Method and apparatus for designing footwear

Abstract

A customized article of footwear and a method for manufacturing a customized article of footwear are disclosed. In some examples, a customized article of footwear includes at least one corrective feature configured to stimulate a user's foot to move and roll according to a pattern. In some examples, customized articles of footwear include soles, insoles, midsoles, outsoles, uppers, or any portion thereof. In some examples, the method includes obtaining footwear-specific data. In some examples, the method includes obtaining user-specific data. In some examples, the method includes generating a model of a customized article of footwear based on acquired footwear-specific data and user-specific data. In some examples, the method includes manufacturing a customized article of footwear based on the model.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Application Serial No. 63 / 364,392, filed on May 9, 2022, the entire disclosure of which is incorporated herein by reference. Background Art

[0003] The present invention relates to the field of footwear, and more particularly to customized footwear design, and methods and apparatus for designing customized footwear.

[0004] The present invention relates to the field of footwear, and more particularly to customized footwear design, and methods and apparatus for designing customized footwear.

[0005] Conventional footwear is not customized for the user. Rather, the footwear is designed based on general characteristics that apply to most feet most of the time. As a result, the footwear is often uncomfortable for the user and / or fails to correct or prevent problematic foot-related conditions.

[0006] Footwear inserts (e.g., insoles) have been used to correct a variety of foot-related problems. Unfortunately, in most cases, footwear inserts do not fit the user's foot any better than the original footwear. Therefore, "custom" footwear inserts have been developed to try and correct or prevent the problem while taking into account, at least to some extent, the user's actual foot.

[0007] The design of custom footwear inserts is typically a manual, time-consuming, error-prone, and expensive operation. Therefore, mass production of such custom footwear inserts is problematic because, by definition, each footwear insert is custom made. These and other factors limit the availability and effectiveness of custom footwear and increase their cost.

[0008] Footwear and components of footwear can be configured to provide a variety of functions, from protecting and supporting the user's foot to correcting the user's gait and posture to providing comfort to the user. Internal footwear components such as insoles, which directly contact the sole of the user's foot, perform many of these functions. Current insole technology is evolving rapidly, with new insole designs incorporating new materials and new structural features, as well as features customized for specific users. Despite this, some core qualities, such as flexibility and durability, remain common to all insoles. The flexibility of the insole ensures that the insole flexes with the movement of the user's foot, for example, allowing the user's toes to flex to the point of full flexion during the gait cycle. The durability of the insole ensures that the insole will continue to perform its function over time without breaking or losing its shape. In addition, breathability is an important quality of an insole, especially for insoles that are worn for long periods of time and / or used frequently.

[0009] In general, adequate ventilation contributes to the comfort, performance, and long-term usability of footwear. Shoes used for sports, in particular, can have unique requirements for ventilation due to the specific shape and function of the shoe designed for a specific sport. In some footwear designs, ventilation comes from air holes and / or breathable areas on the upper portion of the shoe, such as mesh fabric in the toe area of ​​a running shoe. Other footwear designs incorporate ventilation elements in the sole. In cycling shoes, in addition to allowing air flow for ventilation, indentations running diagonally through the sole can be used to optimize aerodynamics. Still other designs feature inlet and outlet channels through which air is pushed when the user steps.

[0010] Many existing ventilation solutions are integrated into footwear designs, which limits the versatility of these solutions for different types of footwear. One approach is to use a removable insole, where the insole has other functions, such as providing support, cushioning or shock absorption, and additionally has ventilation holes that promote air circulation. However, when ventilation holes are added to insoles designed for other purposes, ventilation is a secondary consideration and may not be optimal. In addition, the location of the ventilation holes is not suitable for all designs, types or brands of footwear. For example, in a cycling shoe, the ventilation holes in the insole should ideally match the location of any ventilation holes built into the cycling shoe, but each manufacturer has its own unique shoe design with specific ventilation holes. Finally, many existing insoles are hard and thick, which can hinder the user's movement in certain directions and also limit the type of shoes that the insole is suitable for.

[0011] Therefore, there is a need for improved designs of footwear and footwear portions that provide a better fit for the user and that can be efficiently and economically manufactured, as well as methods and apparatus for designing and manufacturing customized footwear. Summary of the invention

[0012] In one embodiment, a customized article of footwear is disclosed. In some examples, the customized article of footwear includes at least one corrective feature configured to stimulate a user's foot to move and roll according to a pattern. In some examples, the customized article of footwear includes a sole, an insole, a midsole, an outsole, an upper, or any portion thereof.

[0013] In one embodiment, a method for manufacturing a customized article of footwear is disclosed. In some examples, the method includes obtaining footwear-specific data. In some examples, the method includes obtaining user-specific data. In some examples, the method includes generating a model of the customized article of footwear based on the obtained footwear-specific data and the user-specific data. In some examples, the method includes manufacturing the customized article of footwear based on the model.

[0014] Additional embodiments include one or more non-transitory computer-readable storage media comprising instructions that, when executed by one or more processors of a computer system, cause the computer system to perform the above-described method, and a computer system comprising one or more memories and one or more processors configured to perform the above-described method. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 Embodiments of customized articles of footwear including insoles are depicted.

[0016] Figure 2A Depicted Figure 1 A view of an embodiment of components of a base layer of an insole.

[0017] Figure 2B Depicted Figure 1 A view of an embodiment of components of a base layer of an insole.

[0018] Figure 2C Depicted Figure 1 A view of an embodiment of a base layer of an insole.

[0019] Figure 2D Depicted Figure 1 A view of an embodiment of a base layer of an insole.

[0020] Figure 3 Depicted Figure 1 A view of an embodiment of a directional stiffness layer of an insole.

[0021] Figure 4 Depicted Figure 1 Rear and side views of an embodiment of a stabilization layer of an insole.

[0022] Figure 5 Depicted Figure 1 Rear and side views of an embodiment of a stabilization layer of an insole.

[0023] Figure 6 Depicted Figure 1 A view of an embodiment of a stabilization layer of an insole.

[0024] Figure 7 Depicted Figure 1 A view of an embodiment of a reinforcement layer of an insole.

[0025] FIG. 8A to FIG. 8C An example of a forefoot support is depicted. Fig. 8A Depicted is a perspective view of a top surface of an example insole for a customized article of footwear including a forefoot support, showing an anterior-posterior (AP) axis and a medial-lateral (ML) axis.

[0026] Figure 8B Depicted Fig. 8A A top view of a forefoot support of an example insole.

[0027] Figure 8C Depicted Fig. 8A A view of a bottom surface of an example insole.

[0028] Fig. 9A A view of a forefoot support depicting a bottom surface of an example insole for customizing an article of footwear.

[0029] Fig. 9B Depicted from Fig. 9A A view of the flexibility of the forefoot support of an example insole's bottom surface.

[0030] Fig. 10A A bottom surface of an example forefoot support for a customized article of footwear is depicted.

[0031] Fig. 10B A bottom surface of an example forefoot support of a customized article of footwear is depicted relative to an inner side of a user's forefoot.

[0032] Fig.11 is a flow chart of an example process for manufacturing a customized article of footwear.

[0033] Fig. 12A A graph depicting the center of pressure (COP) point at various points in time during a user's roll-off.

[0034] Fig. 12B A graph depicting the COP points at various points in time during another user roll-off.

[0035] Fig.13 An underside of a customized article of footwear including a silhouette is depicted.

[0036] Fig.14 Depicted is a bottom view of a customized article of footwear wherein the stabilization layer includes a surface texture.

[0037] Fig.15 Embodiments of a customized footwear system are depicted.

[0038] Fig.16A Depicted is a side view of an example of an orthotic feature added to a customized article of footwear.

[0039] Fig. 16B Depicted is a bottom view of an example of an orthotic feature added to a customized article of footwear.

[0040] Fig.17A The pressure measurements of the user and the corresponding COP curve of the user are depicted.

[0041] Fig. 17BAnother user's pressure measurement and the other user's corresponding COP curve are depicted. DETAILED DESCRIPTION

[0042] Unless otherwise specified, the term "user" herein refers to a user or intended user of a footwear or custom footwear component. The term "operator" herein refers to a person who performs the methods or method steps described herein, or operates the systems described herein. Unless otherwise specified, the operator may be a medical professional, a non-medical professional, such as a technician, engineer, or trained store employee, or the general public.

[0043] The present disclosure relates to improved designs of footwear and footwear portions, and methods and apparatus for designing customized footwear, particularly customized footwear portions. The terms "custom footwear" or "custom footwear portions" refer herein to one or more articles of footwear or footwear portions, respectively, that are specifically designed for a particular user.

[0044] Custom footwear is beneficial in treating a variety of known foot conditions. For example, pronation of the foot (i.e., the inward rotation of the foot when standing, walking, and running) can cause swelling and Achilles tendon problems. To treat pronation, custom footwear can be designed to correct or improve static and dynamic stresses on the foot. For example, custom footwear can correct the support under the middle arch of the foot and can reduce the ability of the shoe to bend in certain directions.

[0045] As another example, a bunion may be treated with customized footwear that reduces medial loading and provides customized support for the hallux (ie, big toe). Custom footwear may also be used to treat other conditions such as: Achilles tendinitis, Achilles tendinopathy, ankle instability, arthritis, bunions, calcaneal apophysitis (Sevier's disease), Charcot foot, chondromalacia patellae, diabetic neuropathy, plantar fibromatosis, functional hallux contracture, Haglund's deformity, hallux valgus, hallux contracture / stiffness, heel fat pad atrophy, heel spurs, iliotibial band friction syndrome, lateral, medial or tibial knee pain, leg length difference, medial tibial stress syndrome, metatarsalgia, Morton's neuralgia, Morton's toe, osteoarthritis, patellar tendinopathy, patellofemoral knee pain, peroneal tendinopathy, arches, flat feet / planovalgus, plantar fasciitis, poor circulation, posterior tibial tendon dysfunction, pronation of the foot, repetitive strain injuries, rheumatoid arthritis, scoliosis, sesamoiditis, shin splints, tarsal sinus, tarsal tunnel syndrome, and other conditions known to those skilled in the art.

[0046] In addition to treating existing adverse foot conditions, customized footwear can help delay or prevent the onset of pain, injury, and foot disease. For example, customized footwear can reduce stress-related pain and injury to the foot, ankle, leg, knee, back, etc. by better distributing weight during foot strike, or by changing the way the foot falls and rotates during dynamic movements. Similarly, customized footwear can prevent movement in certain directions (such as rotational ankle movement) while facilitating movement in other directions (such as rotation of the forefoot during transitional movements).

[0047] In addition, customized footwear can improve biomechanical performance (e.g., biomechanical performance of an athlete) during activities such as walking, jogging, running, jumping, bicycling, dancing, ballet, tennis, basketball, soccer, fitness and training, skateboarding, golf, track and field, hiking, volleyball, padel, or rock climbing. For example, customized footwear can change the angle of impact of the foot during dynamic activities such as running, which in turn can increase the overall speed of the runner. As known to those skilled in the art, customized footwear also has many other benefits.

[0048] Customized footwear can be designed using data about the physical characteristics or attributes of a particular user, so-called "static" user-specific data. For example, the user's foot size and static foot pressure (e.g., when standing) can be measured.

[0049] Custom footwear can also be designed using dynamic user-specific data, such as dynamic foot pressure measurements. For example, dynamic pressures on a user's foot can be measured during dynamic foot activities, such as: running, walking, jumping, landing, pivoting, rolling, rocking, etc. In fact, any functional biomechanical measurement can be used during the design of custom footwear.

[0050] Static user-specific data

[0051] One aspect of the present disclosure relates to static user data that can be used to customize footwear design, and methods of collecting such data.

[0052] Static user-specific data can be used to customize the design of footwear. Different types of static user-specific data can be generated, determined or measured by different methods. Static user-specific data can include individual numerical values, binary values, text values, selections from enumerated lists, two-dimensional (2D) or three-dimensional (3D) geometric or graphical data, such as photographs, pixelated images, vector-based images, medical images, medical image sets, voxel-based 3D models, 3D surface models, etc. In some cases, static user-specific data can be collected using forms or questionnaires in paper or digital form. In other cases, a measuring instrument or system can be used.

[0053] For example, basic user data, such as gender, height, and weight, can be used to customize the design of footwear.

[0054] Some user data may be objective data (eg, height and weight), while other user data may be subjective data (eg, activity level and user preferences).

[0055] Static user-specific data can be body part-specific data.For example, the data related to the foot of a specific user can include: side (left, right or both), foot length, foot width, arch height, arch position, shape of foot, footprint, shoe size, maximum bending or extension of foot in all directions, maximum bending or extension of foot during rest, maximum inversion and eversion of foot, maximum inversion and eversion of foot during rest, maximum internal rotation and external rotation of foot, internal rotation or external rotation of foot during rest, shape and position of some bones and bone structures, position, track, length and attachment point of some muscles, ligaments and tendons, existence, shape and condition of meniscus, existence, position, shape, thickness and condition of cartilage, existence, position and shape of osteophyte and other characteristics known to those skilled in the art.In some cases, static user-specific data can include symptom description, medical condition or desired processing.In some cases, static user-specific data can include medical report or prescription.In some cases, physical properties can be determined using manual physical measuring instrument (such as tape measure), and others can be determined by digital measurement system (such as digital ruler).

[0056] Given the complexity of the shape and composition of various body parts, such as the foot, a more accurate data acquisition method may be advantageous.

[0057] For example, static user-specific data can be generated using one or more image sensors, such as a live or static camera. Various types of cameras can be used, including: a traditional digital camera with a single image sensor or a stereo camera with two or more image sensors. Traditional digital cameras, including mobile device cameras, can be used by taking multiple images of an object, such as a body part, from different angles to infer depth and 3D structure. Multiple images of a body part, such as a foot (or other anatomical features such as an ankle, calf, etc.), can be analyzed by, for example, a computer system to determine three-dimensional (3D) user-specific data, such as a 3D model, using techniques such as photogrammetry or reflected structured light. For example, U.S. Patent 8,126,261, entitled "Reconstructing 3D Faces from 2D Images", discloses a method for determining a 3D model, such as a face, from multiple two-dimensional (2D) images, the entire contents of which are incorporated herein by reference. Similarly, PCT Patent Publication WO2012 / 129252, entitled "Digital 3D Camera Using Periodic Illumination", the entire contents of which are incorporated herein by reference, discloses a method for determining a 3D model using 2D image data using a digital camera and a projected light pattern.

