 do not define a part of the side surface 430 of the platform 400. In such embodiments, for example as Figure 6 shown, the top platform surface 410 can have a central region 414 where a plurality of struts 330 are directly connected to the top platform surface 410 and a peripheral region 416 disposed around the central region 414. The peripheral region 416 can extend from the central region 414 in the longitudinal direction 390 and / or the transverse direction 392 to define a region that surrounds all or a part of the central region 414.

[0081] In some embodiments, for example as Figure 7As shown, the plurality of nodes 340 defining the bottom surface 312 of the three-dimensional grid 320 may include a first node 340a having a first platform 400 with a first bottom platform surface 420 having a first surface area, and a second node 340b directly adjacent to the first node 340a, the second node having a second platform 400 with a second bottom platform surface 420 having a second surface area greater than the first surface area. In some embodiments, the second surface area may be 10% or more greater than the first surface area. In some embodiments, the first node 340a may have a first platform 400 with a first bottom platform surface 420 having a first flat surface area, and the second node 340b directly adjacent to the first node 340a may have a second platform 400 with a second bottom platform surface 420 having a second flat surface area greater than the first flat surface area. In some embodiments, the second flat surface area may be 10% or more greater than the first flat surface area.

[0082] In some embodiments, the plurality of nodes 340 defining the bottom surface 312 of the three-dimensional grid 320 may include a third node 340c directly adjacent to the second node 340b and having a third platform 400 including a third bottom platform surface 420 having a third surface area greater than the second surface area of the second bottom platform surface 420. In some embodiments, the third surface area may be 10% or more greater than the second surface area. In some embodiments, the third node 340c may have a third platform 400 including a third bottom platform surface 420 having a third flat surface area greater than the second flat surface area of the second bottom platform surface 420. In some embodiments, the third flat surface area may be 10% or more greater than the second flat surface area.

[0083] In some embodiments, such as Figure 8 As shown, the plurality of nodes 340 defining the bottom surface 312 of the three-dimensional grid 320 may include a first node 340d having a first platform 400 with a first bottom platform surface 420, a second node 340e directly adjacent to the first node 340d and having a second platform 400 with a second bottom platform surface 420, and a third node 340f directly adjacent to the second node 340e and having a third platform 400 including a third bottom platform surface 420 that merges with the second bottom platform surface 420 of the second node 340e. In such an embodiment, the third bottom platform surface 420 and the second bottom platform surface 420 form a continuous integrally formed surface 440. Although Figure 8Two nodes 340 are shown merging to form a continuous monolithic surface 440, but any number of nodes 340 at the bottom surface 312 can merge to form a monolithic surface 440. For example, three or more, five or more, ten or more, or twenty or more nodes 340 at the bottom surface 312 can merge to form a monolithic surface 440.

[0084] The monolithic surface 440 can define all or a portion of the bottom surface 820 of the top layer 800 as described herein. For example, as Figure 8 shown, a portion of the bottom surface 312 of the three-dimensional grid 320 can be defined by a top layer 800 having a top surface 810, a bottom surface 820 opposite the top surface 810, and a plurality of struts 330 having a plurality of cells 322 for directly connecting to the top surface 810. The side surfaces 830 of the top layer 800 can connect the top surface 810 to the bottom surface 820.

[0085] The bottom surface 820 of the top layer 800 can include a flat surface. The flat surface of the bottom surface 480 can be perpendicular to the side surfaces 830 connecting the top surface 810 and the bottom surface 820. In some embodiments, the entirety of the bottom surface 820 can be a flat surface. In some embodiments, the thickness of the side surfaces 830 can be in the range of 0.1 mm to 0.8 mm. In some embodiments, the thickness of the side surfaces 830 can be in the range of 0.4 mm to 0.8 mm. In some embodiments, the thickness of the side surfaces 830 can be greater than the thickness of the side surfaces 430 of the platform 400. For example, in some embodiments, the thickness of the side surfaces 830 can be in the range of 0.4 mm to 0.8 mm and greater than the side surfaces 430 having a thickness in the range of 0.1 mm to 0.4 mm.

[0086] In some embodiments, the plurality of struts 330 for a plurality of directly adjacent cells 322 can be directly connected to the top surface 810. In some embodiments, the plurality of struts 330 for a plurality of non-directly adjacent cells 322 can be directly connected to the top surface 810. For example, a first strut 330 directly connected to the top surface 810 can be a strut defining a portion of a first cell 322, and a second strut 330 directly connected to the top surface 810 can be a strut defining a portion of a second cell 322 that is not directly adjacent to the first cell 322 at the bottom surface 312.

