Additive manufacturing footwear

Abstract

An additive manufactured article of footwear includes a sole portion and an upper portion that are 3D printed as a single piece. In some embodiments, an article of footwear may include an outer skin layer including a plurality of continuous beams extending adjacent to each other that define at least a portion of an outer contour of the upper portion, at least a portion of an outer contour of the sole portion, or both. In some embodiments, an article of footwear may include an inner skin layer including a network of beams defining at least a portion of an inner profile of the upper portion. In some embodiments, the article of footwear may include a core structure connecting the beams of the outer skin layer to the beams of the inner skin layer.

Description

Technical Field

[0001] The described embodiments generally relate to footwear articles formed by additive manufacturing (3D printing). More specifically, the described embodiments relate to additively manufactured footwear that includes a vamp portion and a sole portion that are additively manufactured as a single piece. Background Art

[0002] The human foot is a complex and remarkable mechanical component that is capable of withstanding and dissipating many impact forces. The natural fat pads at the heel and forefoot and the flexibility of the arches help cushion the foot. Although the human foot has natural cushioning and resilience characteristics, the foot alone cannot effectively overcome many of the forces encountered during daily activities. Pain and fatigue associated with daily activities are more severe and their onset may be accelerated unless an individual wears footwear that provides adequate cushioning and support.

[0003] People often care about the amount of cushioning and support provided by footwear articles. This is true for footwear articles used for non-sporting activities (such as leisurely walking) and for footwear articles used for sporting activities (such as running) because throughout an average day, an individual's feet and legs are subject to significant impact forces. When a footwear article contacts a surface, significant forces can act on the footwear article and, correspondingly, on the wearer's foot. Part of the function of the upper of a footwear article is to provide cushioning for the wearer's foot and to protect the foot from these forces.

[0004] A suitable shoe should be durable, comfortable, and provide other beneficial features for an individual. Accordingly, there is a continuing need for innovation in footwear. Summary of the Invention

[0005] Embodiments in accordance with the present disclosure are directed to footwear articles that include a sole portion and a vamp portion integrally formed as a single piece. The sole portion, the vamp portion, or both can include structures configured to seamlessly integrate multiple functional or aesthetic features for the footwear article. The structure can include an outer layer as described herein, an inner layer as described herein, a core structure as described herein, or any combination of these components. In some embodiments, the sole portion can include a midsole that includes interconnected unit cells as described herein.

[0006] The first (1) embodiment of the present application relates to an article of footwear, comprising: a sole portion; an upper portion; an outer surface layer including a plurality of continuous beams extending adjacent to each other, the continuous beams defining at least a part of the outer contour of the upper portion and at least a part of the outer contour of the sole portion; an inner surface layer including a network of beams defining at least a part of the inner contour of the upper portion; a core structure connecting the outer surface layer to the inner surface layer, the core structure including struts connecting the beams of the outer surface layer to the beams of the inner surface layer; and a midsole including a three-dimensional mesh, the three-dimensional mesh including a plurality of interconnected unit cells, each interconnected unit cell including a plurality of unit cell struts defining a three-dimensional structure and a plurality of nodes, with one or more unit cell struts connected at the nodes; wherein the midsole forms part of the sole portion; and wherein the sole portion, the upper portion, the outer surface layer, the inner surface layer, the core structure and the midsole are 3D printed as a single piece.

[0007] In a second (2) embodiment, the core structure according to the first (1) embodiment is arranged around the outer and inner sides of the midsole and connects the midsole to the outer surface layer around the outer and inner sides of the midsole.

[0008] In a third (3) embodiment, the inner surface layer according to the first (1) embodiment or the second (2) embodiment is arranged around the outer and inner sides of the midsole and connects the midsole to the core structure around the outer and inner sides of the midsole.

[0009] In a fourth (4) embodiment, the upper portion according to any one of the first (1) embodiment to the third (3) embodiment includes a reinforcement structure disposed within a void formed in the midsole.

[0010] In a fifth (5) embodiment, the sole portion, the upper portion, the outer surface layer, the inner surface layer, the core structure and the midsole according to any one of the first (1) embodiment to the fourth (4) embodiment are all formed of the same material.

[0011] In a sixth (6) embodiment, the nodes of the midsole according to any one of the first (1) embodiment to the fifth (5) embodiment are located at the inner peripheral boundary of the midsole, and each node at the inner peripheral boundary includes a plurality of beams of the inner surface layer directly connected to the node.

[0012] The seventh (7) embodiment of the present application relates to an article of footwear, comprising: a sole portion; an upper portion; an outer skin layer including a plurality of continuous beams extending adjacent to each other, the continuous beams defining at least a portion of the outer contour of the upper portion and at least a portion of the outer contour of the sole portion; an inner skin layer including a network of beams defining at least a portion of the inner contour of the upper portion; and a core structure connecting the beams of the outer skin layer to the beams of the inner skin layer; and the sole portion, the upper portion, the outer skin layer, the inner skin layer and the core structure are 3D printed as a single piece.

[0013] In the eighth (8) embodiment, the core structure according to any one of the first (1) to seventh (7) embodiments includes struts that directly connect the beams of the outer skin layer to the beams of the inner skin layer.

[0014] In the ninth (9) embodiment, the core structure according to any one of the first (1) to eighth (8) embodiments includes a thickness defined as the distance between the outer skin layer and the inner skin layer, and the thickness of the core structure varies across different regions of the upper portion.

[0015] In the tenth (10) embodiment, the inner contour of the upper portion according to any one of the first (1) to ninth (9) embodiments includes a wavy contour that varies relative to the outer contour defined by the outer skin layer.

[0016] In the eleventh (11) embodiment, the wavy contour according to the tenth (10) embodiment includes a first region and a second region, the first region being spaced apart from the outer skin layer by a first distance, and the second region being spaced apart from the outer skin layer by a second distance, the second distance being less than the first distance.

[0017] In the twelfth (12) embodiment, the length of the struts of the core structure connecting the outer skin layer to the inner skin layer in the first region according to the eleventh (11) embodiment is greater than the length of the struts connecting the outer skin layer to the inner skin layer in the second region.

[0018] In the thirteenth (13) embodiment, adjacent beams of the plurality of continuous beams of the outer skin layer according to any one of the first (1) to twelfth (12) embodiments extend substantially parallel to each other.

[0019] In the fourteenth (14) embodiment, the upper portion according to any one of the first (1) to thirteenth (13) embodiments includes a collar defining an opening configured to receive a wearer's foot.

[0020] In the fifteenth (15) embodiment, the plurality of continuous beams of the outer skin layer according to the fourteenth (14) embodiment extend from the collar to the sole portion.

[0021] In the sixteenth (16) embodiment, the shoe collar according to the fourteenth (14) embodiment or the fifteenth (15) embodiment includes an edge defining an opening for receiving a wearer's foot, and a plurality of continuous beams cross the edge at an angle of less than 45 degrees.

[0022] In the seventeenth (17) embodiment, each of the plurality of beams according to the sixteenth (16) embodiment includes a first portion, a turn, and a second portion. The first portion approaches the edge at an angle greater than or equal to 45 degrees and less than or equal to 90 degrees, and the second portion extends from the turn and crosses the edge at an angle of less than 45 degrees.

[0023] In the eighteenth (18) embodiment, one of the continuous beams of the outer surface layer according to any one of the first (1) to seventeenth (17) embodiments includes an extension portion that includes an increased height extending from the outer contour of the shoe upper portion and defining a tab.

[0024] In the nineteenth (19) embodiment, the inner surface layer according to any one of the first (1) to eighteenth (18) embodiments includes a release agent.

[0025] In the twentieth (20) embodiment, the inner surface layer according to any one of the first (1) to nineteenth (19) embodiments includes a low-friction texture.

[0026] In the twenty-first (21) embodiment, a group of adjacent beams among the plurality of continuous beams of the outer surface layer according to any one of the first (1) to twentieth (20) embodiments includes an extension portion with an increased height and defines a beam of an image contour that extends from the outer contour of the shoe upper portion, the outer contour of the sole portion, or both.

[0027] In the twenty-second (22) embodiment, the outer surface layer according to any one of the first (1) to twenty-first (21) embodiments includes a region where the space between a group of adjacent beams is filled with a thin sheet, and on the shoe upper portion, the sole portion, or both the shoe upper portion and the sole portion, the thin sheet defines all or a part of an image.

[0028] In the twenty-third (23) embodiment, the thin sheet according to the twenty-second (22) embodiment is 3D printed integrally with a group of adjacent beams.

[0029] In the twenty-fourth (24) embodiment, the sole portion according to any one of the first (1) to twenty-third (23) embodiments includes a ground-facing surface that includes a ground-facing structure.

[0030] In the twenty-fifth (25) embodiment, the ground-facing structure according to the twenty-fourth (24) embodiment includes a cavity and an outsole material filling the cavity.

[0031] In the twenty-sixth (26) embodiment, a plurality of beams of the outer surface layer according to any one of the first (1) to twenty-fifth (25) embodiments extend from the upper portion to the ground-facing surface of the sole portion and form part of the ground-facing structure.