[0058] In addition, two or more cameras may be used simultaneously to generate 3D user-specific data. For example, U.S. Patent 8,532,368, entitled "Method and Apparatus for Generating a 3D Model of an Environment," describes a method of determining a 3D model using a mobile stereo camera system, the entire contents of which are incorporated herein by reference. Thus, an image sensor may be used with the aforementioned methods and other methods known in the art to capture 2D user-specific data and construct a user-specific 3D model based on the 2D data.

[0059] In some cases, mobile devices (such as smartphones and tablets) may include stereoscopic image sensors, which may be referred to as “3D cameras.” Such devices may have the ability to capture image data and create 3D data or 3D models without requiring additional processing by a separate processing system.

[0060] In addition, more advanced camera systems, such as the "Kinect" available from Microsoft Corporation (Redmond, Washington, USA), provide image data that includes depth information. Similarly, dedicated 3D scanners using image sensors, such as the "Gotcha" 3D scanner from 4D Dynamics (Antwerp, Belgium) or Digitizer TM (New York, NY, USA) can be used.

[0061] An advantage of using an image sensor based device (such as one or more cameras or camera systems described above) to determine user specific data is that such devices are typically digital, portable and relatively inexpensive. Thus, a system for designing custom footwear may be fully or partially portable (e.g., an imaging system). The portability of the system increases the ability to use such a system in different environments.

[0062] For any of the aforementioned image sensor-based devices, it may be beneficial to include objects of known size, such as a ruler, a credit card, or any other one-dimensional or multi-dimensional known device, in some or all of the 2D or 3D image data. The inclusion of such objects may allow for more accurate determination of the scale of other objects in the 2D image data, such as a body part of a user. For example, a user may be asked to stand on a plate with known calibration marks while the image data is captured. As another example, a user may be asked to stand on a plane close to a chip card or magnetic stripe card of standard size (e.g., having a size according to the ID-1 standard defined by ISO 7810) while the image data is captured. Such cards are widely available to the public (e.g., in the form of personal identification cards, driver's licenses, payment cards, public transportation fare cards, or retail loyalty cards) and have convenient sizes for use as scaling elements for body parts.

[0063] Other devices can be used to generate 3D static user-specific data. For example, mechanical scanning systems, optical scanners, laser-based scanners and other scanning systems known to those skilled in the art can be used to scan body parts, such as feet, and create 3D models associated with the scanned body parts. For example, the advantage of laser or optical scanning systems is that they can create very accurate 3D models of scanned objects. However, such scanning systems can be less portable and more expensive than image sensor-based devices, such as those described above. In some cases, a dedicated scanning system configured for a specific type of body part can be used. For example, a dedicated foot scanning system is known in the art, which typically includes a linear scanning element (sole scanning element) on a movable arm mounted under a glass plate. The user can be required to stand on the glass plate, and the movable arm with the linear scanning element passes under the foot. In this way, a 3D model of the lower side of the user's foot can be generated (for example, under load-bearing conditions). Some such foot scanning systems can also include scanning elements for scanning the upper side of the foot. Such scanning systems can generate a 3D model of the entire foot.

[0064] Medical imaging techniques may also be used to generate 2D and 3D static user-specific data. For example, X-ray scans, computed tomography (CT) scans, positron emission tomography (PET) scans, magnetic resonance imaging (MRI), ultrasound scans, and other medical imaging techniques known to those skilled in the art may be used to create 2D and 3D user-specific data, which in turn may be used to create a 2D or 3D model, such as a 3D surface model, of a body part (such as a foot). The process of generating a 2D or 3D model from one or more medical images is generally referred to as "segmentation()", and may be performed using software such as Segmentation. (Materialise NV, Belgium) is executed on a computing device. Segmenting one or more medical images can be done fully automatically, semi-automatically, or may require operator input, such as for fine-tuning the results of an initial automatic segmentation step. Specifically, certain types of medical imaging modalities can also provide additional details about internal anatomical features and functions, such as bone structure, bone alignment, position, trajectory, length and attachment points of certain muscles, ligaments and tendons, the presence, shape and condition of the menisci, the presence, position, shape, thickness and condition of cartilage, the presence, position and shape of osteophytes, and other details known in the art. The design of customized footwear can advantageously take such features into account.

[0065] Other types of sensors may also be used to determine static user-specific data. For example, a pressure-sensitive pad may record a pressure distribution associated with a user's footprint. That is, a user may stand on a pressure-sensitive pad to generate multiple pressure readings associated with the user's static footprint.

[0066] In some cases, the pressure sensor can be worn by the user. For example, the pressure sensor can take the form of an insole sensor, i.e. a thin pressure-sensitive pad, which is shaped so as to be inserted into a footwear item subsequently worn by the user. Such user-wearable pressure sensors can not only record the pressure distribution associated with the user's footprint, but can also record the pressure distribution exhibited when the user wears a footwear item for which a custom footwear portion is designed. Such insole sensors can be provided within a certain range of shoe sizes and can be flexible to adapt to the shape of the footwear item. Such insole sensors can also be customized to be compatible with specific footwear items, such as based on footwear-specific data as described below. The user-wearable pressure sensor may include a data storage component for storing measurement data. Alternatively, they may include a communication interface for transmitting the measurement data to an external data storage system. The communication interface may be a wired communication interface, in which case the external data storage system can be advantageously worn on the user's body. The communication interface may also be a wireless communication interface, in which case the external data storage system may be independent of the user.

[0067] In some cases, various forms of measurement, imaging, and sensing can be performed on a positive or negative cast, mold, or other impression of a user's body part (such as a foot mold). This capability allows the design of customized footwear without requiring the user to be in the same place as, for example, a scanning device. In other cases, the user can use his or her own device, such as a mobile phone or camera equipped with a camera, to generate data, such as 2D or 3D image data, which is then provided to a data processing system intended to design customized footwear for the user. In this way, the user does not need to be in the same place as other aspects of the customized footwear design system. For example, a user can provide basic user data (e.g., height, weight, and preference data) and a plurality of self-generated 2D image data to a remote service, which uses these data to design and manufacture customized footwear for the user. As described above, it can be beneficial to include objects of known size in one or more 2D images to allow accurate determination of the proportions of other objects (such as the user's body parts) in the 2D image data.

[0068] In general, the above-mentioned method of generating static user-specific data can be used to create a detailed 2D or 3D model of a user's body part (such as a foot). These models can in turn be used to design custom footwear for the user. To this end, computer-aided design (CAD) or computer-aided manufacturing (CAM) software, such as software available from Materialise USA (Plymouth, Michigan, USA), can be used to process user-specific data and create a custom footwear design.

[0069] Dynamic user-specific data

[0070] Another aspect of the present disclosure relates to dynamic user data that can be used to customize footwear design, and methods of collecting such data.

[0071] Customized footwear can also be designed using dynamic user-specific data. The dynamic user-specific data can include data collected about dynamic user movements, such as: running, jogging, walking, jumping, landing, pivoting, rolling, rocking, etc.

[0072] One type of equipment for measuring dynamic user-specific data may be a pressure-sensitive pad or liner that may be configured to measure pressure data that varies over time and provide the data to, for example, a processing system. Such pressure-sensitive pads may be relatively large so that they may measure more than one foot during a user's movement and / or multiple movement cycles of the same foot during one measurement period. For example, a pressure-sensitive pad or liner having a length and width between 30 cm and 80 cm, such as 50 cm×50 cm, may measure the pressure distribution on both feet that varies over time when a user jumps onto it from rest and then lands on it during one measurement period. As another example, an elongated pressure-sensitive pad or liner having a width between 30 cm and 80 cm, such as 50 cm, and a length of several meters, such as 2 cm or 3 cm, may measure the pressure distribution on both feet that varies over time during one or more strides as a user walks or runs on it. A pressure-sensitive pad or liner of sufficient size makes it easier for the foot to contact the pad or liner during the user's movement, thus reducing or eliminating the need for the user to adjust his stride and focus on contacting the pad or liner. This can allow measurements that are more representative of the user's natural, unconstrained movement mode. In addition, recording multiple strides within a measurement period (e.g., within a continuous movement of the user across the pad or liner) allows averaging between the measurement data of the corresponding time points of multiple strides to reduce or eliminate noise or measurement artifacts. In addition, a pressure-sensitive pad of sufficient size can measure characteristics, such as stride, gait, alignment, footsteps, foot rotation, and other characteristics known to those skilled in the art. For some dynamic user movements, such as walking, especially jogging and running, it can be beneficial to provide enough space on either end of the pressure-sensitive pad or liner, so as to allow the user to accelerate at a natural speed and enter a natural stride before the foot contacts the pressure-sensitive pad or liner, maintain the speed and natural stride along the full length of the pressure-sensitive pad or liner, and only decelerate after leaving the pressure-sensitive pad or liner. For walking, a space of 1m to 2m at both ends is sufficient. For higher speed movements, such as jogging and running, a larger space is preferred, such as between 2m and 6m, more particularly 3m, 4m or 5m.

[0073] For example, systems for measuring dynamic pressure distribution on the foot are described in European patent applications EP0970657A1 and EP1127541A1, the entire contents of which are incorporated herein by reference. Based on the measurement of dynamic pressure on the foot during movement, assumptions can be made about the movement of various parts of the foot. Ultimately, custom footwear can be designed based on dynamic pressure measurements.

[0074] Another approach to measuring dynamic user-specific data is a user-wearable pressure sensor, as described above.

[0075] There are other dynamic data capture devices, such as user-wearable accelerometers, user-wearable force sensors, motion capture sensors, image sensors, etc. For example, user-wearable accelerometers can appear in the form of activity trackers or smart watches. They can capture the user's activity level, walking or running speed, or other aspects of the user's movement pattern. For example, a force sensor can be attached to the user to measure the force when the user moves dynamically. In some cases, a mobile device including a motion-sensitive sensor can be used to collect the mobile data to be analyzed. Therefore, as described above, a user can not only use his or her own mobile device to capture static user data (such as basic user data and still images), but also dynamic user data, such as force and motion data. In some cases, a user can use his or her own mobile device to collect all data for custom footwear design.

[0076] Motion capture systems can be used to capture and analyze dynamic user data. For example, a system using a computer identifiable target attached to the user and a monitoring system can track the target to generate dynamic user data, such as gait.

[0077] Dynamic data measurements can be combined. For example, pressure sensitive pads and / or motion sensors can be used with video capture equipment so that dynamic data can be compared with video footage of the user's activities. For example, a high-speed camera can record the movement of a user's body part, such as a foot, while the pressure sensitive sensor captures data about the foot's movement, impact, etc.

[0078] Statistical data of body parts

[0079] Another aspect of the present disclosure relates to statistical data that can be used to customize footwear designs, and methods of using such data.

[0080] Customized footwear can also be designed using statistical data, such as statistical body part data, such as demographic data. Statistical data can be used to supplement user-specific data in different ways. For example, a specific size of a shoe can be associated with several characteristics that are statistically predictable based on analyzing demographic data. As described above, a specific size of a shoe can be associated with a statistical mean and distribution of the length and width of a foot of that size, as well as the position, shape and size of various anatomical features of a foot of that size, such as toes, heels, arches, etc. Statistical data can also relate to other user characteristics, such as weight, age, activity level, gender, race, etc. Statistical data can relate to the mean, distribution, standard deviation, variance and correlation of any of these measurements, values ​​or attributes.

[0081] In some cases, a statistical model, such as an active shape model (ASM), a statistical shape model (SSM), or an active appearance model (AAM), can be constructed based on multiple user-specific 2D or 3D body part data from different population members (i.e., a training set). The statistical model can be a deformable model or template, where the deformation is limited to a finite number of modes, each mode is controlled by coefficients included in a coefficient vector to reflect the statistical correlations between the shape changes found in the training set. Assigning values ​​to the coefficients in the coefficient vector can cause a specific deformation of the statistical model, also referred to as an instance. Statistical models can be constructed for a wide range of people, or more specific statistical models can be constructed for more specific people. For example, separate statistical models can be constructed for different genders, different races, different shoe sizes, or a combination thereof.

[0082] In some cases, a statistical model can be used, for example, to analyze the shape of a user's body part. For example, the SSM can be fitted to a 2D or 3D model of a user's body part by determining appropriate values ​​for the SSM coefficients using any fitting strategy known in the art - an instance of the SSM whose shape best matches the 2D or 3D shape of the 2D, or 3D model of the user's body part can be determined. The resulting coefficient values ​​can teach the degree to which the user's body part deviates from the average. A statistical model built based on a sufficiently large training set (e.g., several thousand data sets) can provide the possibility of identifying certain clusters, for example, subgroups of a population concentrated around specific values ​​of one or more coefficients. If, in addition to the 2D or 3D body part data, the training set also includes information about pathologies, conditions, risks of developing certain conditions, risks of certain injuries (e.g., pressure-related injuries), such clusters can be linked to the information for diagnostic purposes or disease scoring. Analysis of the coefficient values ​​of a statistical model (such as an SSM) fitted to a 2D or 3D model of a particular user's body part can then help diagnose a particular user as having a certain condition, assess the risk of a particular user developing a certain condition, or assess the risk of a particular user suffering a certain injury, such as by assigning a score or rating to a particular user. Any suitable analysis technique known in the art may be used, particularly statistical methods and machine learning techniques.

[0083] In some cases, statistical models, such as SSMs, can be used to create a 2D or 3D model of a user's body part in order to design custom footwear. Such statistical shape models can be particularly useful in cases where only user-specific data is sparse, incomplete, or inaccurate. The SSM can then be fitted to such incomplete user-specific data, and the resulting instance of the SSM can provide a "best guess" approximation of the shape of the user's body part, thereby providing a 3D model of the user's body part. For example, a 3D SSM of a body part can be fitted to a sparse set of data points, such as one or more surface profiles or low-resolution 3D scans of a specific user's body part, to produce a higher-resolution 3D model of the user's body part. As a specific example, a 3D SSM of a foot can be fitted only to a 3D scan of the underside of a user's foot, for example, a 3D scan performed with a foot scanning system that includes only a sole scanning element. The resulting instance can then provide a "best guess" approximation of the shape of the entire foot. Similarly, a 3D SSM for a foot may be fit to a 2D contour of the sole of the user's foot, e.g., by determining the coefficient vector of the SSM instance whose projection on the plane best matches the given 2D contour. The resulting instance of the SSM may provide a "best guess" approximation of the shape of the user's foot, and may therefore be used as a user-specific 3D model of the foot.