[0087] In some embodiments, the surface layer 810 may extend over a plurality of directly adjacent cells 322 at the bottom surface 312. In some embodiments, the surface layer 810 may extend over a plurality of non - directly adjacent cells 322 at the bottom surface 312.

[0088] In some embodiments, the size of the bottom - platform surface 420 of adjacent nodes 340 at the bottom surface 312 may increase on adjacent platforms 400 such that the bottom - platform surfaces of two or more of the adjacent nodes merge to form an integrally - formed surface 440. For example, in some embodiments, a three - dimensional grid may include the following nodes 340 arranged in a row: node 340a, node 340b directly adjacent to node 340a, node 340c directly adjacent to node 340b, node 340e directly adjacent to node 340d, and node 340f directly adjacent to node 340e. In such an embodiment, the first node 340a may have a first bottom - platform surface 420 with a first surface area, the second node 340b may have a second bottom - platform surface 420 with a second surface area greater than the first surface area, the third node 340c may have a third bottom - platform surface 420 with a third surface area greater than the second surface area, and the fourth node 340e may have a fourth bottom - platform surface 420 that merges with the bottom - platform surface 420 of the fifth node 340f to form a continuous integrally - formed surface 440. By increasing the bottom - platform surface area along the row of nodes 340, the characteristics of the bottom surface 312 can gradually change from individual nodes 340 to nodes 340 that merge to form a continuous integrally - formed surface 440. In some embodiments, the surface area of the bottom - platform surfaces 420 of directly adjacent nodes 340 may increase by 10% or more for each node in the row until the bottom - platform surfaces 420 of two or more of the adjacent nodes 340 merge to form an integrally - formed surface 440.

[0089] The continuous integrally - formed surface 440 of the surface layer 800 of the three - dimensional grid 320 may not be connected to directly adjacent nodes 340 and / or directly adjacent surface layers 800 without defining a continuous integrally - formed surface 440 at the bottom surface 312. By not being connected to directly adjacent nodes 340 and / or directly adjacent surface layers 800 at the bottom surface 312, the surface layer 800 is able to move independently of directly adjacent nodes 340 and / or surface layers 800 such that they can move relative to each other at the bottom surface 312. This independent nature of directly adjacent nodes 340 and surface layers 800 can facilitate the formation of a bottom surface 312 with high flexibility.

[0090] In some embodiments, the three - dimensional grid 320 may include a plurality of different surface layers 800, for example, Figure 3The top layers 350, 352, and 354 shown in [description]. In such an embodiment, each top layer includes a top layer surface 810, a bottom layer surface 820, and a plurality of struts 330 for directly connecting to a plurality of cells 322 on the top layer surface 810. For example, the first top layer 350 includes a first top layer surface 810, a first bottom layer surface 820 opposite the first top layer surface 810, and a plurality of struts 330 for directly connecting to a plurality of cells 322 on the first top layer surface 810. Similarly, the second top layer 352 includes a second top layer surface 810, a second bottom layer surface 820 opposite the second top layer surface 810, and a plurality of struts 330 for directly connecting to a plurality of cells 322 on the second top layer surface 810.

[0091] In some embodiments, the three-dimensional grid 320 may include a plurality of top layers located in different parts or sides of the three-dimensional grid 320. In some embodiments, the first top layer (e.g., top layer 350) may be located in the forefoot portion 110 of the three-dimensional grid 320, and the second top layer (e.g., top layer 354) may be located in the heel portion 114 of the three-dimensional grid 320. In some embodiments, the first top layer (e.g., top layer 350) may be located on the outer side surface 308 of the three-dimensional grid 320, and the second top layer (e.g., top layer 352) may be located on the inner side surface 306 of the three-dimensional grid 320. In some embodiments, the first top layer (e.g., top layer 350) may include a portion located on the outer side surface 308 of the bottom surface 312 of the three-dimensional grid 320, and the second top layer (e.g., top layer 352) may include a portion located on the inner side surface 306 of the bottom surface 312 of the three-dimensional grid 320.