[0032] In the twenty-seventh (27) embodiment, the ground-facing structure according to the twenty-sixth (26) embodiment includes a region where the spaces between the plurality of beams on the outer surface are filled with a thin sheet, and the thin sheet forms a recess between adjacent beams of the plurality of beams.

[0033] In the twenty-eighth (28) embodiment, the recess according to the twenty-seventh (27) embodiment is filled with an outsole material.

[0034] In the twenty-ninth (29) embodiment, the footwear item according to any one of the first (1) to twenty-eighth (28) embodiments further includes a sockliner boot connected to the inner surface layer.

[0035] In the thirtieth (30) embodiment, the footwear item according to any one of the first (1) to twenty-ninth (29) embodiments further includes a plurality of lace structures formed in the upper portion.

[0036] In the thirty-first (31) embodiment, each of the plurality of lace structures according to the thirtieth (30) embodiment includes an opening extending through the outer surface layer, the core structure, and the inner surface layer.

[0037] In the thirty-second (32) embodiment, each of the plurality of lace structures according to the thirtieth (30) embodiment or the thirty-first (31) embodiment includes an edge defining a through-hole for receiving a lace.

[0038] In the thirty-third (33) embodiment, the beams of the outer surface layer according to any one of the first (1) to thirty-second (32) embodiments do not define part of a repeating unit cell.

[0039] In the thirty-fourth (34) embodiment, the outer contour defined by the beams according to any one of the first (1) to thirty-third (33) embodiments includes a smooth contour that does not oscillate between adjacent connection points of the struts with the core structure.

[0040] In the thirty-fifth (35) embodiment, the spacing distance between adjacent consecutive beams according to any one of the first (1) to thirty-fourth (34) embodiments varies along the outer surface layer.

[0041] In the thirty-sixth (36) embodiment, the outer surface layer according to the thirty-fifth (35) embodiment includes a portion where the spacing distance becomes zero, such that adjacent beams are fused together.

[0042] In the thirty-seventh (37) embodiment, a beam network that defines at least a portion of the inner contour of the defined vamp portion according to any one of the first (1) to thirty-sixth (36) embodiments includes beams that cross each other.

[0043] In the thirty-eighth (38) embodiment, a plurality of beams of the outer surface layer according to any one of the first (1) to thirty-seventh (37) embodiments define a double concave structure at the outer contour of the vamp portion and the outer contour of the sole structure.

[0044] In the thirty-ninth (39) embodiment, the spaces between adjacent beams of the outer surface layer and the spaces between adjacent beams of the inner surface layer form through openings in the vamp portion.

[0045] In the fortieth (40) embodiment, the vamp portion according to any one of the first (1) to thirty-ninth (39) embodiments includes a plurality of interconnected unit cells, which include a solid representation of an implicit surface.

[0046] A forty-first (41) embodiment of the present application relates to a method of manufacturing a footwear object, the method including printing a green 3D printed object, the green 3D printed object including: a sole portion; a vamp portion; an outer surface layer, which includes a plurality of continuous beams extending adjacent to each other, the continuous beams defining at least a portion of the outer contour of the vamp portion and at least a portion of the outer contour of the sole portion; an inner surface layer, which includes a network of beams that define at least a portion of the inner contour of the vamp portion; and a core structure that connects the outer surface layer to the inner surface layer, the core structure including struts that connect the beams of the outer surface layer to the beams of the inner surface layer; and heating the green 3D printed object to cause the 3D printed object to expand into a footwear object.

[0047] In the forty-second (42) embodiment, the method according to the forty-first (41) embodiment further includes: curing the footwear object after causing the 3D printed article to expand.

[0048] In the forty-third (43) embodiment, the method according to the forty-second (42) embodiment further includes: inserting a fixture into the foot cavity of the footwear object before curing the footwear object.

[0049] In a forty-fourth (44) embodiment, the method according to any one of the forty-first (41) through forty-third (43) embodiments further includes: inserting a reinforcement structure among one or more voids formed in a sole portion before heating a green 3D printed article; wherein heating the green 3D printed article causes the sole portion to expand to secure the reinforcement structure within the sole portion. BRIEF DESCRIPTION OF THE DRAWINGS

[0050] Figure 1A A first perspective view of a footwear article in accordance with some embodiments is shown.

[0051] Figure 1B Shows Figure 1A a second perspective view of the footwear article shown.

[0052] Figure 1C Shows Figure 1A a side view of the footwear article shown.

[0053] Figure 1D Shows Figure 1C a cross-sectional view taken along line 1D–1D'.

[0054] Figure 1E Shows Figure 1C a cross-sectional view taken along line 1E–1E'.

[0055] Figure 1F Shows Figure 1A a bottom view of the footwear article shown.

[0056] Figure 1G Shows Figure 1A an enlarged portion of.

[0057] Figure 1H Shows Figure 1B an enlarged portion of.

[0058] Figure 2 A footwear article in accordance with some embodiments including a region having an image profile is shown.

[0059] Figure 3 A ground-facing structure in accordance with some embodiments is shown.

[0060] Figure 4 A ground-facing structure in accordance with some embodiments is shown.

[0061] Figure 5 A footwear article in accordance with some embodiments including a sock liner is shown.

[0062] Figure 6 A footwear article in accordance with some embodiments including a lacing structure is shown.

[0063] Figure 7 An article of footwear including a reinforcement structure is shown in accordance with some embodiments.

[0064] Figure 8 An article of footwear is shown in accordance with some embodiments.

[0065] Figure 9 is a flow chart of a method in accordance with some embodiments.

[0066] Figure 10 A green body on a build plate is shown in accordance with some embodiments.

[0067] Figure 11 A jig is shown in accordance with some embodiments.

[0068] Figure 12 An article of footwear is shown in accordance with some embodiments.

[0069] Figure 13 An article of footwear is shown in accordance with some embodiments.

[0070] Figure 14 An article of footwear is shown in accordance with some embodiments. DETAILED DESCRIPTION

[0071] The present invention will now be described in detail with reference to embodiments of the invention as shown in the accompanying drawings. References to "some embodiments", "an embodiment", "exemplary embodiments", etc. indicate that the described embodiments may include a particular feature, structure, or characteristic, but each embodiment may not necessarily include that particular feature, structure, or characteristic. Moreover, these phrases do not necessarily refer to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is considered within the knowledge of those skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments, whether or not explicitly described.

[0072] The indefinite articles "a", "an", and "the" include plural referents unless expressly contradicted or the context clearly dictates otherwise.

[0073] The term "comprising" is an open transitional phrase. The list of elements following the transitional phrase "comprising" is a non-exclusive list such that elements other than those specifically recited in the list may also be present.

[0074] As used herein, references to "first", "second", "third", "fourth", etc. do not, unless otherwise indicated, denote an order or that a feature with a higher number requires a feature with a lower number. Further, unless otherwise specified, the use of "first", "second", "third", "fourth", etc. does not necessarily imply that the "first", "second", "third", "fourth", etc. features have different properties or values.

[0075] The footwear articles and components described herein can be additively manufactured as a single piece and, in some embodiments, can be additively manufactured from the same material. Additively manufactured footwear having the features described herein can be manufactured without a traditional shoe last and can reduce the amount of adhesive or external bonding steps required to produce a footwear article.

[0076] Integrally forming a sole portion and an upper portion as described herein can result in footwear having desired support, cushioning, and fit characteristics for a wearer. The integrally formed sole portion and upper portion can provide a single, integral structure designed to provide overall characteristics, while the features of the sole portion and upper portion can provide specific characteristics for the sole and upper, respectively.

[0077] Features of the footwear, such as the beams forming the surface layer as described herein, can produce a surface or surface profile that provides overall structural and / or aesthetic characteristics, while components within the surface layer (e.g., a midsole or a core structure) can provide additional characteristics. For example, in some embodiments, the surface layer can be formed internally with a midsole that is configured to provide desired support and locomotion characteristics to the sole portion. As another example, in some embodiments, the surface layer can be integrally formed with a core structure that is configured to provide desired support and fit characteristics to the upper portion. In such embodiments, the core structure can produce a regionally adjusted profile that provides desired fit characteristics without the addition of cushioning materials, such as foam cushioning.

[0078] In addition, the footwear described herein appears to be able to integrate various features into a single additively manufactured component. For example, the footwear described herein appears to be able to integrate aesthetic features (e.g., a manufacturer brand or logo) and structural features (e.g., a footwear collar, a footwear lacing structure, and ventilation). Features of the shoe, such as the beams forming the surface layer as described herein, are capable of providing these integrated features in a seamless and aesthetically pleasing manner.

[0079] Figure 1A – Figure 1H A footwear article 100 is shown in accordance with some embodiments. The footwear article 100 includes a sole portion 120 and an upper portion 160. The sole portion 120 can define all or a portion of the sole of the footwear article 100, and the upper portion 160 can define all or a portion of the upper of the footwear article 100.