[0084] In some cases, multiple statistical models with known correspondences can be used to create a 3D model of a user's body part based on different types of data. For example, international patent application PCT / EP2015 / 050134 discloses a method for predicting the shape of an object based on the relationship between shape models, and its entire content is incorporated herein. Figure 4 A to Figure 4The method illustrated in B and explained in the corresponding chapter of the publication can be applied to generate a user-specific 3D model. For example, starting from a first training set of 2D contours of the soles of multiple individuals forming a sample from a population and a second training set of 3D models of the corresponding feet of the same individual, two statistical models, such as statistical shape models, can be generated, one for each training set. In addition, based on the correspondence between the members of the two training sets, a relationship between the two statistical models can be established. If the 2D contour of the sole of a particular user is available, the first statistical model can be fitted to the user-specific 2D contour, thereby generating a user-specific instance of the first statistical model. The coefficient vector of this instance of the first statistical model, combined with the known relationship between the first statistical model and the second statistical model, can then be used to generate an example of the second statistical model, such as a 3D model, such as a 3D surface model, which can be used as an approximation of the 3D shape of the user's foot. A similar method can be used to generate a 3D model of a user's foot based on a 2D sole scan, starting from a training set of 2D sole scans and a corresponding 3D model of the foot. This type of process is beneficial because it can eliminate the need for an image sensor-based system, a laser-based scanning system, or an optical scanning system if a 2D foot scanner is available. A similar method can be used to generate a 3D model of a user's foot based on static pressure measurements, starting with a training set of static pressure measurements and a corresponding 3D model of the foot. This type of process is beneficial because it can eliminate the need for an image sensor-based system, a laser-based scanning system, or an optical scanning system if a pressure sensor is available. The described methods can also eliminate the need for method steps associated with using those image sensor-based systems, laser-based scanning systems, or optical scanning systems to collect data, thereby achieving efficiency gains. Finally, they can eliminate such data transmission between different components of the systems described herein, thereby further improving efficiency.

[0085] In addition, a statistical model of a body part (such as a foot) can be used to provide automatic analysis of 2D or 3D image data of the body part. For example, a statistical model can be used to identify a body part or a sub-part of a body part in a 2D image, such as a photograph of a body part or a static pressure measurement. More specifically, a statistical model of a foot, such as an AAM, can be used to automatically identify various regions of the sole of the foot, such as the toes, forefoot, or heel, in a pressure measurement of a user's foot. Similarly, a statistical model can be used to identify a body part or a sub-part of a body part in 3D image data, such as a medical image set of a body part (e.g., a CT scan, an MRI scan, or any medical image data generated by the above-mentioned medical imaging technology). More specifically, a statistical model of a foot and / or an anatomical structure of the foot (e.g., bones, tendons, ligaments, cartilage regions) can be used to automatically segment the 3D image data, i.e., automatically identify those regions representing the foot and / or the anatomical structure within the 3D image data, with the purpose of subsequently generating one or more 3D models of the identified regions, or automatically initializing the segmentation for additional manual refinement. Techniques that can be used for this type of analysis can be found in the following literature: Cootes, TF; Edwards, GJ; Taylor, CJ (1998). "Active appearance models". Computer Vision - ECCV'98. Lecture Notes in Computer Science. 1407. p. 484, or Mitchell, SC; Bosch, JG; Lelieveldt, BPF; van der Geest, RJ; Reiber, JHC and Sonka, M. (2002). "3-D active appearance models: segmentation of cardiac MR and ultrasound images". IEEE Trans. Medical Imaging, 21(9): 1167–1178.

[0086] A statistical shape model is only one example of a statistical model. Various other techniques in the fields of artificial intelligence, machine learning, supervised learning, unsupervised learning, reinforcement learning, self-learning, feature learning, anomaly detection, deep learning, etc. are known in the art and can be used to perform the above tasks, such as supplementing (incomplete) user-specific data, analyzing the shape of a user's body part, creating a 2D or 3D model, or analyzing 2D or 3D image data.

[0087] Footwear specific data

[0088] Another aspect of the present disclosure relates to footwear-specific data that can be used to customize footwear design, and methods of collecting such data.

[0089] Customized footwear may also be designed based on specific data of an article of footwear or a footwear portion. For example, a footwear portion may be designed to be compatible with an article of footwear (e.g., an insole may be designed to fit a specific shoe or shoe model). As another example, customized footwear may be designed to mimic certain characteristics of another article of footwear or a footwear portion.

[0090] In some cases, the footwear-specific data may relate to the type or size of an article of footwear or a footwear portion. For example, the footwear-specific data may include a descriptor of the type of article of footwear or a footwear portion as described below, a brand name, a product name, a product number, a shoe size, or any combination thereof.

[0091] In some cases, the footwear-specific data may relate to one or more dimensions of an article of footwear or a footwear portion. For example, the footwear-specific data may include a length, a width, such as the maximum width of the midfoot section or the width of the heel section, or a height, such as the height of a heel counter, a heel cup, or an upper, or the height difference between the midfoot section and the rearfoot section of an insole. In some cases, these dimensions may be obtained with the aid of manual measurements, e.g., using a ruler, a measuring tape, a caliper, etc. In some cases, such dimensions may be derived from 2D or 3D shape data, as described below.

[0092] In some cases, footwear-specific data may relate to the 3D shape of an article of footwear, a footwear portion, or any portion thereof. For example, footwear-specific data may include 3D data representing the external shape of a footwear portion or article of footwear. Such 3D data may be acquired by any of the above-mentioned 3D data acquisition techniques, such as an image sensor-based system, a mechanical scanning system, an optical scanner, or a laser-based scanner. Additionally or alternatively, footwear-specific data may include 3D data representing the internal shape of an article of footwear, such as the shape of any cavity, particularly a cavity configured to accommodate a user's foot. For example, this may be particularly useful for designing custom insoles. Such 3D data of the internal shape of an article of footwear may be obtained, for example, by means of an optical or laser-based scanning system with a handheld probe. The probe may be inserted into the cavity of the article of footwear, and scanning may be performed in one or more movements along the length of the cavity, possibly rotating the probe between consecutive movements. Several intraoral scanning devices are known in the prior art for obtaining 3D scans of a patient's oral cavity. Most use one or more optical elements, such as lenses, prisms, or mirrors, to project structured light from a light source contained in a handheld probe onto the oral surface through a narrow portion of the probe that is sized to fit into the mouth. The reflected light is then captured and returned through the narrow portion to an optical sensor, which is also contained in the handheld probe. Similar techniques can be used to scan the interior cavity of footwear. However, although intraoral scanners generally include straight, elongated handheld probes and operate with a relatively narrow field of view to obtain less than 1 / 10 of the intraoral cavity, they are still difficult to scan.th mm accuracy, but scanners for footwear can offer greater ease of use through curved or angled handheld probes - for easier access to the cavities of footwear items - and a larger field of view - to get a full scan with fewer scanning moves. Its optics can be configured accordingly. A larger field of view can result in lower accuracy, but 1 / 10 th An accuracy of less than 1 mm down to 1 mm is still sufficient for the purpose of designing custom footwear. Alternatively, the probe may include multiple optical sensors and / or multiple light sources in order to still obtain accuracy of less than 1 / 10 th The 3D data of the internal shape of the footwear article can also be obtained from the mold of the cavity, such as a shoe last. The 3D data of the mold can be obtained by means of any of the above-mentioned 3D data acquisition technologies, such as a system based on an image sensor, a mechanical scanning system, an optical scanner, or a laser-based scanner. In some cases, the footwear-specific data can only be related to the shape of the part or feature of the footwear article or footwear part. For example, the footwear-specific data can include 3D data representing the shape of any surface structure, embossing or internal structure (such as a cavity or ventilation channel). Any 3D data related to the external or internal shape of the footwear article, footwear part, or any part thereof can also be obtained from one or more CAD files, such as CAD files created during the design of the footwear article or footwear part. The 3D data can, for example, include a CAD model, a surface model, a triangle mesh, a point cloud, or any other 3D data representation known in the art. The footwear-specific data may include 3D data relating to an entire article of footwear, or 3D data relating to any footwear portion, such as a sole, an insole, a midsole, an outsole, an upper, or any portion thereof.

[0093] In some cases, footwear specific data can be related to the 2D shape of footwear articles or footwear parts. For example, footwear specific data can include the 2D data of the shape of the footwear part or any part of the footwear articles representing footwear articles. For example, footwear specific data can include the 2D profile of the sole, the 2D profile of the insole, the 2D profile of any part of the upper, the 2D cross section of the sole, the insole, the midsole of the shoe or the outsole of the shoe, the 2D cross section of the footwear article cavity, the 2D pattern of any printing, embossing, texture or surface structure present on any surface of the footwear article or any footwear part, or any other 2D profile, 2D cross section, 2D pattern or 2D data useful to the custom footwear design. Such 2D data can be obtained using a 2D optical scanner, or derived from photo data, from a simulation diagram or from a digital diagram, such as a 2D or 3D CAD file, a vector-based file or a pixel-based file. 2D footwear specific data can be in the form of a CAD file, a vector-based file or a pixel-based file.

[0094] In some cases, the footwear-specific data may be related to the appearance of the article of footwear or footwear portion. For example, the footwear-specific data may include photographic data or descriptive data, such as data related to color.

[0095] In some cases, the footwear-specific data may be related to the mechanical properties of the article of footwear or footwear portion. For example, the footwear-specific data may include data related to the strength and stiffness of the article of footwear or footwear portion under load, such as compression, tension, bending, or torsion. Such data may be obtained with the aid of a test bench known in the art, or by computer testing such as finite element analysis.

[0096] In some cases, footwear-specific data may relate to material properties of any material included in an article of footwear or footwear portion, such as material type, material name, chemical composition, presence of reinforcing structures, electrical conductivity, corrosion resistance, density / specific gravity, ductility / ductility, elasticity / hardness (e.g., Young's modulus), fracture toughness, hardness, plasticity, creep, compression strength, fatigue strength, shear strength, tensile strength, yield strength, flexural strength, flexural modulus, brittleness, toughness, wear resistance, hygroscopicity, surface roughness, specific strength, specific modulus, shear modulus, resilience, Poisson's ratio, bulk modulus, flammability, melting point, thermal conductivity, air permeability or water permeability, and other properties known in the art. Material properties may be obtained with the aid of any test apparatus known in the art, or looked up in a database or reference source.

[0097] Footwear

[0098]

[0013] Another aspect of the present disclosure relates to footwear portions that may be used to customize footwear designs.

[0099] Customized footwear may include one or more individual footwear parts, such as: a shoe body, an insole, a midsole, and an outsole.

[0100] The body of a shoe may be the portion of a footwear (such as a shoe) that surrounds the sides and top of a user's foot, sometimes referred to as an upper. The body may include multiple parts, such as a heel support, ankle support, webbing, laces, straps, tongue, toe cap, vamp, counter, heel flap, eyestay, lining, mudguard, and other structures known in the art. In some cases, the body may include two or more parts that are selectively tied together by the user using, for example, laces or straps.

[0101] An insole can be the inside of a footwear (such as a shoe) that directly contacts the bottom (and to some extent the sides) of a user's foot. In different cases, a custom insole can be a fixed (ie, permanent) part of a shoe, or a removable part of a shoe.

[0102] The midsole may be the portion of the footwear between the insole and the outsole, and in some cases, is primarily a shock absorbing portion. In some cases, the midsole may be designed to be primarily responsible for supporting the majority of the user's weight and providing shock absorbing properties to the footwear when in use. In other cases, the midsole may be designed to enhance the effectiveness of features in the insole and / or outsole.

[0103] The outsole may be the outermost portion of the footwear and may be designed to come into contact with the ground. In some cases, the outsole is also referred to as a tread. The outsole may be designed with structures and / or textures, such as to provide traction for the footwear on various surfaces. In addition, the outsole may be designed to protect the user's foot from punctures or other harmful intrusions. As described above, the outsole may also be designed to enhance the effectiveness of features in the midsole.

[0104] In some cases, footwear (such as shoes) can include one or more of the above-mentioned parts. Different combinations of these footwear parts can be envisioned. For example, a specific shoe can have a shoe body, an outer sole and an insole, but no midsole. In some cases, one or more of the shoe body, insole, midsole and outsole can be permanently attached to each other. For example, although designed separately and may include different materials, the shoe body, insole, midsole and outsole can still be assembled into the overall article of footwear. In some cases, footwear articles can include more than one specific type of footwear part. For example, a specific footwear can have two or more insoles, for example, an insole can be permanently attached to the midsole or outsole, and an insole can be removed from the rest of the footwear article. For example, the former can be a standard off-the-shelf component, and the latter can be a custom footwear part.

[0105] In some cases, one or more of the shoe body, insole, midsole, and outsole and / or components thereof may be custom footwear portions designed at least in part based on the various types of data described above. In some cases, one or more of the above footwear portions may include one or more materials and / or structures or corrective features. For example, the midsole may include various 3D structures intended to absorb shock while reducing the overall weight of the shoe.

[0106] In some cases, customized footwear can be customized insoles. Generally speaking, insoles can be the inner part of the shoe that contacts (for example, directly) the bottom of the user's foot (and contacts the side to some extent). Insoles can support at least one of the user's forefoot, midfoot and rear foot. Insoles can be fixed (i.e. permanent) in footwear, or can be removable, so that insoles can be used in different footwear items. For example, insoles can be designed to be suitable for the inside of ready-to-use shoes. Insoles can be configured to be suitable for the inside of footwear products before the final footwear product is fully manufactured or ready to use, and can be permanently fixed to the final footwear product, or can be removable. In order to facilitate matching with specific footwear items, insoles can be designed based on footwear specific data. For example, if footwear specific data include 2D or 3D data related to the shape of footwear items, insoles can be designed to have a contact surface that is substantially consistent with the part of footwear items, such as the surface of the midsole, the permanently attached insole, the upper or any combination of these.

[0107] The insole may be of standard design and / or the insole may be customized for a specific user, such as by designing the insole based on the static and / or dynamic user-specific data described above.