[0092] In some embodiments, the top layer may extend across different parts of the three-dimensional grid 320 and / or extend from the inner side surface 306 to the outer side surface 308 of the three-dimensional grid 320. For example, in some embodiments, the top layer (e.g., top layer 350) may extend from the forefoot portion 110 of the three-dimensional grid 320 to the midfoot portion 112 of the three-dimensional grid 320. As another example, in some embodiments, the top layer (e.g., top layer 350) may extend from the inner side surface 306 to the outer side surface 308 of the three-dimensional grid 320.

[0093] In some embodiments, the top layer does not include an edge shape that extends around the entire perimeter of the bottom surface 312. In other words, the top layer may not include a shape that extends along the entire perimeter shape 313 of the bottom surface 312. In some embodiments, the plurality of top layers that define all or a part of the bottom surface 312 may have different shapes.

[0094] In some embodiments, one or more surface layers may be located in one or more high-wear areas on the bottom surface 312 of the three-dimensional grid 320. For example, in some embodiments, a first surface layer (e.g., surface layer 350) may be located in a first high-wear area on the bottom surface 312 of the three-dimensional grid 320, and a second surface layer (e.g., surface layer 354) may be located in a second high-wear area on the bottom surface 312 of the three-dimensional grid 320.

[0095] In some embodiments, the location of one or more high-wear areas, and thus the location of one or more surface layers, may be based on the physical sign data of an individual or a group of individuals. Such physical sign data may include biometric pressure maps for areas of the foot of an individual or a group of individuals that experience different pressures or stresses during activity. For example, high-stress areas may be associated with the heel portion, the area corresponding to the metatarsal head of the individual's foot (i.e., at a location near the front end of the metatarsal bone), and the innermost portion of the individual's arch. Mild stress areas may be associated with the medial portion of the individual's arch and the area corresponding to the location of the phalanges of the individual. Low stress areas may be associated with the lateral portion of the individual's arch. The size, location, and degree of the stress areas of an individual will depend particularly on the anatomical structure of the individual's foot and the individual's gait. A group of individuals may be individuals classified and grouped based on four stability characteristics (pronators, mild pronators, neutral, and supinators) and four ground contact characteristics (heavy heel strikers, midfoot strikers, and forefoot strikers), which results in sixteen classification groups. Stability characteristics refer to how an individual's foot rolls when it contacts the ground, while ground contact characteristics refer to how an individual's foot lands.

[0096] In some embodiments, an outsole (e.g., outsole 140 or outsole 900) may be coupled to the bottom surface 312 of the three-dimensional grid 320. In some embodiments, the outsole may be directly coupled to the bottom surface 312 of the three-dimensional grid 320. In some embodiments, an outsole (e.g., outsole 140 or outsole 900) may be coupled to the bottom platform surface 420 of a plurality of nodes 340 that define the bottom surface 312 of the three-dimensional grid 320. In some embodiments, the outsole may be directly coupled to the bottom platform surface 420 of a plurality of nodes 340 that define the bottom surface 312 of the three-dimensional grid 320. In some embodiments, an outsole (e.g., outsole 140 or outsole 900) may alternatively or additionally be coupled to the bottom surface layer 820 of one or more surface layers 800 that define the bottom surface 312 of the three-dimensional grid 320. In some embodiments, the outsole may be directly coupled to the bottom surface layer 820 of one or more surface layers 800 that define the bottom surface 312 of the three-dimensional grid 320.

[0097] In some embodiments, the outsole may include a plurality of different outsole components that are coupled to different portions of the bottom surface 312 of the three-dimensional grid 320. Figure 9Illustrated is an outsole 900 having a plurality of outsole components according to some embodiments, the outsole components being connected to a bottom surface 312 of a three-dimensional mesh 320. The outsole 900 includes a first outsole component 910, a second outsole component 920, a third outsole component 930, and a fourth outsole component 940. In some embodiments, one or more of the outsole components 910, 920, 930, 940 may be directly coupled to a bottom platform surface 420 of a plurality of nodes 340 that define the bottom surface 312 of the three-dimensional mesh 320. In some embodiments, one or more of the outsole components 910, 920, 930, 940 may alternatively or additionally be directly coupled to a bottom surface layer surface 820 of one or more surface layers 800 that define the bottom surface 312 of the three-dimensional mesh 320. For example, in some embodiments, the outsole 900 may include a first outsole component (e.g., component 910) directly coupled to the bottom surface layer surface of a first surface layer (e.g., surface layer 350) and a second separate outsole component (e.g., component 920) directly coupled to the bottom surface layer surface of a second surface layer (e.g., surface layer 352).