[0080] The footwear article 100 can include a forefoot end 102, a hindfoot end 104, a medial side 106, and a lateral side 108 opposite the medial side 106. Similarly, for example Figure 1AAs shown, the footwear item 100 can include a forefoot portion 110, a midfoot portion 112, and a hindfoot portion 114. The portions 110, 112, and 114 are not intended to precisely demarcate regions of the footwear item 100. Instead, the portions 110, 112, and 114 are intended to denote approximate regions of the footwear item 100 for reference purposes. Although the portions 110, 112, and 114 generally apply to the footwear item 100, references to the portions 110, 112, and 114 can also specifically apply to the sole portion 120, the upper portion 160, or individual components of the sole portion 120 or the upper portion 160.

[0081] The sole portion 120 can include a midsole 140. In such an embodiment, the midsole 140 forms part of the sole portion 120. In some embodiments, for example Figure 1D As shown, the midsole 140 can include a three-dimensional mesh 142 that includes a plurality of interconnected unit cells 144. Each interconnected unit cell 144 can include a plurality of unit cell struts 146 and a plurality of nodes 148, with the unit cell struts 146 defining a three-dimensional structure and one or more of the unit cell struts 146 connecting at the plurality of nodes 148.

[0082] In some embodiments, the top surface of the midsole 140 can include an insole surface layer 156. In some embodiments, the insole surface layer 156 can include a network of beams 158 that cross each other at intersections 159, such as for example Figure 1B As shown. In some embodiments, the intersections 159 can be located at the nodes 148 of the unit cells 144 of the midsole 140. In embodiments that include the surface layer 156, the beams 158 can include smooth profiles that do not oscillate between adjacent intersections 159 with the struts 146 of the unit cells 144. In such embodiments, the beams 158 can extend continuously in a straight or curved line between the intersections 159. In some embodiments, the beams 158 of the surface layer 156 can not define a part of the repeating unit cells 144 of the midsole 140. Instead, the beams 158 of the surface layer 156 can be integrally formed on the repeating unit cells 144 of the midsole 140.

[0083] As used herein, the term three-dimensional network refers to a three-dimensional structure including a plurality of unit cells 144 arranged in a network structure or a grid structure. The network or grid structure of the three-dimensional network includes interconnecting structural members (such as struts 146 or bands) that define the plurality of unit cells 144. In embodiments including struts 146, the struts 146 and thus the unit cells 144 are connected at nodes 148. For example, the struts 146 are connected at nodes 148 and define unit cells 144 arranged in a grid configuration. In some embodiments, the plurality of interconnected unit cells 144 can be arranged in a regular or repeating grid configuration. Exemplary grid structures include but are not limited to a basic cubic grid, a body-centered cubic grid, a face-centered cubic grid, and modified grids based on these grid types. Exemplary grid structures include but are not limited to the grid structures described in U.S. Application Nos. 17 / 069,623 and 18 / 313,135, which are incorporated herein by reference in their entirety.

[0084] The unit cells 144 can have various sizes and geometries. Additionally, the unit cells 144 within the three-dimensional network can be the same or different. Thus, the three-dimensional network can include unit cells of different sizes or geometries. The three-dimensional shape of the unit cell 144 can be defined by a plurality of interconnected struts 146 that are connected to each other at nodes 148. In such embodiments, each unit cell 144 can have a basic geometry defined by the struts 146. As used herein, "basic geometry" refers to the basic three-dimensional shape, connection, and arrangement of the struts that define the unit cell. The basic geometry of the unit cell can be but is not limited to a dodecahedron (such as a rhombic dodecahedron), a tetrahedron, an icosahedron, a cube, a cuboid, a prism, or a parallelepiped. Each node 148 can connect two or more struts 146.

[0085] In some embodiments, the interconnected unit cells 144 can include a solid representation of a repeating implicit surface of the grid structure. In such embodiments, the unit cell can include a "base surface geometry" defined by the underlying three-dimensional shape of the body, which is formed by one or more strips (walls) of material of the solid representation of the implicit surface that defines the complete unit cell. In some embodiments, the implicit surface can be a periodic implicit surface such that the base surface geometry of each unit cell contacts the base surface geometry of at least some adjacent unit cells to create a grid. An example of a suitable periodic surface is a G-minimal surface (gyroid), but any type of suitable periodic surface can be used.

[0086] Here, an entity representation of an implicit surface refers to an entity object that follows the shape of the implicit surface. The actual implicit surface has no thickness, while the entity representation of the implicit surface has a thickness on one or both sides of the actual implicit surface in three-dimensional space. The thickness gives the volume of the entity representation, meaning the entity representation can be constructed from physical material into a physical object. The added thickness can be uniform, or at least approximately uniform despite the presence of rounded corners or local deformations, and is thin compared to the overall dimensions of the implied surface being represented. In some embodiments, the relative density of the unit cell of the entity representation can be 5% to 30%, 5% to 40%, 10% to 25%, or 15% to 20%. As used herein, the term "relative density" refers to the percentage of the amount of the unit cell occupied by the solid material in the total volume of the unit cell.

[0087] In some embodiments, an implicit surface can be created using a combination of random Fourier series functions, where linear and / or non-linear coefficients and linear and non-linear variables within the sine and cosine terms in the x, y, and z spaces are iterated to generate a function. The resulting unit cell can have different planes of symmetry, e.g., in various examples, zero planes of symmetry, one plane of symmetry, or more than one plane of symmetry. The function can be derived in a manner that satisfies the periodicity of the unit cell. The criteria for selecting an applicable implicit surface within the design space domain can include any one or any combination of the number of terms in the equation, the number of connecting components, the edge boundary length, the surface area, and the volume fraction.

[0088] In some embodiments, the footwear item 100 can include an outer layer 200 that defines at least a portion of the outer contour 162 of the upper portion 160, at least a portion of the outer contour 122 of the sole portion 120, or both at least a portion of the outer contour 162 of the upper portion 160 and at least a portion of the outer contour 122 of the sole portion 120. In some embodiments, the outer layer 200 can include a plurality of continuous beams 202 that extend adjacent to each other and define at least a portion of the outer contour 162 of the upper portion 160, at least a portion of the outer contour 122 of the sole portion 120, or both. The space 204 between adjacent continuous beams 202 can separate the adjacent continuous beams 202 from each other along at least a portion of the sole portion 120, the upper portion 160, or both. The continuous beams 202 of the outer layer 200 may not define a part of a repeating unit cell (e.g., the unit cell 144 as described herein).

[0089] In some embodiments, one or more continuous beams 202 of the outer layer 200 may extend from the upper portion 160 to the sole portion 120. In some embodiments, one or more continuous beams 202 of the outer layer 200 may extend from the upper portion 160 to the sole portion 120 and extend across the ground-facing surface 134 of the sole portion 120. In such embodiments, one or more continuous beams 202 may form part of the ground-facing structure 130 for the sole portion 120.

[0090] The outer contour 122 of the sole portion 120 is defined by the entire outermost surface contour of the sole portion 120. For example, the outer contour 122 is shown in Figure 1E . The grooves or depressions between the beams 202 of the outer layer 200 do not define the shape of the outer contour 122. Instead, the outer contour 122 is characterized by the overall outermost shape of the sole portion 120 defined by the outer layer 200. Similarly, the outer contour 162 of the upper portion 160 is defined by the entire outermost surface contour of the upper portion 160. For example, the outer contour 162 is shown in Figure 1E . The grooves or depressions between the beams 202 of the outer layer 200 do not define the shape of the outer contour 162. Instead, the outer contour 162 is characterized by the overall outermost shape of the upper portion 160 defined by the outer layer 200.

[0091] In some embodiments, the continuous beams 202 of the outer layer 200 may extend continuously at the outer contour 122, where multiple beams 202 extend continuously along a portion of the sole portion 120. In some embodiments, the continuous beams 202 of the outer layer 200 may extend continuously at the outer contour 162, where multiple beams 202 extend continuously along a portion of the upper portion 160. In some embodiments, the continuous beams 202 of the outer layer 200 may extend continuously at the outer contour 122 and the outer contour 162, with multiple beams 202 extending continuously along a portion of the sole portion 120 and a portion of the upper portion 160.

[0092] In some embodiments, one or more beams 202 may continuously extend along a distance of at least 5 centimeters. In some embodiments, one or more beams 202 may continuously extend along a distance of at least 10 centimeters. In some embodiments, one or more beams 202 may continuously extend along a distance of at least 15 centimeters. In some embodiments, one or more beams 202 may continuously extend in a straight line. In some embodiments, one or more beams 202 may continuously extend in a curve. In some embodiments, one or more beams 202 may continuously extend and include a first portion 210 that continuously extends in a straight line or curve before reaching a turn 212 and a second portion 214 that begins at the turn 212 and continuously extends in a straight line or curve. In some embodiments, the turn 212 may have a turn angle ranging from greater than or equal to 10 degrees and less than or equal to 170 degrees. In some embodiments, the turn 212 may have a turn angle ranging from greater than or equal to 20 degrees and less than or equal to 160 degrees. Figure 1H A continuous beam 202 including a first portion 210, a turn 212, and a second portion 214 is shown in accordance with some embodiments.