[0108] In some embodiments, the insole may include one or more insole sections: at least one of a forefoot support, a midfoot support, and a rearfoot support. The insole may be a one-piece structure, for example, wherein the forefoot support may be attached to a first end of the midfoot support, and the rearfoot support may be attached to a second end of the midfoot support. The insole may include a base layer, which may include one or more of a variable thickness layer, a directional hardness layer, a stabilization layer, and / or a reinforcement layer. The insole may include specially designed corrective features to affect the fit and / or behavior of the insole when worn and used by a user. In the insole, the forefoot support may include a structure different from that in the midfoot support and / or the rearfoot support. For example, the midfoot support and the rearfoot support may include a base layer (including at least one of a variable thickness layer, a directional hardness layer, a stabilization layer, and / or a reinforcement layer), and the forefoot support may include a plurality of openings, an edge, a first groove, and a second groove. In some embodiments, the forefoot support may also include at least one groove in the edge.

[0109] In some embodiments, the design and composition of the insole or insole segment may include a soft top layer (e.g., foam, rubber, leather, etc.) attached (e.g., using an adhesive, glue, Velcro, etc.) on top of a base layer. The base layer may be manufactured using additive manufacturing techniques and made of suitable materials, such as those described herein for additive manufacturing. For example, the base layer may be made of a suitable plastic. In some embodiments, the base layer may be manufactured as a single part (e.g., using additive manufacturing, also referred to as 3D printing in some cases), even in embodiments where the base layer may include one or more components. The base layer may fully or partially support the top layer. Figure 1 An example of such an insole 100 is illustrated. However, the following description is equally applicable to insole sections, such as a forefoot support, a midfoot support, or a rearfoot support. As shown, the insole 100 includes a soft top layer 105 and a base layer 110. In this example, the base layer 110 partially supports the soft top layer 105 because a portion of the soft top layer 105 has no support from the base layer 110 below.

[0110] In some embodiments, the base layer 110 may include one or more components. Figure 2A , Figure 2B , Figure 2C and Figure 2D As shown, the base layer 110 may include four components, including a variable thickness layer 205, a directional hardness layer 210, a stabilization layer 215, and a reinforcement layer 220. It should be noted that in some embodiments, the base layer 110 may only include Figure 2A , Figure 2B , Figure 2C and Figure 2D Some of the components shown in the drawings may be different from those shown in the drawings, and / or may include alternative or additional components. Each of the components may be configured to have a specific function or purpose.

[0111] The variable thickness layer 205 may include a manufacturing layer with a variable thickness to control the hardness of the insole 100 in different zones (i.e., regions or positions). For example, the variable thickness layer 205 may generally be shaped and customized according to the user's foot, such as based on the data type described herein. The variable thickness layer 205 may be a solid material layer and may have a generally smooth surface. In areas where greater hardness is required, the variable thickness layer 205 may be made thicker. In areas where less hardness is required, the variable thickness layer 205 may be made thinner. For example, some parts of the variable thickness layer 205, such as areas designed to be close to the user's toes, may be made thinner to allow flexibility when walking. In addition, in areas such as close to the user's heel, the variable thickness layer 205 may be made thicker to prevent undesirable bending.

[0112] The directional stiffness layer 210 may include a layer designed to be more flexible in certain directions and less flexible in other directions. For example, the directional stiffness layer 210 may be configured to bend more freely from left to right (i.e., side of the foot to side of the foot) and be more constrained from front to back (i.e., toe to heel). In other embodiments, the directions used to constrain or promote flexion may be different or customized, such as based on the type of data described herein.

[0113] The directional stiffness layer 210 can be generally shaped and customized based on the user's foot, such as based on the data types described herein. The directional stiffness layer 210 can be a solid material layer. The directional stiffness layer 210 can include a series of curved lines, ribs, cuts, stripes, corrugations, grooves, or other patterns 305, such as Figure 3 As shown. Pattern 305 may be formed on one or more surfaces of directional hardness layer 210. For example, the bottom surface of directional hardness layer 210, i.e., the surface facing the ground when the user wears the insole, may have pattern 305 formed thereon, while the top surface of directional hardness layer 210, i.e., the surface opposite the bottom surface, may be generally smooth. In other examples, the top surface of directional hardness layer 210 may have pattern 305 formed thereon, and the bottom surface of directional hardness layer 210 may be generally smooth. In other examples, both the bottom surface and the top surface of directional hardness layer 210 may have pattern 305 formed thereon.

[0114] The directional hardness layer 210 may be more flexible in a direction perpendicular to the pattern 305. Thus, the directional hardness layer 210 is less flexible (ie, stiffer) in a direction parallel to the pattern 305.

[0115] The pattern 305 (e.g., curved lines, ribs, cuts, stripes, waves, grooves, or other) can be straight or curved. The direction of the pattern 305 can vary between the forefoot, midfoot, and rearfoot regions of the insole, or even within each region. For example, the pattern 305 can be designed to adapt or correct the roll-off pattern of the user's foot based on dynamic user-specific data, such as dynamic pressure measurements. The roll-off pattern can be corrected based on statistical data, such as statistical data characterizing users (e.g., athletes) who perform at a high level over a long period of time without injury.

[0116] The stabilization layer 215 may include layers configured to bend or flatten in different areas to increase the stability of these areas. For example, the stabilization layer 215 may include an ordered structure, such as a plurality of unit cells configured to bend relative to each other. In other examples, the stabilization layer 215 may include a disordered structure, such as an unstructured arrangement of elongated struts, open-cell foams or closed-cell foams, all of which are configured to bend under load. For example, the structure may be configured to bend, deform, and / or compress in certain directions when pressure is applied, and then return to its original form when the pressure is removed. In addition, the structure may be a lightweight structure. The stabilization layer 215 can generally be shaped and customized according to the user's foot and / or footwear, such as based on the data types described herein. In some embodiments, the shape and design of the structure, such as the shape and position of the unit cells in the stabilization layer 215, can be configured or customized, for example, based on the data types described herein.

[0117] In some embodiments, particularly where a stabilization layer is combined with a directional stiffness layer, the ordered structure of the stabilization layer can be designed so that its mechanical properties (such as stiffness) do not offset or mask the effects of the directional stiffness layer. For example, using available design variables (e.g., cell design, design, length and cross-section of struts, design and size of nodes between struts) an ordered structure can be designed that provides greater stiffness in a direction perpendicular to the directional stiffness layer than in a direction parallel to the directional stiffness layer, for example, to carry the weight of a user or impact loads during dynamic activities.

[0118] In other embodiments, a stabilization layer, such as stabilization layer 215, can be designed to also serve the purpose of a directional stiffness layer, such as directional stiffness layer 210. For example, by selecting a particular orientation for the ordered structure, and using the design variables listed above (e.g., cell design, design, length and cross-section of struts, design and size of nodes), an ordered structure can be designed that provides greater bending resistance in a first direction than in a second direction perpendicular to the first direction.

[0119] In some embodiments, the unit cells of the stabilization layer 215 may be designed to be manufactured using additive manufacturing techniques (eg, 3D printing) together as a single form design (ie, one integral part).

[0120] Unit cells and ordered structures have been described above in the context of the stabilization layer 215. However, one skilled in the art will readily appreciate that the aspects and features described herein are also applicable to units and ordered structures in other footwear components or portions of footwear components.

[0121] In some embodiments, the stabilization layer 215 may additionally or alternatively include a surface texture, such as an ordered or disordered pattern of concave or convex surfaces. Fig.14A bottom view of an insole 1400 is shown, with a stabilizing layer including a surface texture 1430. Such surface texture 1430 can increase the grip of the insole on the inner surface of the footwear article in which it will be worn. Therefore, it can increase stability by reducing the risk of the insole sliding in the footwear article during use. In some cases, for example, where the insole is subdivided into discrete regions, each region having a specific insole thickness, such as determined based on the desired local bending resistance, the surface texture can bridge and smooth any sharp boundaries between these regions. For example, such subdivided discrete regions can include thickness zones 1440, 1450. In this way, the surface texture can reconcile local thickness variations with a smooth top surface configured to contact the user's foot and a collection of point, line or surface contacts configured to stably contact the footwear article in which the insole is to be worn.

[0122] In some embodiments, such as Figure 4 As shown, the stabilization layer 215 includes a flat region (e.g. Figure 5 20). For example, the structure can be designed to have a flatter shape in certain areas. These flattened areas can, for example, enhance stability (e.g., medial and lateral stability). For example, the flat areas can include a flat heel area 405 and / or a flat sole area 410 of the stabilization layer 215.

[0123] Additionally, in some embodiments, the stabilization layer 215 may be configured to compensate for certain variables, such as differences in leg length or foot movement, such as based on static or dynamic user-specific data. Figure 6 As shown, the stabilization layer 605 of the left leg can be shorter than the stabilization layer 610 of the right leg to compensate for the length difference between the left leg and the right leg, which can be included in the static user-specific data. In the design of the stabilization layer 215, the stabilization layer 215 can be made thinner or thicker (i.e., shorter or taller) by using fewer or more unit cells, respectively. Alternatively, in the design of the stabilization layer 215, the stabilization layer 215 can be made thinner or thicker (i.e., shorter or taller) by reducing or increasing the height of the unit cells, respectively. In some embodiments, the stabilization layer 215 can be configured to correct certain movements of the user's foot. For example, the stabilization layer 215 can be configured to correct for internal rotation and / or external rotation, such as by tilting the structure of the stabilization layer 215 to the inside or outside.

[0124] The reinforcement layer 220 may include a layer configured to conform to the heel edge of the insole 100. The reinforcement layer 220 may generally be shaped and customized to the user's heel, such as based on the data types described herein. The reinforcement layer 220 may be a solid material layer and may have a generally smooth surface. The reinforcement layer 220 may provide additional strength in the heel area, which may be subject to high tension during heel strikes, such as Figure 7As shown. Reinforcement layer 220 can have sufficient thickness to provide the required strength. For example, reinforcement layer 220 can be configured to provide support in response to tension from the rotation of base layer 110, such as during heel strike. These tensions can cause base layer 110 to break, unless reinforcement layer 220 is provided to prevent such breakage by at least partially offsetting the tension. Therefore, reinforcement layer 220 can include portion 221, as shown, which is configured to extend along the outside of the heel near base layer 110. These portions 221 can help compensate for the tension caused by the rotation of base layer 110 during heel strike. In addition, reinforcement layer 220 can include portion 222, which is configured to extend along the bottom of the heel near base layer 110. Portion 222 can provide reinforcement to compensate for the force that pushes down base layer 110, such as due to heel strike.

[0125] In some embodiments, the customized insole may also include a forefoot support. Such a forefoot support may be flexible and preferably durable. One aspect of the present disclosure relates to a forefoot support for an insole providing ventilation, comprising a plurality of openings; an edge configured to form a boundary around at least a portion of the forefoot support; a groove in the edge; a first groove passing through the forefoot support along a first axis, wherein the first groove is configured to provide flexibility to the forefoot support in a first direction; and a second groove passing through the forefoot support along a second axis, wherein the second groove is configured to provide flexibility to the forefoot support in a second direction. It should be noted that each of these features may be optional, and each combination of features may fall within the scope of the present disclosure. For example, the forefoot support may include any combination listed in Table 1. Table 1 below provides a non-exhaustive list of combinations of features that may be included in a forefoot support according to different embodiments of the present disclosure, wherein each column represents a different combination, and an X in a column indicates that a feature exists in the combination of that column.

[0126]

[0127]

[0128] Also contemplated is a forefoot support that lacks a plurality of openings; lacks a lip; lacks a first groove through the forefoot support along a first axis; and lacks a second groove through the forefoot support along a second axis.

[0129] FIG. 8A to FIG. 8C An example of a forefoot support is shown. Fig. 8A is a perspective view of a top surface of an insole configured to contact the sole of a user's foot. Fig. 8A8, the insole 800 is a one-piece structure including a forefoot support 801 that may be connected to a midfoot support 802 and a rearfoot support 803. The boundary between the forefoot support 802 and the midfoot support 803 is indicated by the letter "B", and the different structures of the forefoot support and the midfoot support are evident on each side of the boundary. The boundary between the midfoot support and the rearfoot support is not indicated because the structures of these areas may be similar. Figure 8B A top view of a forefoot support is shown, the top surface of which may be configured to contact a user's forefoot. The forefoot support includes a plurality of openings 814, rim 815, and grooves in rim 816. Figure 8C 82 is a bottom view of a sockliner that may be configured to contact an article of footwear or another footwear portion (e.g., a midsole or outsole of an article of footwear). In this view, a first groove in one direction 827 may be repeated (vertical arrows indicate most but not all grooves in that direction), and a second groove in a second direction 828 may be repeated (horizontal arrows indicate most but not all grooves in that direction). Example structure in the bottom surface of the midfoot support is visible 829. An opening 824 is depicted. As shown in FIG. Fig. 8A As shown by the arrows in FIG. , this combination of structural features in the forefoot support can impart flexibility about the anterior-posterior (AP) axis and the medio-lateral (ML) axis.

[0130] With regard to flexibility, the openings can be configured to enable the insole to bend in one or more directions. The insole may be made of a resilient material to provide support for the user's foot, but resilient materials such as hard plastic or polyamide may be too stiff to bend or twist as the foot moves. The openings can be configured to impart flexibility to a rigid material that would otherwise not bend.

[0131] For ventilation, moisture and heat inside the shoe and air outside the shoe should be able to circulate. In the forefoot support described herein, multiple openings allow air to flow around the forefoot structure, while heat and moisture from the user's foot can escape. In some embodiments, multiple openings can be arranged in a line, which can be straight, curved, or a combination of both. The line can follow the user's anatomical profile, or can be placed in an area that will support the forces applied when the user's foot moves. The location of the openings can also correspond to high heat and / or high humidity areas of the user's foot. In some embodiments, multiple openings can be arranged in one or more rows. FIG. 8A to FIG. 8C As shown, multiple lines can be arranged in rows. These rows can be evenly spaced.

[0132] Each of the plurality of openings may have a different shape, or all of the openings may have the same shape. For example, the opening may be a rectangle, a rounded rectangle, or a portion of a rectangle (see Figure 8B 814 and Figure 8C In some embodiments, each of the plurality of openings may be rectangular, and the openings may be arranged in repeated rows. Fig. 8A and Figure 8B As shown, the rows of rectangular openings may span the entire surface of the forefoot support. The plurality of openings may be regularly spaced. The plurality of openings may be staggered so that each row of openings is offset relative to the row of openings adjacent thereto. The rectangles may be truncated at the edges of the forefoot support.