[0098] In some embodiments, different outsole components of the outsole (e.g., outsole components 910, 920, 930, 940) are not connected to each other at the bottom surface 312 of the three-dimensional mesh 320. In such embodiments, the different outsole components may be independent components that are capable of moving independently of each other.

[0099] In some embodiments, the three-dimensional mesh 320 may be manufactured using an additive manufacturing process that includes printing a plurality of interconnected cells 322 on a plurality of platforms 400 and / or surface layers 800 that are attached to and directly connected to a build surface of a build plate. In such embodiments, for example as Figure 10 shown, a sole for a footwear article (e.g., sole 110) may be manufactured using a method that includes 3D printing a three-dimensional mesh 320 on a build surface 1010 of a build plate 1000. In some embodiments, 3D printing the three-dimensional mesh 320 includes printing a plurality of nodes 340 on the build surface 1010 of the build plate 1000, wherein each of the plurality of nodes 340 includes a platform 400 as described herein. In some embodiments, 3D printing the three-dimensional mesh 320 includes printing one or more surface layers 800 on the build surface 1010 of the build plate 1000. After forming the platforms 400 and / or the (multiple) surface layers 800, a plurality of struts 330 may be printed on a top platform surface 410 of the platforms 400 and / or the (multiple) top surface layer surfaces 810 of the (multiple) surface layers 800.

[0100] In some embodiments, as discussed herein, 3D printing a three-dimensional grid 320 on a build surface 1010 of a build plate 1000 can include a continuous liquid interface production process. In such embodiments, a platform 400 and / or one or more skins 800 are printed on the build surface 1010, where a bottom platform surface 420 and a bottom skin surface 820 are attached and directly connected to the build surface 1010. These surfaces are printed by curing a liquid resin 1030 in a liquid resin reservoir below the build plate 1000 that is present on the build surface 1010. And, as the build plate 1000 is raised in a vertical direction 1020, the platform 400 and / or one or more skins 800 are printed by curing the liquid resin 1030 in the liquid resin reservoir below the build plate 1000, and struts 330 are printed on a top platform surface 410 of the platform 400 and / or (a) top skin surface(s) 810 of the one or more skins 800. The liquid resin 1030 can be cured using light such as ultraviolet light. The surface areas of the bottom platform surface 420 and the bottom skin surface 820 that are attached and directly connected to the build surface 1010 can be arranged and shaped as discussed herein to reduce the likelihood of the three-dimensional grid 320 detaching from the build surface 1010 during 3D printing and to provide desired characteristics for a bottom surface 312 of the three-dimensional grid 320 as discussed herein.

[0101] The skins described herein can include bottom surfaces having various shapes. In some embodiments, a skin can include a particular shape to facilitate attachment of one or more outer bottom components to the bottom surface of the three-dimensional grid. In some embodiments, the three-dimensional grid can include a bottom surface having one or more skins that have a perimeter frame. Figure 11A and 11B Shown is a midsole 1100 including a three-dimensional grid 1120 according to some embodiments, the three-dimensional grid having a bottom surface 1112 that is defined in whole or in part by two skins 1150, 1152 having a perimeter frame. Similar to the three-dimensional grid 320, the three-dimensional grid 1120 includes a plurality of interconnected cells 1122.

[0102] The bottom surface 1112 of the three-dimensional grid 1120 is defined by a first skin 1150 and a second skin 1152 that are separated by a midfoot region 1140. The first skin 1150 may not be connected to the second skin 1152 at the bottom surface 1112 such that the first skin 1150 and the second skin 1152 can move independently of each other at the bottom surface 1112. The first skin 1150 includes a first frame 1151 that defines a perimeter shape of the first skin 1150, and the second skin 1152 includes a second frame 1153 that defines a perimeter shape of the first skin 1150.

[0103] In some embodiments, as Figure 11BAs shown, the outsole 1190 can be coupled to the bottom surface 1112 of the three-dimensional mesh 1120 defined by the upper layers 1150, 1152. In some embodiments, the outsole 1190 can be directly coupled to the bottom surface 1112 of the three-dimensional mesh 1120 defined by the upper layers 1150, 1152. In some embodiments, the outsole 1190 can include a first outsole component 1192 directly coupled to the bottom surface of the first upper layer 1150 and a second separate outsole component 1194 directly coupled to the bottom surface of the second upper layer 1152. In some embodiments, the first outsole component 1192 and the second outsole component 1194 do not connect to each other at the bottom surface 1112 of the three-dimensional mesh 1120. In such embodiments, the outsole components 1192, 1194 can be independent components that are capable of moving independently of each other.