[0093] In some embodiments, the outer contour 122 defined by the continuous beam 202 may include a smooth contour that does not oscillate between adjacent connection points 276 of the struts 272 of the core structure 270 as described herein. In such embodiments, the continuous beam 202 may continuously extend in a straight line or curve between the connection points 276. In some embodiments, the distance between adjacent connection points 276 on the sole portion 120 may be at least 1 millimeter (mm). In some embodiments, the distance between adjacent connection points 276 may be at least 2 mm. In some embodiments, the distance between adjacent connection points 576 may be at least 5 mm.

[0094] In some embodiments, the outer contour 162 defined by the continuous beam 202 may include a smooth contour that does not oscillate between adjacent connection points 276 of the struts 272 of the core structure 270 as described herein. In such embodiments, the continuous beam 202 may continuously extend in a straight line or curve between the connection points 276. In some embodiments, the distance between adjacent connection points 276 on the upper portion 160 may be at least 1 mm. In some embodiments, the distance between adjacent connection points 276 may be at least 2 mm. In some embodiments, the distance between adjacent connection points 576 may be at least 5 mm.

[0095] In some embodiments, adjacent beams 202 among the plurality of continuous beams 202 may extend substantially parallel to each other at the outer contour 122, the outer contour 162, or both. As used herein, "substantially parallel" means that two or more beams 202: (i) extend along a straight line or a curve that is precisely parallel to each other for a specified length, or (ii) extend along a straight line or a curve that is parallel to each other with a + / - 10-degree deviation for a specified length. In some embodiments, the specified length may be at least 5 mm, at least 10 mm, or at least 15 mm.

[0096] In embodiments including a plurality of continuous beams 202, the plurality of continuous beams extend substantially parallel to each other at the outer contour 122, the outer contour 162, or both, and the plurality of beams 202 may define a two-sided convex structure at the outer contour 122, the outer contour 162, or both.

[0097] Adjacent continuous beams 202 extending at the outer contour 122, the outer contour 162, or both may be spaced apart from each other by a spacing distance 206, such as Figure 1H shown. In some embodiments, the range of the spacing distance 206 may be from greater than or equal to 0.1 mm to less than or equal to 10 mm.

[0098] In some embodiments, the spacing distance 206 between two adjacent beams 202 may be constant along a specified length, such as at least 5 mm, at least 10 mm, or at least 15 mm. In such embodiments, the two adjacent beams 202 may extend along a straight line or a curve that is precisely parallel to each other for the specified length.

[0099] In some embodiments, the spacing distance 206 between two adjacent beams 202 may vary along the outer surface layer 200. In such embodiments, the two adjacent beams 202 may extend along a straight line or a curve that is not precisely parallel to each other for the specified length. In some embodiments, the outer surface layer 200 may include one or more portions 208 where the spacing distance 206 between two or more adjacent beams 202 is zero. In such embodiments, two or more adjacent beams 202 may merge together at the outer contour 122, the outer contour 162, or both. In some embodiments, two or more adjacent beams 202 may be spaced apart when approaching the portion 208, merge in the portion 208, and then diverge in a spaced-apart relationship after the portion 208. In some embodiments, the portion 208 may include three or more, four or more, or five or more adjacent beams 202 that merge together.

[0100] In some embodiments, the footwear article 100 may include an inner layer 240 that defines at least a portion of the inner profile 164 of the upper portion 160. In some embodiments, the inner layer 240 may include beams 242 that define at least a portion of the inner profile 164 of the upper portion 160. In some embodiments, the beams 242 may be the same as the continuous beams 202. In such embodiments, the beams 242 may include any of the features of the beams 202 described herein. In some embodiments, the inner layer 240 may include a network of beams 242 that define at least a portion of the inner profile 164 of the upper portion 160. In such embodiments, for example Figure 1G as shown, the network of beams 242 may include beams 242 that cross each other at intersections 244. The spaces 246 between adjacent beams 242 may separate adjacent beams 242 from each other along at least a portion of the upper portion 160.

[0101] In embodiments that include the layer 240, the beams 242 may include a smooth profile that does not oscillate between adjacent connection points 278 of the struts 272 of the core structure 270 as described herein. In such embodiments, the beams 242 may extend continuously in a straight or curved line between the connection points 278. The beams 242 of the inner layer 240 may not define a part of a repeating unit cell (e.g., unit cell 144 as described herein).

[0102] In some embodiments, the inner surface 250 of the inner layer 240 may include a low-friction surface and / or a low-friction texture. In such embodiments, the inner surface 250 may include a coefficient of friction ranging from greater than or equal to 0.1 to less than or equal to 0.7. In some embodiments, the coefficient of friction may be in the range of greater than or equal to 0.1 to less than or equal to 0.4.

[0103] In some embodiments, the inner surface 250 of the inner layer 240 may include a slip agent. In such embodiments, the slip agent may facilitate the insertion and / or removal of the wearer's foot from the footwear article 100. Exemplary slip agents include, but are not limited to, polydimethylsiloxane (PDMS), petroleum, wax, silicone, and magnesium stearate.

[0104] In some embodiments, as Figure 1H shown, the spaces 204 between adjacent beams 202 of the outer layer 200 and the spaces 246 between adjacent beams 242 of the inner layer 240 may form through openings 166 in the upper portion 160. In some embodiments, the core structure 270 as described herein may not occupy any volume within the through openings 166. The through openings 166 may be used to provide ventilation to the upper portion 160.

[0105] The inner profile 164 of the upper portion 160 is defined by the entire innermost surface profile of the upper portion 160. The inner profile 164 is, for example, atFigure 1E as shown. The grooves or depressions between the beams 242 of the inner surface layer 240 do not define the shape of the inner contour 164. Instead, the inner contour 164 is characterized by the overall innermost shape of the shoe upper portion 160 defined by the inner surface layer 240.

[0106] In some embodiments, for example Figure 1E as shown, the inner contour 164 of the shoe upper portion 160 may include a wavy contour that varies relative to the outer contour 122 defined by the outer surface layer 200. In such an embodiment, the wavy inner contour 164 may include a first region 170 spaced from the outer surface layer 200 by a first distance 172 and a second region 174 spaced from the outer surface layer 200 by a second distance 176 that is less than the first distance 172. In such an embodiment, the length 275 of the struts 272 of the core structure 270 that connect the outer surface layer 200 to the inner surface layer 240 in the first region 170 may be greater than the length 275 of the struts 272 that connect the outer surface layer 200 to the inner surface layer 240 in the second region 174.

[0107] In some embodiments, the first distance 172 and the second distance 176 may range from greater than or equal to 0.2 mm to less than or equal to 30 mm, including sub - ranges. For example, the distances 172 and 176 may range from greater than or equal to 0.2 mm to less than or equal to 26 mm, from greater than or equal to 0.2 mm to less than or equal to 22 mm, from greater than or equal to 0.2 mm to less than or equal to 18 mm, from greater than or equal to 0.4 mm to less than or equal to 30 mm, from greater than or equal to 1 mm to less than or equal to 30 mm, or from greater than or equal to 2 mm to less than or equal to 30 mm. In some embodiments, the distances 172 and 176 may range from greater than or equal to 0.4 mm to less than or equal to 26 mm.

[0108] In some embodiments, the second distance 176 may be at least 4 mm less than the first distance 172. As another example, in some embodiments, the second distance 176 may be at least 10 mm less than the first distance 172.

[0109] The distances 172 and 176 may vary to provide a targeted amount of cushioning and / or fit for different regions of the shoe upper portion 160. Additionally, the distances 172 and 176 may vary based on the contour of the wearer's foot.

[0110] In some embodiments, for example Figure 1DAs shown, the inner surface layer 240 can be disposed around the outer side 152 of the midsole 140. In some embodiments, the inner surface layer 240 can be disposed around the inner side 150 of the midsole 140. In some embodiments, the inner surface layer 240 can be disposed around both the outer side 152 and the inner side 150 of the midsole 140. In such an embodiment, the inner surface layer 240 can connect the midsole 140 to the struts 272 of the core structure 270 that surrounds all or a portion of the outer side 152 of the midsole 140 and / or all or a portion of the inner side 150. In some embodiments, the inner surface layer 240 can directly connect the midsole 140 to the struts 272 of the core structure 270 that surrounds all or a portion of the outer side 152 of the midsole 140 and / or all or a portion of the inner side 150. In some embodiments, the inner surface layer 240 can directly connect the nodes 148 of the unit cell 144 to the struts 272 of the core structure 270 that surrounds all or a portion of the outer side 152 of the midsole 140 and / or all or a portion of the inner side 150.

[0111] In some embodiments, for example Figure 1G As shown, a plurality of nodes 148 of the midsole 140 can be located at the inner peripheral boundary 154 of the midsole 140. In some embodiments, each of the plurality of nodes 148 at the inner peripheral boundary 154 can include a plurality of beams 242 of the inner surface layer 240 that are directly connected to the node 148. In some embodiments, the intersection 159 of the inner bottom surface layer 156 can be located at the node 148 of the inner sole 140, at the inner peripheral boundary 154.