[0133] The plurality of openings may be arranged in a pattern or randomly arranged. In some embodiments, the openings may be spaces between beams in a microstructure, an ordered structure, or a lattice structure. For example, the mesh may be a woven mesh, or may include an array of cells, each of which includes at least one wall and one opening. The openings may also be placed in a direction corresponding to the direction in which the user's foot moves, so that the openings may be configured to provide flexibility to the insole in the direction of movement.

[0134] Grooves in the forefoot support can impart additional flexibility and can provide greater or less flexibility in a desired direction (or directions) depending on the needs of the user. Figure 8C As shown, first groove 827 and second groove 828 can be located on the bottom surface of the forefoot support. The bottom surface of the forefoot support can be configured to contact a surface on the footwear article without contacting the bottom of the user's foot. It should be noted that in other embodiments, the grooves can additionally or alternatively be present on the top surface of the forefoot support. The first groove and / or the second groove can be repeated to create multiple first grooves and / or multiple second grooves. The location of the opening can be completely or partially located in the groove. For example, in Figure 8C 824 is located entirely in horizontal groove 828 and partially in vertical groove 827. In some embodiments, whether arranged in one or more rows, the openings may be located in a first groove through the forefoot support, in a second groove through the forefoot support, or in both the first groove and the second groove.

[0135] Where the first groove and the second groove intersect, a recessed structure may be formed. These recessed structures may be separated by raised structures. The first groove and the second groove may be configured to provide greater flexibility when the raised structures are bent away from each other than when the raised structures are bent toward each other. For example, the groove and the raised structure may be designed so that in the latter case, the raised structures collide when bent to a certain degree. FIG. 9A to FIG. 9B A view of the bottom surface of forefoot support 900 is shown. Fig. 9A The recessed structures 901 and the raised structures 902 created by the intersecting grooves are shown. Fig. 9BThe flexibility of the forefoot support 910 is shown when the raised structures such as 912 are bent away from each other. This directional flexibility is configured to allow the forefoot support to bend with the user's foot. Depending on the shape of the first groove and the second groove, the shape of the raised structure and the recessed structure can vary. In some embodiments, the first groove and the second groove can be polygonal, such as rectangular. The raised structure generated by these example rectangular grooves can also be rectangular. In some embodiments, either of the first groove and the second groove can have a rounded cross-section, for example, to reduce the risk of cracking or crack propagation.

[0136] The sizes of the first groove and the second groove can correspond to the size of the forefoot support, or can correspond to the area of ​​the user's foot. For example, a first groove that traverses the length of the forefoot support can traverse the entire length of the forefoot support (i.e., from a point on the edge at the distal end of the insole to a point at the boundary where the forefoot support meets the midfoot support), or can partially traverse the length of the forefoot support. Similarly, a second groove that traverses the width of the forefoot support can traverse the entire width of the forefoot support (i.e., from a point on the inner or medial edge of the forefoot support to another point on the outer or lateral edge of the forefoot support), or can partially traverse the width of the forefoot support. In some embodiments, the first groove can traverse the entire line between two points on the edge of the forefoot support.

[0137] The bending of the first groove and the second groove creates flexibility of the forefoot support. Therefore, the groove can be configured in any direction where flexibility of the forefoot support is needed. Flexibility may be required to allow the metatarsophalangeal (MTP) joint in the forefoot to move, such as flexion, extension, abduction, adduction, and rotation. During walking or running, the forefoot support may bend in the same direction as the user's foot. The forefoot support may bend in a direction that facilitates the insertion or removal of the insole from the footwear article. In some embodiments, the forefoot support may be flexible in a direction about the medial-lateral axis, may be flexible in a direction about the anterior-posterior axis, or may be flexible in both directions.

[0138] The first groove may extend through the forefoot support along a front-to-back axis. The second groove may extend through the forefoot support along a medial-lateral axis. The first groove and / or the second groove may extend through the forefoot support along an angle relative to the front-to-back axis or relative to the medial-lateral axis. Multiple grooves may be substantially parallel to the first groove and / or multiple grooves may be substantially parallel to the second groove. Within each of the multiple grooves in the first direction, the second direction, or both directions, there may be multiple openings. Thus, any given opening may be partially or completely aligned within the groove. Figure 8C828 , while a portion of the opening 824 is located in the groove 827 .

[0139] The first groove and the second groove can be arranged at an angle relative to each other. The angle can be 90°, substantially equal to 90°, or any other angle. The grooves can be present on the top surface of the forefoot support and / or on the bottom surface of the forefoot support. In some embodiments, at least the first groove traverses the top surface of the forefoot support and at least the second groove can traverse the bottom surface of the forefoot support.

[0140] The edge of the forefoot support can provide stability and strength. In the absence of an edge, the edge of the forefoot support can have a groove, a raised structure, a recessed structure, or a portion of these structures. The structural changes at the edge of the forefoot support can create a rough surface, and any protruding portion of the structure may get stuck in the shoe during the insertion or removal of the insole, or during the use of the insole. For example, if the protruding portion gets stuck in the user's foot or socks, the rough surface can also cause discomfort to the user. If stress is applied or concentrated in the area of ​​the exposed structure, especially the thin recessed structure, the rough finish is also easy to tear. In some embodiments, the edge can span the entire edge of the forefoot support. Alternatively, the edge can only span a portion of the edge of the forefoot support, for example, only the front edge, the middle (inner) edge or the side (outer) edge, or any combination thereof.

[0141] In some embodiments, the edge of the forefoot support may have a suspended structure or a suspended end, for example, a portion of the opening is cut away at the boundary of the forefoot support (see Fig. 10B The edge around the forefoot structure may include a ring or beam connecting two or more of the free ends. In some embodiments, the edge may include a series of beams connecting each free end to at least one other free end. The series of beams may or may not be a continuous series.

[0142] The edges of some areas of the forefoot support may be wider than other areas, for example, to cover more surface area of ​​the forefoot support, or the edges of some areas may be thicker than other areas. In some embodiments, a portion of the edge may include structures such as undercuts or perforations.

[0143] In some embodiments, the edge may include one or more notches. Fig. 10A The bottom surface of an example forefoot support 1000 is shown, where the edge can include two grooves 1002a and 1002b. The grooves can be positioned to correspond to joints in the user's forefoot, for example, at locations on the edge of the forefoot support corresponding to the user's metatarsophalangeal (MTP) joints.

[0144] The forefoot support may be large enough to support the user's entire forefoot, including all phalanges. The forefoot support may be sized to support the entire forefoot, plus some additional area, in order to fill as completely as possible the shoe in which it will be placed. In some embodiments, the forefoot support may be smaller than the user's forefoot and provide support to only one area of ​​the forefoot. Fig. 10B The bottom surface of the example forefoot support 1010 is shown, which can only support the medial (inner) side of the user's forefoot. Since the forefoot support can be configured to align with the user's foot, knee and / or hip, all or part of the user's forefoot can be supported.

[0145] As described above, an insole section, such as a forefoot support, may also include a soft top layer (e.g., foam, rubber, leather, etc.) secured (e.g., using adhesive, glue, hook and loop fasteners, etc.) atop the base layer of the insole section.

[0146] Although the forefoot support described herein can be part of a standard insole that is configured to fit any number of users (one size fits all) or shoes, a customized forefoot support can provide a better fit for the user and can customize the forefoot based on the shoe type, for example, based on the footwear specific data as described above. The customized forefoot support can also be used to correct certain conditions of the user, or to correct or improve the static and dynamic pressures of the foot. The customized forefoot support can also be used to prevent injuries or prevent the onset of foot diseases, such as pressure-related injuries to the foot, ankle, leg, knee, hip or back. For athletes, the customized forefoot support can be used to improve biomechanical performance, for example, by changing the impact angle of the user's foot during dynamic activities such as running, thereby improving the overall speed of running. Similarly, if the forefoot support provides optimal alignment for the user's feet, knees and hips in activities such as cycling, the cyclist's strength, endurance and comfort will be improved.

[0147] Data about specific user physical characteristics or attributes, such as the above-mentioned static user-specific data, can be used to design a customized forefoot support.For example, the user's foot size and static foot pressure can be measured (e.g., when standing).

[0148] The custom forefoot support may also be designed using the dynamic user data described above, such as dynamic foot pressure measurements. For example, dynamic pressures on the user's foot may be measured during dynamic foot activities, such as: running, walking, jumping, landing, pivoting, rolling, rocking, etc. In fact, any functional biomechanical measurement may be used during the design of custom footwear.

[0149] Custom forefoot supports can also be designed using non-user specific data, such as statistical population data. For example, the average shape of a foot of a particular size can be determined statistically, or obtained from an existing statistical data set. In addition, statistical averages of these and other physical foot characteristics can have associated statistical parameters, such as distribution, standard deviation, variance, and other parameters known in the art. Thus, knowing a single foot characteristic associated with a user, such as shoe size, a number of associated statistical foot characteristics (e.g., shape, size, etc.) can be used.

[0150] Customized forefoot supports can also be designed using footwear-specific data. For example, an article of footwear can include certain ventilation channels, such as in any portion of its sole, midsole, insole, or upper. A customized forefoot support for a removable insole combined with the article of footwear can be designed with multiple openings that are aligned with the ventilation channels so that air and moisture can circulate freely in and out of the ventilation channels through the multiple openings. To this end, it can be advantageous if the footwear-specific data associated with the article of footwear includes 2D or 3D data associated with the shape and / or position of the ventilation channels relative to the shape of the article of footwear. Alternatively or additionally, footwear-specific data associated with the 2D or 3D shape of the article of footwear can be used to design the shape of the customized forefoot support. For example, as described above, a 2D projection of the interior cavity of the article of footwear may be used to design the contour of a customized forefoot support so that the forefoot support fills the article of footwear as completely as possible, and / or 3D shape data of the top surface of a midsole or fixed insole of the article of footwear may be used to design the underside of the forefoot support, i.e., the side of the customized forefoot support facing away from the user, to conform to the shape of the surface. Fig. 9A The height of raised structures 902 in can be configured so that the raised structures as a group match the shape of the surface without the customized forefoot support having to deform.

[0151] Because the arrangement of the grooves in the forefoot support can impart flexibility, the grooves can be customized to the flexibility needs of the user.

[0152] Orthotic features of footwear

[0153] Customized footwear may include one or more specially designed corrective features to affect the fit and / or behavior of a user when wearing and using the footwear. For example, one or more components of an insole may be correspondingly shaped to include one or more corrective features (e.g., corrective structures). To this end, any of the above data types may be used to design customized footwear. Examples of corrective features may be: areas of reduced thickness, localized depressions, areas of increased thickness, directional stiffness features, microstructures, surface features, areas of reduced stiffness, areas of increased stiffness, areas of reduced stiffness, areas of increased stiffness, plantar fascia grooves, heel pads, localized depressions under the heel, full length offsets, heel bumps, full length wedges, full width wedges, heel cups, heel wedges, heel shavings, navicular supports, lateral arch fillers, raised lateral edges, raised medial edges, metatarsal supports such as metatarsal strips or metatarsal pads, metatarsal reliefs, such as metatarsal depressions or metatarsal cutouts, power wedges, forefoot supports, forefoot wedges, toe bumps such as Cluffy wedges, Morton extensions, and reverse Morton extensions, all of which are described in more detail below. Some of these corrective features may be applicable to the entire foot. Others may be applied to certain areas of the foot, such as the rearfoot, midfoot, forefoot, toes, or individual toes.

[0154] In some embodiments, corrective features can be used to correct anatomical or biomechanical problems or conditions of a user's foot. For example, a user may have a relatively high arch, which creates support issues for ordinary shoes. Thus, customized footwear can include customized footwear portions, such as insoles, that add support under the high arches to better distribute the user's weight in the footwear.

[0155] In some embodiments, the corrective features may be meant to prevent injuries rather than correct injuries or anatomical problems or conditions. For example, dynamic data may be used to determine the balance of a user's foot during movement (e.g., while running). The determined balance may be compared to an optimal balance sequence that may be derived from dynamic or statistical data characterizing users (e.g., athletes) who perform at a high level over a long period of time without injury. Thus, the corrective structure may be designed to promote better foot balance during movement to prevent injury.

[0156] In other embodiments, corrective functionality may be meant to improve performance rather than correct existing or potential problems. For example, it has been shown that characteristics associated with initial foot contact during running can be related to the athlete's running speed. With this in mind, dynamic data can be collected to determine characteristics of a user's initial foot contact during running, such as: landing area (e.g., heel, midfoot, forefoot); the ratio between the corresponding forces acting on the medial and lateral portions of the foot; the maximum force upon landing; the speed at which the foot unwinds; and / or the efficiency of customized footwear or customized footwear portions, such as insoles, midsoles, or outsoles, can be configured to change the user's initial foot contact when running.

[0157] FIG. 16A to FIG. 16BAn example of a corrective feature added to a custom insole 1600 is shown. The corrective feature may be a heel bump and may be added to the custom insole 1600, for example, to treat certain adverse conditions, such as Achilles tendinopathy, calcaneal apophysis, etc., or to compensate for a length difference between a user's left and right legs. The depicted heel bump may include a central post 1620 and three peripheral posts 1630. It should be noted that there may be one or more peripheral posts 1630. It should also be noted that in some embodiments, the heel bump may include only the central post 1620, while in other embodiments, the heel bump may include only one or more peripheral posts 1630. The height of the heel raise may be determined based on the condition to be treated and / or the leg length difference to be compensated. The central post 1620 may have a substantially cylindrical shape. It may be added to the underside 1610 of the custom insole 1600, ideally below the center of the heel area of ​​the insole. In this position, when the user stands or in the gait cycle of heel landing, it can transfer most of the user's weight. In order to help save materials and not make the insole too hard, the central column 1620 may not cover the entire heel area. Instead, its size can be smaller than the heel area, but large enough to provide sufficient mechanical strength to bear the weight of the user. However, a smaller central column 1620 can increase the risk of instability. In order to reduce this risk, the central column 1620 can be located below the center of the center of pressure (COP point) obtained from the heel landing time point of static pressure measurement or dynamic pressure measurement, rather than below the center point of the heel area. The COP point obtained from the pressure measurement can be the center of gravity of the total pressure applied to the pressure-sensitive pad or pad by the user's foot or a certain area of ​​the user's foot (such as heel, midfoot or forefoot) at a specific time point. In other words, this is the position where a single force vector can balance the total pressure applied by the user's foot or the relevant area of ​​the user's foot at a specific time point. From the static pressure measurement, a single COP point for the entire foot or relevant area can be obtained. From the dynamic pressure measurements, a COP point can be derived for each single time point measured based on the total pressure applied to the pressure sensitive device at that time point. In some embodiments, the center column 1620 can be located below the COP point of the heel area obtained from the static pressure measurements. In other embodiments, the center column 1620 can be located below the COP point derived from the heel landing time point of the dynamic pressure measurement. It should be noted that the term "below" refers to the vertical direction when the user is standing and wearing the customized insole. In the case where the customized insole is designed to have corrective features that change the position of the foot, such as heel shaving, this direction may be different from the direction perpendicular to the surface of the pressure sensitive device.