[0104] In some embodiments, such as Figure 12 As shown, the three-dimensional mesh 1120 for the footwear article 1200 can include a forefoot region 1230 and a heel region 1250, where the forefoot region has a height measured in the vertical direction 394 that is at least twice the height of the midfoot region 1140, and the heel region has a height measured in the vertical direction 394 that is at least twice the height of the midfoot portion 1140. In some embodiments, the peripheral bottom surface of the forefoot region 1230 can have a peripheral shape defined by a first frame 1151. In some embodiments, the peripheral bottom surface of the heel region 1250 can have a peripheral shape defined by a second frame 1153. Compared to the midfoot region 1140, the relative heights of the forefoot region 1230 and the heel region 1250 create a void 1260 between the forefoot region 1230 and the heel region 1250 at the midfoot region of the shoe.

[0105] It should be understood that the detailed description section, rather than the summary and abstract sections, is intended to be used to interpret the claims. The summary and abstract sections may set forth one or more, but not all, exemplary embodiments contemplated by the inventors, and thus are not intended to limit the invention and the appended claims in any way.

[0106] The present invention has been described above in terms of functional building blocks that illustrate the implementation of specific functions and their relationships. For ease of description, the boundaries of these functional building blocks have been arbitrarily defined herein. Alternative boundaries can be defined as long as the specified functions and their relationships are performed appropriately.

[0107] The description of the above specific embodiments will so fully disclose the general nature of the present invention that others can, by applying the knowledge of those skilled in the art, easily modify and / or adapt these specific embodiments for various applications without undue experimentation, without departing from the general concept of the present invention. Therefore, such changes and variations are intended to be within the meaning and equivalence of the disclosed embodiments, based on the teachings and guidance provided herein. It is to be understood that the language or terminology herein is for the purpose of description and not of limitation, so that the terminology or language of this specification is to be interpreted by those skilled in the art in accordance with the said teachings and guidance.

[0108] The breadth and scope of the present invention should not be limited by any of the above exemplary embodiments, but should be defined only in accordance with the appended claims and their equivalents.

Claims

1. A sole for a footwear product, the sole including a midsole, the midsole comprising: Three-dimensional mesh, comprising: A plurality of interconnected cells, each interconnected cell including a plurality of struts defining a three-dimensional shape and a plurality of nodes at which one or more of the plurality of struts are connected; A top surface; and A bottom surface opposite the top surface, the bottom surface being at least partially defined by a plurality of the nodes, wherein each node of the plurality of nodes defining the bottom surface includes a platform, the platform including: A top platform surface, A bottom platform surface, Side surfaces connecting the top platform surface and the bottom platform surface, and A plurality of struts directly connected to the top platform surface; Wherein the side surfaces of two directly adjacent nodes defining the bottom surface are not connected by a strut at the bottom surface, such that the two directly adjacent nodes are capable of moving independently of each other; wherein the midsole includes an edge disposed around all or a portion of the perimeter of the top surface of the midsole, the edge including a serrated top line having a plurality of protrusions, wherein the three-dimensional mesh includes struts defining the serrated top line, the struts defining the serrated top line defining the protrusions extending upward from the edge such that they are configured to be disposed above a portion of the upper of a footwear article.

2. The sole according to claim 1, the sole further including an outsole directly connected to the bottom surface of the three-dimensional grid.

3. The sole according to claim 1, wherein, The side surfaces of two directly adjacent nodes defining the bottom surface are not connected to each other at the bottom surface.

4. The sole according to claim 1, wherein, The plurality of nodes defining the bottom surface do not include struts connected to the side surfaces of the platform.

5. The sole according to claim 1, the plurality of struts directly connected to the top platform surface do not define a part of the side surface of the platform.

6. The sole according to claim 1, wherein, The top platform surface includes a top peripheral edge, the bottom platform surface includes a bottom peripheral edge, and the side surfaces connect the top peripheral edge and the bottom peripheral edge.

7. The sole according to claim 1, wherein, The top platform surface includes a central region and a peripheral region disposed around the central region, in the central region, the plurality of struts are directly connected to the top platform surface.

8. The sole according to claim 1, wherein, The plurality of nodes defining the bottom surface include: A first node, the first node including a first platform, the first platform including a first bottom platform surface having a first surface area, and A second node, the second node being directly adjacent to the first node and including a second platform, the second platform including a second bottom platform surface, the second bottom platform surface having a second surface area that is 10% or more greater than the first surface area.