[0112] For example Figure 1D and Figure 1E As shown, the footwear item 100 can include a core structure 270 that connects the outer surface layer 200 to the inner surface layer 240. The core structure 270 can include struts 272 that connect the beams 202 of the outer surface layer 200 to the beams 242 of the inner surface layer 240. In some embodiments, the core structure 270 can include struts 272 that directly connect the beams 202 of the outer surface layer 200 to the beams 242 of the inner surface layer 240. In such an embodiment, a first end of the strut 272 can be connected to the beam 202 at the connection point 276, and a second end of the strut 272 can be connected to the beam 242 at the connection point 278. In some embodiments, the upper portion 160 can include one or more regions having the core structure 270 and one or more regions not having the core structure 270. In the regions without the core structure 270, the beams 202 of the surface layer 200 can be directly connected to the beams 242 of the inner surface layer 240.

[0113] In some embodiments, the struts 272 of the core structure 270 can be linear struts that directly connect the beams 202 of the outer surface layer 200 to the beams 242 of the inner surface layer 240. In such embodiments, the linear struts can extend directly from the beams 202 of the outer surface layer 200 to the beams 242 of the inner surface layer 240 with changes in direction at nodes or turns. In some embodiments, the struts 272 of the core structure 270 can define a unit cell (e.g., unit cell 144) that connects the beams 202 of the outer surface layer 200 to the beams 242 of the inner surface layer 240. In such embodiments, the unit cell can include a plurality of struts (e.g., struts 146) that form the connection between the beams 202 of the outer surface layer 200 and the beams 242 of the inner surface layer 240.

[0114] In some embodiments, the core structure 270 can be disposed around the outer side 152 of the midsole 140. In some embodiments, the core structure 270 can be disposed around the inner side 150 of the midsole 140. In some embodiments, the core structure 270 can be disposed around both the outer side 152 and the inner side 150 of the midsole 140. In such embodiments, the core structure 270 can connect the midsole 140 to the outer surface layer 200 around all or a portion of the outer side 152 and / or all or a portion of the inner side 150 of the midsole 140. In such embodiments, the struts 272 of the core structure 270 can connect the beams 202 of the outer surface layer 200 to the unit cell 144 of the midsole 140. In some embodiments, the core structure 270 can include struts 272 that directly connect the beams 202 of the outer surface layer 200 to the struts 146 of the nodes 148 or the unit cell 144. In some embodiments, the struts 272 of the core structure 270 can be linear struts that directly connect the beams 202 of the outer surface layer 200 to the struts 146 of the nodes 148 or the unit cell 144. In such embodiments, the linear struts can extend directly from the beams 202 of the outer surface layer 200 to the struts 146 of the nodes 148 or the unit cell 144 with changes in direction at nodes or turns.

[0115] In some embodiments, the thickness 274 of the core structure 270 can vary over different regions of the upper portion 160. In such embodiments, as Figure 1D shown, the thickness 274 is defined as the distance between the outer surface layer 200 and the inner surface layer 240. In embodiments that include a core structure 270 with linear struts 272, the thickness 274 can be the length 275 of the linear struts 272 that directly connect the beams 202 of the outer surface layer 200 to the beams 242 of the inner surface layer 240.

[0116] In some embodiments, the thickness 274 can range from greater than or equal to 0.2 mm to less than or equal to 30 mm, including sub - ranges. For example, the thickness 274 can range from greater than or equal to 0.2 mm to less than or equal to 26 mm, from greater than or equal to 0.2 mm to less than or equal to 22 mm, from greater than or equal to 0.2 mm to less than or equal to 18 mm, from greater than or equal to 0.4 mm to less than or equal to 30 mm, from greater than or equal to 1 mm to less than or equal to 30 mm, or from greater than or equal to 2 mm to less than or equal to 30 mm. In some embodiments, the thickness 274 can range from greater than or equal to 0.4 mm to less than or equal to 26 mm.

[0117] In some embodiments, in a first region 170 of the upper portion 160, the core structure 270 can include a first thickness 274, and in a second region 174 of the upper portion 160, the core structure 270 can include a second thickness 274 that is less than the first thickness 274. For example, in some embodiments, the second thickness 274 can be at least 4 mm less than the first thickness 274. In another embodiment, the second thickness 274 can be at least 10 mm less than the first thickness 274.

[0118] The thickness 274 of the core structure 270 can vary to provide a targeted amount of cushioning and / or conform to different regions of the upper portion 160. Additionally, the thickness 274 of the core structure 270 can vary based on the contour of the wearer's foot.

[0119] As discussed herein, the sole portion 120 and the upper portion 160 can be additively manufactured (3D printed) as a single piece. Additionally, various components of the footwear 100 can be additively manufactured (3D printed) as a single piece. Any two or more components of the footwear 100 can be 3D printed as a single piece. For example, in embodiments including the outer layer 200, the inner layer 240, the core structure 270, and the midsole 140, each of the sole portion 120, the upper portion 160, the outer layer 200, the inner layer 240, the core structure 270, and the midsole 140 can be 3D printed as a single piece. As another example, in embodiments including the outer layer 200, the inner layer 240, and the core structure 270, each of the sole portion 120, the upper portion 160, the outer layer 200, the inner layer 240, and the core structure 270 can be 3D printed as a single piece. As another example, the outer layer 200, the inner layer 240, and the core structure 270 can be 3D printed as a single piece.

[0120] In some embodiments, the sole portion 120 and the upper portion 160 may be formed of the same material. Additionally, the various components of the footwear 100 may be formed of the same material. Any two or more components of the footwear 100 may be formed of the same material. For example, in embodiments including an outer layer 200, an inner layer 240, a core structure 270, and a midsole 140, each of the sole portion 120, the upper portion 160, the outer layer 200, the inner layer 240, the core structure 270, and the midsole 140 may be formed of the same material. As another example, in embodiments including an outer layer 200, an inner layer 240, and a core structure 270, each of the sole portion 120, the upper portion 160, the outer layer 200, the inner layer 240, and the core structure 270 may be formed of the same material. As another example, the outer layer 200, the inner layer 240, and the core structure 270 may be formed of the same material.

[0121] Exemplary materials for the sole portion 120 and the upper portion 160, as well as any other components of the footwear 100, include but are not limited to foams, rubbers, ethylene vinyl acetate (EVA), thermoplastic elastomers, polyurethanes, thermoplastic polyurethanes (TPU), elastic polyurethanes, expanded thermoplastic polyurethanes (eTPU), expanded elastic polyurethanes, polyether block amides (PEBA), expanded polyether block amides (ePEBA), thermoplastic rubbers (TPR), and polyolefins such as polyethylene (PE), polystyrene (PS), or polypropylene (PP), polyamides (nylon), or combinations of any of these materials, or foams containing one or more of these materials. Other materials for forming the sole portion 120 and the upper portion 160 include carbon and carbon allotropes such as graphene, carbon nanotubes, and carbon fibers, fiber-reinforced polymers, biomaterials such as mycelium, and metals such as aluminum, steel, or titanium, etc., and combinations thereof.

[0122] The footwear articles described herein (e.g., footwear article 100) and any component of the footwear described herein (e.g., sole portion 120 or upper portion 160) can be formed by additive manufacturing (e.g., three-dimensional (3D) printing). Exemplary additive manufacturing techniques generally include, for example, selective laser sintering, selective laser melting, selective heat sintering, stereolithography, fused deposition modeling, or 3-D printing. Various additive manufacturing techniques related to footwear articles are described, for example, in US2009 / 0126225, WO 2010 / 126708, US2014 / 0300676, US2014 / 0300675, US2014 / 0299009, US2014 / 0026773, US2014 / 0029030, WO 2014 / 008331, WO2014 / 015037, US2014 / 0020191, EP 2564719, EP 2424398, and US2012 / 0117825. In some embodiments, the additive manufacturing process can include a continuous liquid interface production process. For example, the additive manufacturing process can include a continuous liquid interface production process as described in U.S. Patent 9,453,142, issued September 27, 2016, which is incorporated herein by reference in its entirety.

[0123] In some embodiments, 3-D printing a footwear article or a component thereof can include 3-D printing a sole or component in an intermediate green state, shaping the green state article or component, and curing the green state into its final shape. 3-D printing a footwear article or a component thereof can include 3-D printing an article or component in an intermediate green state, expanding the green state, shaping the green state article or component, and curing the green state into its final shape.

[0124] Techniques for producing intermediate green state objects from resin by additive manufacturing are known. Suitable techniques include bottom-up and top-down additive manufacturing commonly referred to as stereolithography. These methods are known and are described, for example, in U.S. Patent 5,236,637 to Hull, U.S. Patents 5,391,072 and 5,529,473 to Lawton, U.S. Patent 7,438,846 to John, U.S. Patent 7,892,474 to Shkolnik, U.S. Patent 8,110,135 to El-Siblani, U.S. Patent Application Publication No. 2013 / 0292862 to Joyce, and U.S. Patent Application Publication No. 2013 / 0295212 to Chen et al. The disclosures of these patents and applications are incorporated herein by reference in their entireties.