[0158] Additionally or alternatively, one or more peripheral columns 1630 may be added to the central column 1620. Since they are less involved in the transfer of the user's weight than the central column, they can be kept thinner. By keeping them separate from the central column 1620, the flexibility of the insole is less affected. The peripheral columns 1630 may take the form of one or more columns distributed around the central column 1620. They may have an annular, arc-shaped, crescent-shaped or any other cross-section, such as a shape based on one or more offsets of the central column cross-section, or a shape that is not based on the central column cross-sectional shape, such as a circle, rectangle or triangle. By having multiple smaller, non-intersecting peripheral columns 1630, rather than a large annular peripheral column, material can be reduced and flexibility can be increased. In some embodiments, there may be only peripheral columns 1630. As described above, these may be ideally distributed around the center of the heel area, or around the COP point obtained from the heel landing time point of the static pressure measurement or the dynamic pressure measurement. The central column 1620 and the peripheral columns 1630 may or may not have a constant cross-section. For example, they may have a larger cross-section at their proximal end where they are attached to the rest of the custom insole to increase mechanical strength, and / or a larger cross-section at their distal end to achieve greater stability during use while having a smaller cross-section in between to reduce weight and material usage.

[0159] Footwear

[0160] Another aspect of the present disclosure relates to a customized article of footwear including a fixed or removable customized footwear portion as described above.

[0161] Many types of footwear articles are known in the prior art, such as shoes, boots, sandals, skates, slippers or any combination thereof. For example, boots can be low-tube boots or high-tube boots, such as riding boots. Shoes or boots can be specifically used for sports, such as track and field, walking, jogging, running, cycling, skiing, dancing, such as ballet, tennis, basketball, American football, hockey, ice hockey, skating, football, fitness and training, skateboards, golf, track and field, hiking, volleyball, padel, rock climbing, surfing, canyon sports, boxing, wrestling, badminton, cricket, baseball, table tennis, rugby or any other sports, such as sports carried out in stadiums, courts, rings, open areas or water. The system, method, customized footwear part and corrective footwear features described herein can be applied to any of these types of sports shoes or boots, or the subtype of shoes or boots. For example, in the category of bicycle shoes, there are road bicycle shoes, mountain bike shoes, indoor bicycle shoes and bicycle sandals. The forefoot support of the example can be formed into a bicycle shoe suitable for any of these categories. Cycling shoes are generally designed to be aerodynamic, curved, and lightweight. Forefoot supports in such shoes should be flexible so that they fit the curved shoe profile, ventilate for user comfort and performance, and be thin. The systems, methods, customized footwear portions, and orthotic footwear features disclosed herein relate to any kind of footwear, and in particular any of the kinds listed herein.

[0162] Additive Manufacturing

[0163] Customized footwear can be manufactured using additive manufacturing techniques. Many additive manufacturing methods are known in the art, such as stereolithography (SLA), selective laser sintering (SLS), selective laser melting (SLM), and fused deposition modeling (FDM).

[0164] Stereolithography (SLA) is an additive manufacturing technology used to "print" a 3D object one layer at a time. An SLA device can use, for example, a laser to cure a photoreactive material with emitted radiation. In some embodiments, an SLA device directs a laser through the surface of a photoreactive material, such as a curable photopolymer ("resin"), to build an object one layer at a time. For each layer, the laser beam traces a cross-section of the object on the surface of the liquid resin, which cures and solidifies the cross-section and connects it to the layer below. After a layer is completed, the SLA device lowers the build platform a distance equal to the thickness of a single layer, and then deposits a new surface of uncured resin (or similar photoreactive material) on the previous layer. On this surface, a new pattern is depicted, forming a new layer. By repeating this process one layer at a time, a complete 3D part can be formed.

[0165] Selective laser sintering (SLS) is another additive manufacturing technology used to 3D print objects. An SLS device typically uses a high-energy laser (such as a CO2 laser) to "sinter" (i.e., fuse) small particles of plastic, metal, ceramic, or glass powder into a 3D object. Similar to SLA, an SLS device can use a laser to scan a cross-section on the surface of a powder bed according to a CAD design. Also similar to SLA, an SLS device can lower the build platform by one layer after completing a layer and add a new layer of material so that a new layer can be formed. In some embodiments, the SLS device can preheat the powder to make it easier for the laser to increase the temperature during sintering.

[0166] Selective laser melting (SLM) is another additive manufacturing technology used to 3D print objects. Like SLS, SLM equipment typically uses a high-powered laser to selectively melt thin layers of metal powder to form a solid metal object. Although similar, SLM is different from SLS because it typically uses materials with much higher melting points. When constructing an object using SLM, various coating mechanisms can be used to distribute the thin layers of metal powder. Like SLA and SLS, the build surface moves up and down to allow the layers to be formed individually.

[0167] Fused deposition modeling (FDM) is another additive manufacturing technique in which 3D objects are produced by extruding small beads of, for example, thermoplastic material from an extrusion nozzle to form layers. In a typical arrangement, the extrusion nozzle is heated to melt the raw material as it is extruded. The raw material hardens immediately after being extruded from the nozzle. The extrusion nozzle can be moved in one or more dimensions by suitable machinery. Similar to the aforementioned additive manufacturing techniques, the extrusion nozzle follows a path controlled by CAD or CAM software. Again, the part is built from the bottom up, one layer at a time.

[0168] The object can be formed by an additive manufacturing device using various materials, such as: polypropylene, thermoplastic polyurethane, polyurethane, acrylonitrile butadiene styrene (ABS), polycarbonate (PC), PC-ABS, PLA, polystyrene, lignin, polyamide, polyamide with additives (such as glass or metal particles), methyl methacrylate-acrylonitrile butadiene styrene copolymer, resorbable materials (such as polymer-ceramic composites), and other similar suitable materials. In some embodiments, commercially available materials can be utilized. These materials can include: DSM Somos Series materials 7100, 8100, 9100, 9420, 10100, 11100, 12110, 14120 and 15100; ABSplus-P430, ABSi, ABS-ESD7, ABS-M30, ABS-M30i, PC-ABS, PC-ISO, PC, ULTEM9085, PPSF and PPSU from Stratasys; Accura Plastic, DuraForm, CastForm, Laserform and VisiJet series materials from 3-Systems; aluminum, cobalt chrome alloys and stainless steel materials; Maranging steel; nickel alloys; titanium; PA series materials, PrimeCast and PrimePart materials, as well as Alumide and CarbonMide from EOS GmbH.

[0169] Customized footwear, including customized footwear portions, can be manufactured using additive manufacturing techniques. Advantageously, an additive manufacturing device can "3D print" an entire footwear portion or a whole shoe in a single, unitary workpiece. For example, rather than separately manufacturing an insole, midsole, and outsole, an additive manufacturing device can create a customized footwear portion layer by layer, with non-uniform corrective features (e.g., microstructures) in each individual layer. Thus, 3D printing can provide a higher degree of footwear customization than traditional manufacturing techniques.

[0170] Furthermore, 3D printing customized footwear can advantageously reduce the number of materials and pieces that need to be manufactured in order to achieve the desired footwear design. In addition, additive manufacturing technology can utilize a wider range of materials to manufacture customized footwear than traditional manufacturing techniques.

[0171] In some cases, additive manufacturing techniques can improve traditional manufacturing steps. For example, a footwear portion can include surface textures, patterns, structures, etc. that are useful for traditional manufacturing steps, such as gluing, fusing, or otherwise fastening the portions together. In some cases, the surface texture can be created by microstructures. As another example, an additively manufactured footwear portion can be finished with a manufacturing layer having a high porosity and / or a specific texture to improve the connection of the portion to another footwear portion by glue or other fastening means.

[0172] Description of Certain Exemplary Methods, Systems, and Apparatus

[0173] Disclosed herein are methods for designing and manufacturing customized footwear or customized footwear portions. Any of the following systems or methods are applicable to the design of customized footwear and the design of customized footwear portions. For efficiency reasons, unless otherwise expressly stated, the terms "customized footwear" or "customized footwear articles" in the following paragraphs should be interpreted as covering one or more customized footwear articles, one or more customized footwear portions, or any combination thereof.

[0174] Fig.11 An exemplary method 1100 is shown that includes the following steps:

[0175] 1. Obtain footwear specific data;

[0176] 2. Obtain user-specific data;

[0177] 3. generating a virtual model of the customized article of footwear based on the acquired data; and

[0178] 4. Manufacture customized footwear items based on virtual models.

[0179] The customized footwear article can be a customized footwear article or a customized footwear part, or any part thereof. In the following description, the method will be described by taking a customized insole as an example. However, it will be readily appreciated by those skilled in the art that the present disclosure can be applied to other customized footwear parts or customized footwear articles. For example, the following method is equally effective for the design and manufacture of a customized outsole, a customized midsole, or an entire customized sole. The described method can also be applied to the design and manufacture of a customized footwear article, such as a shoe, a sandal, a boot, or a sneaker, including a customized insole, an outsole, a midsole, or a sole.

[0180] The method 1100 may be a computer-implemented method. The steps of the method may be performed by a computing device with or without input from an operator.

[0181] In step 1110, footwear specific data is obtained. The footwear specific data may be any combination of one or more types of footwear specific data as described above, and may be obtained using any of the systems described above. Alternatively, the footwear specific data may be loaded or imported from one or more files or databases. Fig.11 In the embodiment, step 1120 is described as being after step 1110. However, it should be noted that in some embodiments, step 1110 is an optional step, and in other embodiments, step 1120 may also be performed before step 1110.

[0182] In step 1120, user specific data is obtained. The user specific data may be any combination of one or more types of static or dynamic user specific data as described above, and may be obtained using any of the systems described above. Alternatively, the user specific data may be loaded from one or more files or from a database.

[0183] In some embodiments, user-specific data includes dynamic user-specific data. As described above, dynamic user-specific data may include pressure data acquired during user movement. For example, a pressure-sensitive pad or cushion may be used to measure the pressure distribution changes on one or both feet when a user walks or runs on it. From this measurement, at any time point during the stride, a center of pressure point (COP point) may be derived. As described above, this is the center of gravity of the total pressure applied by the user's foot on the pressure-sensitive pad or cushion at that time point. In other words, this is the point at which a single force vector can balance the total pressure applied by the user's foot at that time point. If the dynamic pressure measurement covers more than one stride, the pressure measurements at the corresponding time points on multiple strides may be averaged. While walking or running, at each stride or roll-off, the point moves from the initial contact point to the push-off point. For some users, it may move from a rear position (under the heel) to a front position (under the toes). For other users with different gaits, the COP point may present different trajectories, for example, from the forefoot toward the midfoot and back to the forefoot. This trajectory is user-specific and may indicate the presence of an undesirable condition.

[0184] Fig. 12A A graph 1200 showing COP points 1210 at various points in time during a particular user's roll-off is shown. The COP points 1210 are plotted in a two-dimensional coordinate system, with the horizontal axis being the lateral-medial coordinate and the vertical axis being the posterior-anterior coordinate. The COP points 1210 follow a trajectory 1220, also referred to as a center of pressure curve (COP curve), from an initial COP point 1211 measured at landing to a final COP point 1212 measured at departure. Fig. 12B Similar curves for different users are shown. It can be seen that here the COP curve follows a more irregular trajectory.

[0185] In step 1130, based on the user-specific data obtained and the optional footwear-specific data obtained, a virtual model of a customized footwear article is generated. As described above, the customized footwear article can be any customized footwear article or customized footwear part, such as a customized insole, a customized midsole, a customized outsole, a customized sole or a customized footwear article including a customized insole, a customized midsole, a customized outsole or a customized sole. The virtual model can include any type of virtual three-dimensional model known in the art, such as a CAD model, a surface model, such as a free-form surface model, a NURBS surface model, a surface mesh or a triangular mesh, a point cloud, a model including a geometric precursor, such as the model described in WO2015 / 022341A2, which is incorporated herein by reference as a whole, or any combination of these models. The virtual model can be stored in any appropriate data format in the form of binary or ASCII encoding, such as any known CAD format, VRML, STL, XML or TXT.

[0186] The virtual model of the customized article of footwear may include shape data representing any combination of footwear parts and subcomponents, layers, and features of the footwear parts. By way of example, Table 2 below provides a non-exhaustive list of combinations of footwear parts that may be included in customized articles of footwear according to various embodiments of the present disclosure, wherein each column represents a different combination, and an X in a column indicates that a certain footwear part is present in the combination in that column.

[0187]

[0188]

[0189] Table 3 below provides a non-exhaustive list of combinations of footwear parts, subcomponents, and layers that may be included in a customized footwear article according to different embodiments of the present disclosure when the customized footwear article is a customized insole, wherein each column represents a different combination and an X in a column indicates that a certain footwear part, subcomponent, or layer is present in the combination in that column.

[0190]

[0191]

[0192]

[0193]

[0194]

[0195]

[0196] Generating a virtual model of a custom footwear article may include generating 3D shape data of some or all footwear parts, subcomponents, layers, and features in the custom footwear article. This can be accomplished using general CAD software or dedicated software that automates some or all of the processes, such as dedicated software with a wizard-like structure that guides the operator through a predefined sequence of design operations. In some cases, the virtual model may represent only a portion of the custom footwear article. For example, in some embodiments, the custom footwear article may be a custom insole comprising a top layer and a base layer. In this case, the virtual model may include only 3D shape data representing the base layer. The top layer may then be added during manufacturing step 1140, for example, made of a piece of compliant material. In some embodiments, the virtual model may include more than one three-dimensional model, for example, for each component that will be manufactured separately and then assembled. Additionally or alternatively, the virtual model may include one or more models with 2D shape data, for example, the outline of the footwear part to be cut from the sheet.