9. The sole according to claim 8, further including a third node directly adjacent to the second node and including a third platform, the third platform including a third bottom platform surface having a third surface area that is 10% or more larger than the second surface area.

10. The sole according to claim 1, wherein, The plurality of nodes defining the bottom surface include: A first node, the first node including a first platform, the first platform including a first bottom platform surface, A second node, the second node being directly adjacent to the first node and including a second platform, the second platform including a second bottom platform surface, and A third node, the third node being directly adjacent to the second node and including a third platform, the third platform including a third bottom platform surface, wherein the third bottom platform surface and the second bottom platform surface form a continuous integrally formed surface.

11. The sole according to claim 10, wherein, The bottom surface of the three-dimensional mesh is further defined by a surface layer, the surface layer including: A top surface layer surface, A bottom surface layer surface opposite the top surface layer surface, and A plurality of struts for directly connecting to a plurality of cells of the top surface layer surface, Wherein, the continuous integrally formed surface defines a part of the bottom surface layer surface.

12. The sole according to claim 11, wherein, The surface layer and the first node are not connected to each other at the bottom surface of the three-dimensional grid.

13. The sole according to claim 1, further comprising an outsole, the outsole being coupled to the bottom platform surface of the plurality of nodes that define the bottom surface of the three-dimensional grid.

14. The sole according to claim 1, wherein, The bottom platform surface includes a flat surface.

15. A sole for a footwear article, the sole comprising a midsole, the midsole comprising: A three-dimensional grid, comprising: A plurality of interconnected cells, each interconnected cell including a plurality of struts defining a three-dimensional shape and a plurality of nodes at which one or more struts are connected; A top surface; and A bottom surface opposite to the top surface, the bottom surface being defined by a first surface layer, a second surface layer, and a plurality of nodes directly adjacent to the first surface layer or the second surface layer, Wherein, the first surface layer includes: a first top surface layer surface, a first bottom surface layer surface opposite to the first top surface layer surface, and a plurality of struts of a plurality of cells for directly connecting to the first top surface layer surface, Wherein, the second surface layer includes: a second top surface layer surface, a second bottom surface layer surface opposite to the second top surface layer surface, and a plurality of struts of a plurality of cells for directly connecting to the second top surface layer surface, Wherein, each of the plurality of nodes defining the bottom surface includes a platform, the platform including: a top platform surface and a bottom platform surface opposite to the top platform surface, and Wherein, the first surface layer, the second surface layer, and the plurality of nodes are not connected to each other at the bottom surface of the three-dimensional grid, such that the first surface layer, the second surface layer, and the plurality of nodes can move independently of each other; Wherein, the midsole includes an edge disposed around all or a part of the perimeter of the top surface of the midsole, the edge including a serrated top line having a plurality of protrusions, wherein the three-dimensional grid includes struts defining the serrated top line, and the struts defining the serrated top line define the protrusions extending upward from the edge such that they are configured to be disposed above a part of the upper of the footwear article.

16. The sole according to claim 15, wherein, The first surface layer is located in the forefoot part of the three-dimensional grid, and the second surface layer is located in the heel part of the three-dimensional grid.

17. The sole according to claim 15, wherein, The first surface layer is located in a first high-wear area on the bottom surface of the three-dimensional grid, and the second surface layer is located in a second high-wear area on the bottom surface of the three-dimensional grid.

18. The sole according to claim 15, wherein, The first surface layer includes a part located on the outer side of the bottom surface of the three-dimensional grid, and the second surface layer includes a part located on the inner side of the bottom surface of the three-dimensional grid.

19. The sole according to claim 15, further comprising an outsole, the outsole being coupled to the first bottom surface layer surface, the second bottom surface layer surface, and the bottom platform surface of the platform.

20. The sole according to claim 15, further comprising an outsole, the outsole being coupled to the first bottom surface layer surface and the second bottom surface layer surface.

21. The sole according to claim 20, wherein, The outsole includes a first outsole component directly connected to the first bottom surface layer surface and a second outsole component directly connected to the second bottom surface layer surface.

22. A method of manufacturing the sole according to claim 1, the method comprising: 3D printing the three-dimensional grid on a build surface of a build plate, including 3D printing the bottom platform surface of each of the plurality of nodes, the bottom platform surface being in contact with the build surface.

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