[0125] In some embodiments, the additive manufacturing step may be performed by one of a family of methods sometimes referred to as continuous liquid interface production (CLIP). CLIP is known and is disclosed in, for example, U.S. Patent Nos. 9,211,678; 9,205,601; 9,216,546; and other documents; "Continuous Liquid Interface Production of 3D Objects" by J. Tumbleston et al. (Science 347, 1349 - 1352 (2015)); "Layerless Manufacturing by Continuous Liquid Interface Production" by R. Janusziewcz et al. (Proc. Natl. Acad. Sci. USA 113, 11703 - 11708 (October 18, 2016)). Other examples of methods and apparatuses for specific embodiments of performing CLIP include, but are not limited to: Batchelder et al., U.S. Patent Application Publication No. US2017 / 0129169 (May 11, 2017); Sun and Lichkus, U.S. Patent Application Publication No. US2016 / 0288376 (October 6, 2016); Willis et al., U.S. Patent Application Publication No. US2015 / 0360419 (December 17, 2015); Lin et al., U.S. Patent Application Publication No. US2015 / 0331402 (November 19, 2015); D. Castanon, U.S. Patent Application Publication No. US2017 / 0129167 (May 11, 2017); B. Feller, U.S. Patent Application Publication No. US2018 / 0243976 (published August 30, 2018); M. Panzer and J. Tumbleston, U.S. Patent Application Publication No. US2018 / 0126630 (published May 00, 2018); K. Willis and B. Adzima, U.S. Patent Application Publication No. US2018 / 0290374 (October 11, 2018); L. Robeson et al., PCT Patent Publication No. WO 2015 / 164234 (also see U.S. Patent Nos. 10,259,171 and 10,434,706); and C. Mirkin et al., PCT Patent Publication No. WO 2017 / 210298 (also see U.S. Patent Application US2019 / 0160733). The disclosures of these patents and applications are hereby incorporated by reference in their entirety.

[0126] Although stereolithography techniques such as CLIP are preferred, it should be understood that other additive manufacturing techniques such as jet printing (see, for example, U.S. Patent No. 6,259,962 to Gothait and U.S. Patent Application Publication No. US2020 / 0156308 to Ramos et al.) may also be used.

[0127] In some embodiments, the upper portion 160 may include a collar 180 defining an opening 182 configured to receive a wearer's foot. In some embodiments, the collar 180 may include an edge 184 defining the opening 182. In some embodiments, one or more continuous beams 202 of the outer layer 200 may extend from the collar 180 (e.g., from the edge 184 of the collar). In some embodiments, one or more continuous beams 202 of the outer layer 200 may extend from the collar 180 to the sole portion 120. In some embodiments, one or more continuous beams 202 of the outer layer 200 may extend from the collar 180 to the ground-facing surface 134 of the sole portion 120.

[0128] In some embodiments, for example Figure 1G As shown, a plurality of continuous beams 202 of the outer layer 200 can intersect the edge 184 at an angle 215 less than 45 degrees. In some embodiments, a plurality of continuous beams 202 of the outer layer 200 can intersect the edge 184 at an angle 215 less than 30 degrees.

[0129] In some embodiments, a plurality of continuous beams 202 intersecting the edge 184 at an angle 215 less than 45 degrees may each include a first portion 210 approaching the edge 184 at an angle 211 in a range from greater than or equal to 45 degrees and less than or equal to 90 degrees, a turn 212, and a second portion 214 extending from the turn 212 and intersecting the edge 184 at an angle less than 45 degrees. In some embodiments, a plurality of continuous beams 202 intersecting the edge 184 at an angle 215 less than 30 degrees may each include a first portion 210 approaching the edge 184 at an angle 211 in a range from greater than or equal to 30 degrees and less than or equal to 90 degrees, a turn 212, and a second portion 214 extending from the turn 212 and intersecting the edge 184 at an angle less than 30 degrees.

[0130] In some embodiments, by intersecting the edge 184 at an angle less than 45 degrees or at an angle less than 30 degrees, undesired high stress concentrations at the connection points between the beam 202 and the edge 184 during use can be limited or avoided.

[0131] In some embodiments, for example Figure 12 As shown, the collar 180 may include a tab 190 extending into the opening 182. In such embodiments, the tab 190 may form all or a part of the tongue of the footwear item 100. In some embodiments, the tab 190 may be integrally formed with the upper portion 160 (e.g., integrally 3D printed). In some embodiments, the tab 190 may be integrally formed with the inner layer 240 of the upper portion 160 (e.g., integrally 3D printed). In some embodiments, the tab 190 may extend from the edge 184 of the collar 180.

[0132] In some embodiments, such as Figure 13 shown, the shoe collar 180 may include a notch 192 that extends forward from the opening 182 toward the forefoot end 102 of the footwear item. In such embodiments, the notch 192 may form all or a part of the throat of the footwear item 100. In some embodiments, the edge 184 of the shoe collar 180 may extend around the notch 192.

[0133] In some embodiments, such as Figure 13 shown, the shoe collar 180 may include a perimeter beam 186 that is spaced apart from and extends around all or a part of the edge 184. In such embodiments, the perimeter beam 186 may be integrally formed (e.g., integrally 3D printed) with the upper portion 160. In some embodiments, the perimeter beam 186 may be integrally formed (e.g., integrally 3D printed) with the outer surface layer 200 of the upper portion 160. The perimeter beam 186 may intersect with a plurality of continuous beams 202 of the outer surface layer 200 around all or a part of the perimeter of the edge 184. In some embodiments, the perimeter beam 186 may intersect with the plurality of continuous beams 202 of the outer surface layer 200 at turns 212 around all or a part of the perimeter of the edge 184. In some embodiments, the perimeter beam 186 may extend around at least a part of the edge 184 around the notch 192.

[0134] In some embodiments, such as Figure 14 shown, the shoe collar 180 may include a pull tab 190 and a notch 192. In such embodiments, the pull tab 190 may be disposed within the notch 192.

[0135] In some embodiments, one or more of the continuous beams 202 of the outer surface layer 200 may include an extension portion 220 that includes an increased height 221 extending from the outer contour 122 of the sole portion 120, the outer contour 162 of the upper portion 160, or both. In some embodiments, the extension portion 220 of the continuous beam 202 may define a tab 222 on the upper portion 160. Figure 1B A tab 222 on the upper portion 160 is shown according to some embodiments. In some embodiments, the extension portion 220 of the continuous beam 202 may define a tab 222 on the sole portion 120.

[0136] For example, as Figure 1A shown, in some embodiments, the outer surface layer 200 may include a region 230 having one or more images 232. The images 232 may include, but are not limited to, manufacturer logos, trademarks, technical names, digital images, non-digital images, user-customized images, and other graphic images.

[0137] Exemplary graphical image types of the (one or more) images 232 can include basic geometric shapes, animal character shapes, sports object shapes, or symbols. Exemplary basic geometric shapes of the image 232 include triangles, quadrilaterals, polygons (e.g., pentagons, hexagons, heptagons, etc.), circles, ellipses, crescent shapes, and pill shapes. Exemplary animal character shapes of the image 232 include bears, bison, cats, dogs (e.g., Huskies), tigers, lions, horses, elephants, giraffes, monkeys, gorillas, birds, rams, turtles, snakes, spiders, fish, or sharks. Exemplary sports object shapes of the image include soccer balls, baseballs, softballs, basketballs, tennis balls, volleyballs, frisbees, footballs, golf clubs, lacrosse sticks, hockey sticks, ice skates, baseball caps, baseball bats, skateboards, and surfboards. Exemplary symbols of the image 232 include dollar signs, Greek letters, peace signs, yin-yang, Chinese zodiac symbols, hearts, spades, and musical notes.

[0138] In some embodiments, the region 230 can include one or more sheets 234 that fill the space 204 between one or more sets of adjacent continuous beams 202. In such embodiments, the (one or more) sheets 234 can define all or a portion of the image 232 on the upper portion 160, the sole portion 120, or both. In some embodiments, the (one or more) sheets 234 can have a thickness less than that of the beams 202 to create cavities 236 between adjacent beams 202. The beams 202 and the sheets 234 together can define one or more images 232 on the outer surface layer 200 and thus on the footwear 100. In some embodiments, the sheets 234 can be 3D printed integrally with the sets of adjacent continuous beams 202 within the region 230.

[0139] In some embodiments, the region 230 can include one or more sheets 234 that fill the space 246 between one or more sets of adjacent continuous beams 242. In such embodiments, the (one or more) sheets 234 can define all or a portion of the image 232 on the upper portion 160, the sole portion 120, or both. The beams 242 and the sheets 234 together can define one or more images 232 on the inner surface layer 240 and thus on the footwear 100. In some embodiments, the sheets 234 can be 3D printed integrally with the sets of adjacent beams 242 within the region 230.

[0140] In some embodiments, for example Figure 2 as shown, the region 230 can include one or more images 232 defined by an image contour 226 extending from the outer contour 122, the outer contour 162, or both. In such embodiments, one or more groups 224 of adjacent beams 202 of the outer surface layer 200 can include beams 202, each beam having an extension portion 220 with an increased height 221 and defining the image contour 226 extending from the outer contour 122, the outer contour 162, or both.