[0197] In some embodiments, for example, in the case where the customized footwear is an insole, the footwear-specific data obtained in step 1110 can be used for the design of certain parts of the virtual model. For example, in an embodiment where the footwear-specific data includes 3D shape data related to one or more surfaces of the footwear (such as a shoe), such shape data can be used to generate a virtual model of the insole, so as to have one or more contact surfaces complementary to at least one part of the one or more surfaces of the footwear, thereby improving the stability of the insole when the insole is worn in the footwear. This increased stability improves the load transfer from the user's foot to the footwear, and reduces the risk of sprains. In addition, providing an insole with one or more contact surfaces complementary to the surface of the footwear can reduce the risk of the insole moving inside the footwear, which is annoying for the user. The complementary contact surface can include one or more adjacent surfaces, a set of linear contacts, a set of point contacts, or any combination of these. For example, the virtual model of the insole may include an underside, such as a side configured to face away from the user during use, the underside including one or more abutment surfaces, each abutment surface complementary to at least a portion of a surface of the article of footwear, such as a top surface of a midsole or a fixed insole. Additionally or alternatively, the virtual model of the insole may include a three-dimensional texture of the underside, wherein the three-dimensional texture has one or more smaller surfaces, line contacts, and / or point contacts that are complementary to at least a portion of the surface of the article of footwear. Additionally or alternatively, the virtual model of the insole may include an ordered or disordered structure, such as on its underside, for example as part of a stabilization layer as described above, such as may be provided. FIG. 2A to FIG. 2DThis ordered or disordered structure may fill a volume at least partially defined by an imaginary surface that is complementary to at least a portion of at least one surface of the article of footwear. As a result, the ordered or disordered structure may include a collection of linear contacts and / or point contacts that are complementary to at least a portion of the surface of the article of footwear. Additionally or alternatively, the virtual model of the insole may include a forefoot support as described above, with a raised structure between the grooves and the holes, such as FIG. 9A to FIG. 9B and FIG. 10A to FIG. 10B These raised structures may include a collection of surface contacts, line contacts, and / or point contacts that are complementary to at least a portion of at least one surface of the article of footwear.

[0198] In some embodiments, for example, in the case where the customized footwear article is a sole or insole, the user-specific data obtained in step 1120 may be used additionally or alternatively for the design of certain parts of the virtual model. For example, in an embodiment where the user-specific data includes 3D shape data associated with a body part of the user (such as a foot), the 3D shape data is obtained, for example, in any manner described, such as using an image sensor-based system or a 3D scanner (such as a foot scanner), or partially or completely derived from medical images, pressure measurements and / or statistical data, such 3D shape data can be used to generate a virtual model of the insole to have one or more contact surfaces that are complementary to at least one portion of one or more surfaces of the body part, thereby improving the user's comfort and the load transfer between the user's body part and the customized footwear article. The complementary contact surfaces may include one or more adjacent surfaces, a set of linear contacts, a set of point contacts, or any combination of these. For example, the virtual model of the insole may have an upper side, such as a side configured to face the user during use, the upper side including one or more adjacent surfaces, each adjacent surface complementary to at least one portion of the surface of the sole of the user's foot. In some embodiments, additional design operations may be performed on these one or more complementary surfaces. For example, a smoothing operation may be performed to remove any excessive protrusions. Additionally or alternatively, corrective features may be added to the virtual model of the insole, such as any one or more corrective features described above. Some of these corrective features, although not necessarily designed on top of one or more complementary surfaces, may still deform the shape of the complementary surfaces to a certain extent, thereby changing the shape and weight distribution of the user's foot during the gait cycle. Additionally or alternatively, in those embodiments where the insole is designed to include a top layer, the thickness of the top layer may be considered when designing the top surface of the base layer. For example, when the top layer is made of a sheet having a constant thickness, the top surface of the base layer may be designed to be offset at a fixed distance from one or more complementary surfaces. The distance may be selected to be equal to the thickness of the top layer, or less than the thickness of the top layer, so as to take into account the compression of the top layer. In this example, the 2D profile of the top layer may be additionally determined and stored to allow the top layer to be cut from the sheet during manufacturing step 1140. In some cases, particularly where certain user-specific data is missing or available user-specific data is scarce, statistical body part data can be used to generate "best guess" 3D shape data representing the user's body parts, which data will be used when generating a virtual model of a customized footwear article using any of the above-described techniques.

[0199] In some embodiments, the acquired user-specific data includes dynamic user-specific data, and a COP curve can be determined, which can be used to customize the design of an article of footwear, for example, a sole, an outsole, or an insole. As described above, in some embodiments, the shape of the COP curve can be an indicator of an adverse condition, a risk of future pain or injury, or a suboptimal gait or weight distribution. For example, Fig.17A Shown are pressure measurements 1700 for a particular user and a corresponding COP curve 1720 for the same user. The COP curve 1720 exhibits a fairly general shape. Fig. 17B Pressure measurement 1700' and corresponding COP curve 1720' of another user are shown. COP curve 1720' has a shape indicating midfoot and forefoot pronation, causing increased load on the middle forefoot. This can imply unfavorable conditions, such as shin splints. The purpose of customizing footwear can be to deal with unfavorable conditions, reduce the risk of future injuries or pain, or improve performance by changing the roll-off pattern of the user and / or the weight distribution in the gait cycle. Such modified roll-off pattern and / or weight distribution can be converted into a modified COP curve. In some embodiments, custom footwear can be designed according to a corrected, healthier target COP curve, for example, a target COP curve corrected based on statistical data, which characterizes users who have not suffered any adverse conditions or have performed at a high level for a long time without injury. The target COP curve can be based on a COP curve determined from dynamic user-specific data, and certain target corrections can be introduced in the user-specific COP curve, such as the smoothing of the curve, the straightening of the curve, or the movement of at least one portion of the curve toward the middle side, the side or the center. Customized articles of footwear, such as soles, outsoles, or insoles, may be designed to include features, such as the corrective features described above, which stimulate the user's foot to move and roll according to a pattern that produces a COP curve that approximates a target COP curve. For example, features may be designed to affect the directional stiffness of the customized article of footwear with reference to the target COP curve. In some embodiments, this may be accomplished by making the customized article of footwear, at each point along the target COP curve, more resistant to bending about an axis that is tangent to the target COP curve at that point than about an axis that is perpendicular to the direction of the target COP curve at that point. For example, as described above, directional stiffness features, such as bend lines, ribs, cuts, stripes, corrugations, grooves, or others, may be designed into a virtual model of the customized article of footwear. As described above, the directional stiffness features may be part of a distinguishable directional stiffness layer, or may be incorporated into another portion or layer of the customized article of footwear. For example, as described above, Fig.1313, which shows the underside of a sole, outsole, or insole 1300 having a profile 1310 designed for a user whose measured roll-off pattern results in a COP curve 1320 (dashed line). If the COP curve 1320 exhibits a healthy appearance, the directional stiffness feature 1330 may be designed in the form of a curved line, rib, cutout, stripe, corrugation, or groove that is present on at least a portion of the underside of the customized article of footwear 1300, i.e., the side facing away from the user, and is substantially perpendicular to the COP curve 1320 at each point of the COP curve 1320. Otherwise, the COP curve 1320 may be corrected by a computing system or operator to a target COP curve 1320' (solid line). Then, the directional stiffness feature 1330 may take the form of a curved line, rib, cutout, stripe, corrugation, or groove that is substantially perpendicular to the target COP curve 1320' at each point of the target COP curve 1320'. At locations where point cloud curve 1320 or target point cloud curve 1320' exhibits a small radius of curvature or many irregularities, this can cause unusual patterns. These can be avoided by introducing additional smoothing and / or straightening steps on COP curve 1320 or target COP curve 1320', respectively, to produce guide curve 1320" (dashed line) and basing the design of directional hardness feature 1330 on guide curve 1320" rather than COP curve 1320 or target COP curve 1320'. The directional hardness feature 1330 makes the customized footwear article 1300 less resistant to bending about an axis A parallel to a bend line, rib, cut, stripe, corrugation or groove than bending about an axis B tangent to COP curve 1320, target COP curve 1320' or guide curve 1320". In other embodiments, such as Fig.14As shown, COP curve, target COP curve or guide curve 1420 can be used to deform the pattern of surface texture 1430, which is applied to the surface of customized footwear article 1400, such as bottom surface, such as sole, insole or outsole. Such deformation can affect one-dimensional, two-dimensional or three-dimensional surface texture. For example, in some cases, surface texture can be deformed in u and v coordinates, and in other cases, surface texture can be deformed in u, v and w coordinates, or only deformed in w coordinates, wherein u and v coordinates are locally parallel to the surface to which texture is applied, and w coordinates are locally perpendicular to the surface. Deformation can be achieved by applying transformation on u, v and w coordinates, which affects one or more of u, v and w coordinates and depends on the shape of point cloud curve, target point cloud curve or guide curve. Deforming surface texture in u and v coordinates can cause surface texture pattern to be locally rotated and / or uniformly or non-uniformly scaled (e.g., stretched and / or compressed). Deforming the surface texture in the w coordinate can cause the surface texture pattern to be locally higher or lower in the case of a convex texture (e.g., a rib located on top of the surface), or deeper or shallower in the case of a concave texture (e.g., a groove in the surface). Deforming the surface texture based on a point cloud curve, a target point cloud curve, or a guide curve can help to visualize the user's roll-off pattern to a user, an operator, or a trained professional (e.g., a podiatrist). In addition, it can beneficially affect the mechanical properties of the customized footwear article, such as its resistance to bending or its directional stiffness, taking into account adverse conditions to be addressed or avoided, or performance improved by means of the customized footwear article. For example, if Fig.14 As shown, in the case of a convex surface texture (e.g., ribs located on top of the surface), the deformation of the surface texture directs more material toward area 1440 located on the concave side of curve 1420 and away from area 1450 located on the convex side of curve 1420, or alternatively, in the case of a concave surface texture (e.g., grooves in the surface), more material is directed toward area 1450 and away from area 1440. Additionally or alternatively, by deforming the w coordinate as described above, more material can be directed toward or away from a particular area. In some cases, the height (for convex texture) or depth (for concave texture) of the surface texture can be locally varied between 0.1% and 35% of the thickness of the sole, outsole, insole, or texture-applied layer of such sole, outsole, or insole.

[0200] In some embodiments, the COP curve or target COP curve may be made visible in the design of the customized article of footwear. For example, in the case of a sole, outsole, or insole, grooves, grooves, ribs, or any visible breaks in a pattern, texture, or pattern that follows the shape of the COP curve or target COP curve may be designed on the surface (e.g., underside) of the customized article of footwear. Fig.14Region 1460 in FIG. 14 is a smooth region representing visible breaks in surface texture 1430 and follows the shape of COP curve or target COP curve 1420. As with the deformed surface texture described above, making the COP curve or target COP curve visible in the design of a custom article of footwear can help a user, operator, or trained professional (such as a technician or podiatrist) visualize the user's roll-off pattern.

[0201] In some cases, when the correction between the COP curve and the target COP curve is particularly large, the larger difference between the current roll-off pattern of the user's foot and the mechanical properties of the customized footwear (such as its directional hardness) can initially cause discomfort or pain. In this case, it is beneficial to design not one but a series of customized footwear, each of which is based on a target COP curve in a series of target COP curves. For example, these can be continuous interpolations between the current COP curve and the desired final target COP curve. Wearing each of these customized footwear items continuously within a limited time will give the user and the user's foot the opportunity to gradually adapt to each new roll-off pattern and corresponding gait with minimal discomfort or pain before entering the next one. As the process proceeds, such a series of customized footwear items can be manufactured one by one. This allows the effectiveness of the process to be monitored and adjusted when needed. Alternatively, all customized footwear items in the customized footwear sequence can be manufactured and / or delivered to the user at once. The time period for wearing each sequence in the sequence of customized footwear articles can be automatically determined, for example, based on the difference between continuous target COP curves, or determined by a trained professional, such as a technician, foot specialist or foot disease doctor. Alternatively, it can be determined by the user when to switch to the next customized footwear article sequence of the customized footwear article sequence. In the case where the order of customized footwear articles is designed, it can be beneficial to incorporate an identifier into the design to indicate the order in which the user should wear the customized footwear article. For example, each individual customized footwear article can be marked with a number indicating its grade and / or the date on which the user should start wearing it. The label can be an adhesive label attached to the customized footwear article, it can be printed on the surface of the customized footwear article, or it can be designed as a surface relief, for example, recessed into the surface of the customized footwear article or protruding on the surface of the customized footwear article. In addition or alternatively, it can be particularly useful to make the target COP curve based on the design of each sequence in the sequence of customized footwear articles visible in the design, such as visible in any of the above-mentioned ways. This may help determine the order in which the customized article of footwear should be worn, and may help visualize the envisioned gradual modifications to the user's roll-off pattern to a user, operator, or trained professional, such as a technician or podiatrist.

[0202] Then, the method enters optional step 1140, in which a customized article of footwear is manufactured based at least in part on the virtual model generated in step 1130. The customized article of footwear can be manufactured using any suitable combination of computer-aided manufacturing techniques and / or manual operations. For example, a computer-aided cutting machine or milling machine can be used to cut one or more parts from a piece or piece of material. For example, as described above, the virtual model can include 2D shape data representing the top layer contour of the customized insole. The top layer can then be cut from a piece of suitable material based on the 2D contour. Additionally or alternatively, at least one portion of the customized article of footwear can be manufactured using any of the above-mentioned additive manufacturing techniques. In contrast to more traditional manufacturing techniques (such as injection molding), additive manufacturing techniques are particularly suitable for manufacturing personalized articles, such as customized articles of footwear, and injection molding requires at least one portion of the manufacturing machine (e.g., a mold) to be suitable for each new design of the article. Furthermore, in contrast to, for example, milling, additive manufacturing techniques offer the advantage of no material waste, objects with more complex geometries can be manufactured compared to conventional manufacturing techniques, and objects with many parts, which may have complex geometries, flexible hinges, or even moving parts, can be manufactured as a whole object, eliminating the need for assembly. In cases where the individual components of the customized article of footwear may be manufactured separately from different materials and / or using different manufacturing techniques, they may be assembled automatically or manually. For example, a soft top layer, such as cut from a sheet of foam, rubber, or leather, may be secured (e.g., using an adhesive, glue, hook-and-loop fastener, etc.) on top of a base layer manufactured using additive manufacturing techniques.