[0141] In some embodiments, the sole portion 120 may include a ground-facing surface 134 that includes a ground-facing structure 130. In some embodiments, the ground-facing structure 130 may include an outsole. In some embodiments, the outsole may be a separate component (e.g., attached by adhesive bonding or thermal bonding) attached to the ground-facing surface 134. In some embodiments, the outsole may be 3D printed integrally with the ground-facing surface 134. In some embodiments, the ground-facing structure 130 may be formed, in whole or in part, by beams 202 that extend from the outer or inner side of the sole portion 120 to the outer surface layer 200 of the ground-facing surface 134 of the sole portion 120. In some embodiments, the ground-facing structure 130 may be formed, in whole or in part, by beams 202 that extend from the upper portion 160 to the outer surface layer 200 of the ground-facing surface 134 of the sole portion 120.

[0142] In some embodiments, for example Figure 1F As shown, the ground-facing structure 130 may include one or more outsole portions 132 that are 3D printed integrally with the sole portion 120. In some embodiments, the ground-facing structure 130 may include one or more outsole portions 132 that are 3D printed integrally with continuous beams 202 of the outer surface layer 200 that extend across the ground-facing surface 134 of the sole portion 120.

[0143] In some embodiments, for example Figure 3 As shown, the ground-facing structure 130 of the sole portion 120 may include a ground-facing structure 300 that includes one or more cavities 302, and an outsole material 304 is filled in the one or more cavities 302. In such embodiments, the one or more cavities 302 may be 3D printed integrally with the sole portion 120. In some embodiments, the one or more cavities 302 may be 3D printed integrally with continuous beams 202 of the outer surface layer 200 that extend across the ground-facing surface 134 of the sole portion 120.

[0144] In some embodiments, for example Figure 4 As shown, the ground-facing structure 130 of the sole portion 120 may include a ground-facing structure 400 that includes one or more regions 402 where the space 204 between a plurality of beams 202 of the outer surface layer 200 is filled with a sheet 404, and the film forms a cavity 406 between adjacent beams 202 that extend across the ground-facing surface 134 of the sole portion 120. In such embodiments, the cavity 406 may be filled with an outsole material 408. In some embodiments, the (one or more) sheets 404 may include a thickness less than that of the beam 406 to create a cavity 406 between adjacent beams 202.

[0145] Exemplary outsole materials for the ground-facing structure 300 and the ground-facing structure 400 include, but are not limited to, rubber, ethyl vinyl acetate (EVA), thermoplastic elastomer, polyurethane, thermoplastic polyurethane (TPU), thermoplastic rubber (TPR), and polyolefins such as polyethylene (PE), polystyrene (PS), polypropylene (PP), polyether block amide (PEBA), expanded polyether block amide (ePEBA), elastic polyurethane (EPU), expanded elastic polyurethane (ePEU), polyamide (nylon), any combination of these materials, or foams containing one or more of these materials. Additional exemplary materials include polyamide (nylon), carbon and carbon allotropes (such as graphene, carbon nanotubes, and carbon fibers), fiber-reinforced polymers, biomaterials (such as mycelium), and metals (such as aluminum, steel, or titanium, etc.).

[0146] In some embodiments, for example Figure 5 as shown, the footwear item 100 may include a sockliner 500. In such embodiments, the sockliner 500 may include an inner surface 504 that defines a space for receiving a wearer's foot and an outer surface 502 that is opposite the inner surface 504. In some embodiments, the sockliner 500 may be directly or indirectly coupled to the inner liner 240, the midsole 140, or both. In embodiments that include the outsole outer liner 156, the sockliner 500 may be directly or indirectly coupled to the outsole outer liner 156.

[0147] In some embodiments, the outer surface 502 of the sockliner 500 may be mechanically coupled to the inner liner 240, for example, by an adhesive or stitching. Additionally or alternatively, the outer surface 502 of the sockliner 500 and the inner liner 240 may be frictionally coupled together. In such embodiments, the inner surface 250 of the inner liner 240 may include a texture configured to engage a corresponding texture on the outer surface 502 of the sockliner 500.

[0148] In some embodiments, for example Figure 6 as shown, the upper portion 160 of the footwear 100 may include a plurality of lace structures 600 formed in the upper portion 160. In some embodiments, the lace structures 600 may be 3D printed integrally with the upper portion 160.

[0149] In some embodiments, each of the shoelace structures 600 may include an opening 602 that extends through the outer layer 200, the core structure 270, and the inner layer 240 of the upper portion 160. The opening 602 may define a hole for receiving a shoelace. In some embodiments, the opening 602 may include an edge 604 that defines a through-hole for receiving a shoelace. In such embodiments, the edge 604 may include any of the same features described herein for the edge 184 of the shoe collar 180. For example, the continuous beam 202 can intersect the edge 604 at an angle less than 45 degrees or less than 30 degrees, as described herein for the continuous beam 202 and the edge 184.

[0150] In some embodiments, for example Figure 7 As shown, the sole portion 120 may include one or more reinforcement structures 700. In some embodiments, the reinforcement structure(s) may be disposed within one or more voids 702 formed in the sole portion 120. In some embodiments, one or more voids 702 may be formed in the midsole 140. In some embodiments, one or more voids 702 may be 3D printed integrally with the sole portion 120. In some embodiments, one or more voids 702 may be tubes formed in the sole portion 120.

[0151] In some embodiments, the upper portion 160 may include one or more reinforcement structures 700. In such embodiments, the reinforcement structure 700 may be disposed within one or more voids 702 formed in the upper portion 160. For example, in some embodiments, one or more voids 702 may be formed in the core structure 270 of the upper portion 160. In some embodiments, one or more voids 702 may be 3D printed integrally with the upper portion 160.

[0152] In some embodiments, the reinforcement structure(s) 700 may include a shank or a torsion bar. In such embodiments, the shank or the torsion bar may be made of a nylon polymer or a fiber composite material.

[0153] Figure 8 An article of footwear 800 in the form of a slide sandal is shown in accordance with some embodiments. The article of footwear 800 may include a sole portion 120 and an upper portion 160 in the form of straps for a slide sandal. As Figure 8 shown, the article of footwear 800 may include an outer layer 200 and an inner layer 240. The article of footwear 800 may also include any of the other features described herein for the article of footwear 100, including the core structure 270, the image area 230, and the shoe collar 180.

[0154] Figure 9A method of manufacturing a footwear article 100 in accordance with some embodiments is shown. Unless otherwise stated, the steps of method 900 need not be performed in the order set forth herein. Additionally, unless otherwise indicated, these steps need not be performed sequentially. These steps can be performed in a different order or simultaneously.

[0155] First, in step 902, method 900 can include printing a green 3D printed article (e.g., Figure 10 article 1010 as shown) for the footwear article 100. The green 3D printed article can include any feature of the footwear 100 as described herein, as well as any combination of two or more features of the footwear 100 as described herein. For example, the green 3D printed article can include a sole portion corresponding to the sole portion 120, an upper portion corresponding to the upper portion 160, an outer surface layer corresponding to the outer surface layer 200 and including a plurality of continuous beams, an inner surface layer corresponding to the inner surface layer 240 and including a mesh of beams defining at least a portion of the inner contour of the upper portion, and a core structure corresponding to the strut structure 270 that connects the outer surface layer to the inner surface layer and includes beams that connect the beams of the outer surface layer to the beams of the inner surface layer, the plurality of continuous beams extending adjacent to each other and defining at least a portion of the outer contour of the upper portion and at least a portion of the outer contour of the sole portion.

[0156] In some embodiments, as Figure 10 shown, the green 3D printed article 1010 can be printed on the build surface 1002 of the build plate 1000. In some embodiments, the green 3-D printed article 1010 can be printed on the build surface 1002 using a continuous liquid interface production process. In such an embodiment, the green 3-D printed article 1010 is printed by curing a liquid resin present in a liquid resin reservoir below the build plate 1000 on the build surface 1002. And, as the build plate 1000 is raised in the vertical direction 1020, the green 3-D printed article 1010 is printed by curing the liquid resin present in the liquid resin reservoir below the build plate 1000. The liquid resin can be cured using light, such as ultraviolet light.

[0157] In some embodiments, in step 902, the green 3D printed article may include a support structure 1012 that is printed in direct contact with the build surface 1002. In such embodiments, the support structure 1012 may include a first side 1014 that is in direct contact with the build surface 1002 and a second side 1016 that is in direct contact with the outer layer of the green 3D printed article 1010. In embodiments that include a flat build surface 1002, the first side 1014 may be flat. The second side 1016 may follow the outer contour of the outer layer of the green 3D printed article 1010. The support structure 1012 may include, for example, columns or unit cells that extend from the build surface 1002 to the outer layer of the green 3D printed article 1010.

[0158] The support structure 1012 may be a sacrificial structure that is discarded after step 902. In some embodiments, after step 902, the support structure 1012 may be removed (e.g., excised) from the green 3D printed article. In some embodiments, after step 906 or step 910, the support structure 1012 may be removed (e.g., excised) from the footwear article 100.

[0159] In some embodiments, method 900 may include inserting one or more reinforcement structures 700 into voids (e.g., void 702) formed in the sole portion and / or upper portion of the green 3D printed article in step 904.