[0203] As described above, in step 1130, where a virtual model may be designed for a series of customized articles of footwear, in step 1140, one, some, or all of the customized articles of footwear may be manufactured simultaneously, sequentially, or at time intervals.

[0204] Disclosed herein are systems for designing and manufacturing customized footwear or customized footwear portions. Any of the following systems or methods are applicable to the design of customized footwear and the design of customized footwear portions. For efficiency reasons, unless otherwise expressly stated, the terms "customized footwear" or "customized footwear articles" in the following paragraphs should be interpreted as covering one or more customized footwear articles, one or more customized footwear portions, or any combination thereof.

[0205] Fig.15An embodiment of a customized footwear system 1500 is depicted. In the illustrated embodiment, the customized footwear system 1500 includes a data collection system 1510, a data processing system 1520, a manufacturing system 1530, and a data storage 1540. In some examples, any of the components making up the customized footwear system 1500 may include any number of processors and / or memories, and the processors may be configured to execute one or more executable instructions on any device. Without limitation, the customized footwear system 1500 may include fewer or more modules or components that define the customized footwear system 1500.

[0206] The data collection system 1510 collects data about a particular user, such as information about one or more feet of the user and / or data about a particular article of footwear. The data collection system 1510 may include a static data collection module 1512 configured to obtain static user-specific data, a dynamic data collection module 1514 configured to obtain dynamic user-specific data, and / or a footwear data collection module 1516 configured to obtain footwear-specific data. In some embodiments, the data collection system 1510 may be configured to perform or may be used by an operator to perform steps 1110 and / or 1120 of the above method.

[0207] In some embodiments, the data collection system 1510 may include one or more devices configured to acquire, measure, or collect various types of user-specific data and / or footwear-specific data, such as pressure-sensitive pads or socks, image sensor-based systems, mechanical scanning systems, 2D or 3D optical scanners, laser-based scanners, cavity scanners, or any other of the foregoing.

[0208] In some embodiments, data collection system 1510 may be portable and independent of other elements of customized footwear system 1500, while in other embodiments, data collection system 1510 may be integrated. Data collection system 1510 may include sensors (e.g., pressure sensitive pads and cameras, or any combination of the above sensors or data acquisition devices) and processing devices (e.g., mobile devices, computers, servers, etc.) that may be configured to support these sensors.

[0209] The data collection system 1510 may include a local data storage device (not shown) and / or a connection to a remote data storage device, such as the data storage device body 1540. The data collected by the data collection system 1510 may be stored in a local or remote data storage device (or both) after being sensed, measured, determined, input, uploaded, or otherwise created.

[0210] Data collection system 1510 may communicate data with other elements of customized footwear system 1500 via, for example, a hardwired or wireless data connection. For example, in embodiments where data collection system 1510 is portable and independent of other elements of customized footwear system 1500, data collection system 1510 may be configured to be connected to those elements and share data via a network connection, such as the Internet. In other embodiments, the connection may instead be established ad hoc between the various elements.

[0211] The data processing system 1520 is in data communication with the data collection system 1510. The data processing system 1520 can be configured to receive static and / or dynamic user-specific data and / or footwear-specific data collected by the data collection system 1510, and use the data in the design of the customized footwear. The data processing system 1520 can include a local data storage (not shown) and / or a connection to a remote data storage such as a data storage 1540. The data processing system 1520 can be configured to receive statistical body part data from such data storages, and use the data in the design of the customized footwear. The data processing system 1520 can include general CAD software, or special software that automates some or all processes, such as special software with a wizard-like structure that guides the operator through a predetermined design operation sequence. In some embodiments, the data processing system 1520 can be configured to perform or can be used by the operator to perform step 1130 of the above method.

[0212] In some embodiments, data processing system 1520 is portable and independent of the other elements of customized footwear system 1500, while in other embodiments, it may be integrated. For example, data processing system 1520 may be a portable computer system, such as a laptop computer. In other embodiments, data processing system 1520 may be remote from the other elements of customized footwear system 1500. For example, data processing system 1520 may be a remote server that may be configured to receive data via a data link and process the data remotely.

[0213] As described above, data processing system 1520 may include a local data storage device (not shown) and / or a connection to a remote data storage device, such as data storage device body 1540. The output of data processing system 1520 (e.g., a virtual model of a customized article of footwear) may be stored in data storage 140.

[0214] Data processing system 1520 may be in data communication with other elements of customized footwear system 1500 via, for example, a hardwired or wireless data connection. For example, in embodiments where data processing system 1520 is portable and separate from other elements of customized footwear system 1500, data processing system 1520 may be configured to be connected to those elements and share data via a network connection such as the Internet. In other embodiments, the connection may instead be established ad hoc between the various elements.

[0215] Manufacturing system 1530 may include controller 1532 and additive manufacturing device 1534. Manufacturing system 1530 may receive data from data processing system 1520 to manufacture customized footwear or customized footwear parts, such as insoles, midsoles, and outsoles. For example, manufacturing system 1530 may receive customized footwear design data in the form of an "STL" or "PLY" format file from data processing system 1520, which may be interpreted by controller 1532 to drive additive manufacturing device 1534. In some embodiments, manufacturing system 1530 performs or may be used by an operator to perform step 1140 of the above method.

[0216] It should be noted that Fig.15 The data communication lines depicted between data collection system 1510, data processing system 1520, manufacturing system 1530, and data storage 1540 are merely representative. The data communication paths between the various elements of customized footwear system 1500 may be direct or indirect, may traverse one or more networks, may include intermediary devices, may be wired or wireless, may use different protocols, may use different media, etc. Furthermore, the data communication paths may be unidirectional or bidirectional so that data may be shared between the various elements.

[0217] In some embodiments, Fig.15 The elements of the customized footwear system 1500 shown can be integrated into a single system. In such embodiments, a user can be scanned (e.g., using an image sensor) and tested (e.g., using a pressure-sensitive pad), and then receive customized footwear or customized footwear parts, such as a shoe body, insole, midsole, or outsole, in the same place. In such embodiments, an operator can be present to participate in or at least verify the design of the customized footwear. However, in other embodiments, the entire process can be automated. For example, in some embodiments, the entire customized footwear system 1500 can be a kiosk, etc., in a shoe store, a sporting goods store, or any other type of store.

[0218] In other embodiments, the elements of the customized footwear system 1500 may be independent. For example, the data collection system 1510 may be separate from the data processing system 1520 and the manufacturing system 1530 (although the latter two systems may be integrated or co-located). For example, a kiosk or the like may include a data collection system that includes various sensors, such as image sensors and pressure-sensitive pads, that may communicate data with the data processing system 1520 and the manufacturing system 1530 at another location. It is noteworthy that while these different elements may be physically separated in some embodiments, they may still be co-located at a particular location, such as a shoe store, so that a user may be scanned and provided with customized footwear at the same location.

[0219] In other embodiments, the data collection system 1510 and the manufacturing system 1530 can be co-located, while the data processing system 1520 can be located in different locations. Due to the complex processing performed by the data processing system 1520, it may be desirable to locate the data processing system 1520 away from the data collection system 1510 and the manufacturing system, such as at a remote server location. For example, a footwear store may have the data collection system 1510 and the manufacturing system 1530 in the same location, while the data processing system (and potentially its operator) may be located in a completely different location. In this way, the seller of custom footwear can limit the cost and space associated with each element, and only have those elements in the custom footwear system 1500 that are most convenient for the user. Such embodiments also allow suppliers of custom footwear systems to utilize different appliance allocation and sales models. For example, a custom footwear system supplier may sell certain elements of the system, such as a data collection system, while providing an ordering model to other elements, such as a data processing system. Ultimately, the custom footwear system 1500 may be integrated or modular, such as for a specific end user of the system.

[0220] Customized articles of footwear are disclosed herein because they can be designed and / or manufactured using any of the methods and / or systems described herein. The customized article of footwear can be any article of footwear or any footwear portion described herein, and can include any combination of footwear portions or features described herein. In particular, the customized article of footwear can include any combination of footwear portions or features listed in Tables 1-3.

[0221] In some embodiments, the customized footwear disclosed herein is a sole, outsole, or insole, the design of which is directly or indirectly based on the user's COP curve. For example, the customized footwear may include a directional hardness feature or a surface pattern, the design of which is based on the user's COP curve, target COP curve, or guide curve as described above. Additionally or alternatively, as described above, in the design of the customized footwear, the user's COP curve or target COP curve may be visible.

Claims

1. A customized article of footwear, comprising: at least one corrective feature configured to stimulate a user's foot to move and roll according to a pattern, and The sole, insole, midsole, outsole, upper or any part thereof.

2. The customized article of footwear according to claim 1, wherein the pattern is based on a target center of pressure (COP) curve.

3. The customized article of footwear according to any one of claims 1 to 2, wherein the at least one corrective feature comprises: A surface texture is at least partially located on at least one surface of the customized article of footwear and / or one or more layers defining the customized article of footwear. 4 . The customized article of footwear according to claim 3 , wherein the surface texture comprises a surface texture pattern configured to deform along one or more coordinates.

5. The customized article of footwear according to any one of claims 1 to 4, wherein the at least one corrective feature comprises: A directional stiffness layer comprising one or more of a series of bend lines, ribs, cuts, stripes, waves, grooves or other patterns.

6. The customized article of footwear according to any one of claims 1 to 5, further comprising: A stabilization layer includes a layer configured to bend or flatten in different areas.

7. The customized article of footwear according to any one of claims 1 to 6, further comprising: Forefoot support.

8. The customized article of footwear according to any one of claims 1 to 7, wherein the one or more corrective features are selected from: one or more flex lines, ribs, cuts, striations, corrugations, or grooves.

9. The customized article of footwear according to any one of claims 1 to 8, further comprising: The grooves, channels, ribs or visible breaks in the pattern, texture or pattern of the customized article of footwear that follow the shape of the target COP curve or another COP curve.

10. A customized footwear article according to any one of claims 1 to 9, wherein the customized footwear article is configured to have less resistance when bending about an axis tangent to the target COP curve at that point than when bending about an axis perpendicular to the direction of the target COP curve at that point.

11. The customized article of footwear according to any one of claims 1 to 10, wherein the customized article of footwear is an insole.

12. A method for manufacturing a customized article of footwear, the method comprising the steps of: a) obtaining footwear specific data; b) obtaining user-specific data; c) generating a model of a customized article of footwear based on the acquired footwear-specific data and the acquired user-specific data; and d) manufacturing the customized article of footwear based on the model.

13. A method according to claim 12, wherein in step b), the user-specific data includes pressure data and centers of pressure points, and step d) includes manufacturing the customized footwear article with at least one corrective feature, wherein the at least one corrective feature is configured to stimulate the user's foot to move and roll according to a pattern based on a target center of pressure curve.

14. The method according to claim 13, wherein in step b) the user-specific data comprises dynamic user-specific data and in step d) the target centre of pressure curve is based on the dynamic user-specific data.

15. A method according to any one of claims 12 to 14, wherein step d) comprises manufacturing the customized footwear having a center of pressure curve, the center of pressure curve being located on at least one surface of the customized footwear and / or one or more layers defining the customized footwear.

16. A method according to any one of claims 12 to 15, wherein step d) comprises manufacturing the customized footwear article having a surface texture, the surface texture being at least partially located on at least one surface of the customized footwear article and / or one or more layers defining the customized footwear article.

17. The method of claim 16, wherein the surface texture comprises a surface texture pattern configured to deform along one or more coordinates.

18. A method according to any one of claims 15 to 17, wherein in step d), the customized footwear article is manufactured to have at least one corrective feature, and the at least one corrective feature is configured to stimulate or comfort the user's foot to move and roll according to a pattern that produces a user-specific center of pressure curve based on a target center of pressure curve.

19. The method of any one of claims 12 to 18, wherein the customized article of footwear comprises a plurality of regions and a raised surface texture, wherein deformation of the surface texture directs more material away from a second region toward a first region.

20. The method of any one of claims 12 to 18, wherein the customized article of footwear includes a plurality of regions and visible contours in the surface texture and follows the shape of a center of pressure curve or a target center of pressure curve.

21. A method according to any one of claims 12 to 18, wherein the customized footwear article includes a plurality of regions, wherein at least one of the plurality of regions includes a first region located on a concave side of a target pressure center curve, and at least one of the plurality of regions includes a second region located on a convex side of the target pressure center curve.

22. The method of any one of claims 12 to 21, wherein a target centre of pressure curve is used to deform a pattern of surface texture applied to a surface of the customized article of footwear.

23. The method of any one of claims 12 to 22, wherein the customized article of footwear is an insole.

24. The method of claim 23, wherein the insole comprises a base layer comprising one or more of a variable thickness layer, a directional stiffness layer, a stabilization layer, and a reinforcement layer.

25. The method of claim 23, wherein the insole comprises a variable thickness layer, the variable thickness layer comprising a thickness configured to control a stiffness of the insole.

26. The method of claim 23, wherein the insole includes a directional stiffness layer configured to be more flexible in a first direction and less flexible in a second direction.

27. The method of claim 12, further comprising: A statistical model is constructed based on a plurality of user-specific two-dimensional or three-dimensional body part data from a training set, the training set comprising a plurality of members of a population, wherein generating the model is also based on the statistical model.

28. The method of claim 27, wherein the statistical model comprises a statistical shape model (SSM).

29. The method of claim 27, wherein generating the model comprises fitting the statistical model to the user-specific data.

30. The method of claim 29, wherein fitting the statistical model to the user-specific data comprises fitting a three-dimensional statistical model of a user's foot to a two-dimensional contour of the user's foot.

31. The method of claim 29, wherein fitting the statistical model to the user-specific data comprises determining one or more coefficient values ​​of the statistical model.

32. The method of claim 27, wherein obtaining the user-specific data comprises automatically analyzing image data using the statistical model.

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