[0160] In step 906, the green 3D printed article may be expanded into a footwear article 100. In some embodiments, the green 3D printed article may be heated to expand the 3D printed article into a footwear article 100. In some embodiments, the green 3D printed article may be heated to a temperature range from greater than or equal to 100°C to less than or equal to 130°C to expand the 3D printed article into a footwear article 100. In some embodiments, the green 3D printed article may be heated to a temperature range from greater than or equal to 110°C to less than or equal to 120°C to expand the 3D printed article into a footwear article 100. Expanding the 3D printed article in step 906 includes increasing the volume of the 3D printed article. In some embodiments, the volume may be increased by at least 10%, at least 20%, or at least 50%.

[0161] In embodiments that include step 904, expanding the green 3D printed article may cause the voids disposed around one or more reinforcement structures 700 to contract to fix the reinforcement structures 700 in place. For example, expanding the green 3D printed article may expand the sole portion of the green article to contract the voids in the sole portion and fix the reinforcement structures 700 within the sole portion 120 of the footwear article 100.

[0162] After expanding the green 3D printed article in step 906, in step 910, the 3D printed article can be cured into the footwear article 100. In some embodiments, the footwear article 100 can be heated to a temperature in the range of greater than or equal to 100°C to less than or equal to 130°C to cure the footwear article 100. In some embodiments, the footwear article 100 can be heated to a temperature in the range of greater than or equal to 110°C to less than or equal to 120°C to cure the footwear article 100.

[0163] In some embodiments, prior to curing in step 910, a fixture can be inserted into the foot cavity of the footwear article 100 to support the footwear article 100 during curing and prevent undesired deformation of the foot cavity.

[0164] In some embodiments, after curing in step 910, an outsole can be attached to the ground-facing surface of the footwear article 100. In some embodiments, the outsole can be bonded to the ground-facing surface of the footwear article 100. In some embodiments, the outsole can be bonded to the ground-facing surface with an adhesive. In such an embodiment, the adhesive can be applied to the ground-facing surface of the footwear article 100. After applying the adhesive, the outsole and the footwear article 100 can pass through a heating tunnel. In certain embodiments, the temperature range of the heating tunnel can be from greater than or equal to 50°C to less than or equal to 70°C. In some embodiments, after passing through the heating channel, the footwear article 100 and the outsole can be placed in a press to attach the outsole and the footwear article 100 via the adhesive applied to the ground-facing surface.

[0165] Figure 11 An exemplary fixture 1100 within the foot cavity 1110 is shown in accordance with some embodiments. In some embodiments, the outer surface 1102 of the fixture 1100 can support the inner lining 240, the midsole 140, or both. In embodiments including an insole lining 156, the outer surface 1102 can support the insole lining 156. In some embodiments, the fixture 1100 can include a hollow shape that includes a hollow interior 1106 and an inner surface 1104 opposite the outer surface 1102.

[0166] When a numerical range including an upper limit value and a lower limit value is recited herein, unless otherwise specified in a particular context, the range is intended to include its endpoints, as well as all integers and fractions within the range. When defining a range, the present disclosure is not intended to be limited to the specific values recited. Additionally, when a quantity, concentration, or other value or parameter is given as a range, a list of one or more ranges, or upper limit values and lower limit values, this should be understood to specifically disclose all ranges formed by any pair of an upper limit or value of any range and a lower limit or value of any range, regardless of whether such pairs are separately disclosed.

[0167] It should be understood that the detailed description section, rather than the summary and abstract sections, is intended to explain the invention. The summary and abstract sections may set forth one or more, but not all, exemplary embodiments of the invention as contemplated by the inventor, and thus are not intended to limit the invention in any way.

[0168] The above description of specific embodiments will so fully reveal the general nature of the invention that others may, by applying knowledge within the art, readily modify and / or adapt these specific embodiments for various applications without undue experimentation and without departing from the general concept of the invention. Therefore, such adaptations and modifications are intended to be within the meaning and range of equivalents of the disclosed embodiments based on the teachings and guidance presented herein. It should be understood that the language or terminology herein is for the purpose of description and not of limitation, such that the terminology or wording of this specification may be interpreted by those skilled in the art in light of the teachings and guidance.

[0169] The breadth and scope of the present invention should not be limited by any of the above exemplary embodiments.

Claims

1. An article of footwear, comprising: a sole portion; an upper portion; an outer skin layer, which includes a plurality of continuous beams extending adjacent to each other, the continuous beams defining at least a part of the outer contour of the upper portion and at least a part of the outer contour of the sole portion; an inner skin layer, which includes a network of beams defining at least a part of the inner contour of the upper portion; a core structure, which connects the outer skin layer to the inner skin layer, the core structure including struts that connect the beams of the outer skin layer to the beams of the inner skin layer; and a midsole including a three-dimensional mesh, which includes a plurality of interconnected unit cells, each interconnected unit cell including a plurality of unit cell struts defining a three-dimensional structure and a plurality of nodes, with one or more unit cell struts connected at the nodes; wherein, the midsole forms a part of the sole portion; and wherein, the sole portion, the upper portion, the outer skin layer, the inner skin layer, the core structure and the midsole are 3D printed as a single piece.

2. The footwear article according to claim 1, wherein, The core structure is disposed around the outer and inner sides of the midsole, and connects the midsole to the outer skin layer around the outer and inner sides of the midsole.

3. The footwear article according to claim 1, wherein, The inner skin layer is disposed around the outer and inner sides of the midsole, and connects the midsole to the core structure around the outer and inner sides of the midsole.

4. The footwear article according to claim 1, wherein, The core structure includes struts that directly connect the beams of the outer skin layer to the beams of the inner skin layer.

5. The footwear item according to claim 1, wherein, The core structure includes a thickness defined as the distance between the outer skin layer and the inner skin layer, and wherein, the thickness of the core structure varies across different regions of the upper portion.

6. The footwear article according to claim 1, wherein, The inner contour of the upper portion includes a wavy contour that varies relative to the outer contour defined by the outer skin layer.

7. The footwear item according to claim 6, wherein, The wavy contour includes a first region and a second region, the first region being spaced from the outer skin layer by a first distance, the second region being spaced from the outer skin layer by a second distance, with the second distance being less than the first distance.

8. The footwear article according to claim 7, wherein, The length of the struts of the core structure connecting the outer skin layer to the inner skin layer in the first region is greater than the length of the struts connecting the outer skin layer to the inner skin layer in the second region.

9. The footwear article according to claim 1, wherein, The upper portion includes a reinforcement structure disposed within a void formed in the midsole.

10. An article of footwear, comprising: a sole portion; an upper portion; an outer skin layer, which includes a plurality of continuous beams extending adjacent to each other, the continuous beams defining at least a part of the outer contour of the upper portion and at least a part of the outer contour of the sole portion; an inner skin layer, which includes a network of beams defining at least a part of the inner contour of the upper portion; and a core structure, which connects the beams of the outer skin layer to the beams of the inner skin layer, wherein, the sole portion, the upper portion, the outer skin layer, the inner skin layer and the core structure are 3D printed as a single piece.

11. The footwear article according to claim 10, wherein, The adjacent beams of the plurality of continuous beams of the outer skin layer extend substantially parallel to each other.

12. The footwear article according to claim 10, wherein, The upper portion includes a collar defining an opening configured to receive a wearer's foot.

13. The footwear article according to claim 12, wherein, The plurality of continuous beams of the outer skin layer extend from the collar to the sole portion.

14. The footwear article according to claim 12, wherein, The shoe collar includes an edge defining an opening for receiving a wearer's foot, and wherein a plurality of continuous beams cross the edge at an angle of less than 45 degrees.

15. The footwear article according to claim 14, wherein Each of the plurality of beams includes a first portion, a turn, and a second portion, the first portion approaching the edge at an angle greater than or equal to 45 degrees to less than or equal to 90 degrees, and the second portion extending from the turn and crossing the edge at an angle of less than 45 degrees.

16. The footwear article according to claim 10, wherein, The upper portion includes a plurality of interconnected unit cells, which include a solid representation of an implicit surface.

17. A method of manufacturing an article of footwear, the method comprising: Printing a green 3D printed article, the green 3D printed article comprising: A sole portion; An upper portion; An outer skin, which includes a plurality of continuous beams extending adjacent to each other, the continuous beams defining at least a portion of the outer contour of the upper portion and at least a portion of the outer contour of the sole portion; An inner skin, which includes a network of beams defining at least a portion of the inner contour of the upper portion; and A core structure connecting the outer skin to the inner skin, the core structure including struts that connect the beams of the outer skin to the beams of the inner skin; and Heating the green 3D printed article to expand the 3D printed article into an article of footwear.

18. The method of manufacturing an article of footwear according to claim 17, the method further comprising: After expanding the 3D printed article, curing the article of footwear.

19. The method of making a footwear item according to claim 18, the method further comprising: Before curing the article of footwear, inserting a jig into the foot cavity of the article of footwear.

20. The method of making a footwear item according to claim 17, the method further comprising: Before heating the green 3D printed article, inserting a reinforcing structure into one or more voids formed in the sole portion; wherein heating the green 3D printed article causes the sole portion to expand to secure the reinforcing structure in the sole portion.

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