Footwear

Abstract

The footwear includes a sleeve formed of a knit material and defining a front distal end and a rear distal end. The sleeve includes an exterior surface and an interior surface defining an interior cavity. The footwear includes a midsole disposed within the interior cavity and a framework printed layer-by-layer on a portion of the exterior surface. The framework includes a plurality of segments and an outsole. The outsole is disposed on a bottom of the exterior surface, and the plurality of segments extend along the exterior surface of the sleeve between the front distal end and the rear distal end.

Description

[Technical field]

[0001] [CROSS REFERENCE TO RELATED APPLICATIONS] This application claims the benefit of and priority to U.S. Provisional Application No. 63 / 232,928, filed August 13, 2021, which is incorporated by reference herein in its entirety.

[0002] [Federally Sponsored Research and Development Reference] N / A

[0003] [Sequence table] N / A

[0004] FIELD OF THE DISCLOSURE This disclosure relates generally to systems and methods for manufacturing footwear.

[0005] Many conventional shoes or footwear generally include an upper and a sole attached to a lower end of the upper. Conventional shoes further include an interior space, e.g., a void or cavity formed by the interior surfaces of the upper and the sole, that receives the user's foot before the shoe is fastened to the foot. The sole is typically attached to the lower surface of the upper and is located between the upper and the ground. In some embodiments, the sole may include multiple components, such as an outsole, a midsole, and an insole. The outsole provides traction to the bottom surface of the sole, and the midsole may be attached to the interior surface of the outsole. Summary of the Invention [Means for solving the problem]

[0006] The footwear described herein can have a variety of configurations. In some embodiments, the footwear includes a sleeve or sock and a midsole disposed within the sleeve or sock. Generally, the sleeve or sock is formed of a knit or woven material and encases the midsole. A framework is selectively printed layer by layer on the exterior of the sleeve or sock to reinforce the sleeve or sock. The framework may include an outsole that is printed layer by layer on the exterior or sole side of the bottom of the sleeve or sock. This design of the footwear allows the midsole and sleeve or sock to be manufactured as separate pieces and assembled in a customized manner (e.g., the same sleeve / sock may be able to accommodate midsoles of different designs), and the framework may be printed on the sleeve or sock via an additive manufacturing process, which further provides customization options for the manufactured footwear (e.g., location of reinforcement provided by the framework, amount of reinforcement provided by the framework, design of the framework and integrally formed outsole, etc.). This improved customization allows the footwear to be produced with improved manufacturing efficiencies when compared to traditional manufacturing techniques and can provide improved performance characteristics (e.g., cushioning, energy return, stability, etc.) to the end user wearing the footwear.

[0007] In some embodiments, the present disclosure provides footwear including a sleeve formed from a knitted material and defining a forward distal end and a rearward distal end. The sleeve includes an exterior surface and an interior surface defining an interior cavity. The footwear includes a midsole disposed within the interior cavity and a framework printed layer-by-layer on a portion of the exterior surface. The framework includes a plurality of segments and an outsole. The outsole is disposed on a bottom of the exterior surface, and the plurality of segments extend along the exterior surface of the sleeve between the forward distal end and the rearward distal end.

[0008] In some embodiments, the present disclosure provides footwear comprising an upper including an upper portion and a midsole portion. The upper portion is formed from a first knit material and the midsole portion is formed from a second knit material. The footwear comprises a midsole disposed within the upper, a framework printed layer-by-layer on the upper, and an outsole printed layer-by-layer on a sole side of the upper. The framework defines a matrix pattern including row segments and column segments extending along an exterior medial side of the upper and an exterior lateral side of the upper. The outsole is connected to the framework on an exterior medial side and an exterior lateral side of the upper.

[0009] In some embodiments, the present disclosure provides a method of manufacturing footwear, the method including forming an upper from a knitted material, inserting a last into an interior cavity defined by the upper to interlock with and support an exterior surface of the upper, printing a framework layer-by-layer on a portion of the exterior surface defined by the upper, and printing an outsole layer-by-layer on a sole side of the exterior surface of the upper. The method further includes removing the last from the interior cavity of the upper and inserting a midsole into the interior cavity of the upper.

[0010] In some embodiments, the present disclosure provides a method of manufacturing footwear. The method includes forming a sleeve from a knitted material. The sleeve includes an exterior surface defining a front distal end and a rear distal end. The method further includes inserting a last into an interior cavity of the sleeve and printing a framework layer-by-layer on a portion of the exterior surface of the sleeve. The framework includes a plurality of segments and an outsole. The outsole is disposed at a bottom of the exterior surface, and the plurality of segments extend along the exterior surface of the sleeve from the front distal end to the rear distal end. The method further includes removing the last from the interior cavity of the sleeve, printing a midsole layer-by-layer, and inserting the midsole into the interior cavity of the sleeve.

[0011] In some aspects, the footwear includes a sleeve formed from a knitted material and defining a forward distal end and a rearward distal end. The sleeve includes an exterior surface and an interior surface defining an interior cavity. A midsole is disposed within the interior cavity, and a framework is printed layer-by-layer on a portion of the exterior surface. The framework includes a plurality of segments and an outsole disposed on a bottom of the exterior surface. Further, the plurality of segments extend along the exterior surface of the sleeve between the forward distal end and the rearward distal end. The sleeve includes an aperture through which a portion of the midsole is visible.

[0012] Other aspects of the footwear or portions of the footwear described herein, including their features and advantages, will become apparent to one of ordinary skill in the art upon review of the drawings and detailed description, and thus, all such aspects of the footwear are intended to be included in the detailed description and this summary. [Brief description of the drawings]

[0013] [Figure 1] A flowchart showing an overview of a method for manufacturing footwear according to one embodiment of the present disclosure. [Diagram 2] A flowchart outlining a method for manufacturing footwear according to another embodiment of the present disclosure. [Diagram 3] FIG. 1 is a lateral side view of a sleeve or upper according to one embodiment of the present disclosure. [Figure 4] Top view of the sleeve or upper in Figure 3 [Diagram 5] FIG. 3 is a side view of the outer side of the sleeve or upper and last. [Figure 6] A side view of the outer side of the sleeve or upper of Figure 3 with the skeleton printed on it and the midsole inserted therein. [Figure 7] FIG. 4 is an exterior side view of footwear including the sleeve or upper of FIG. [Figure 8] FIG. 8 is a side view of the inside of the footwear of FIG. [Figure 9] 8 is a bottom view of the footwear of FIG. [Figure 10] FIG. 8 is a top view of the footwear of FIG. 7 with the upper removed and the user's foot skeletal structure superimposed. [Figure 11] 11 is a cross-sectional view of the footwear of FIG. 9 taken along line 11-11; [Figure 12] Block diagram of additive manufacturing system [Figure 13] FIG. 8 is an exterior side view of the footwear of FIG. 7 having a print heat printed on the upper or sleeve of the framework; [Figure 14] Schematic of the footwear of FIG. 7 placed within an additive manufacturing system. [Figure 15] FIG. 1 is a side view of a medial side of a piece of footwear including an upper or sleeve having a hole. [Figure 16] FIG. 16 is a top perspective view of the footwear of FIG. [Figure 17] FIG. 16 is a top perspective view of the midsole of the footwear of FIG. [Figure 18] FIG. 1 is a bottom perspective view of an upper or sleeve having a plurality of holes [Figure 19] 1 is a bottom perspective view of a midsole having multiple projections; [Figure 20] FIG. 20 is a medial side view of footwear including the upper or sleeve of FIG. 18 and the midsole of FIG. 19. [Figure 21] 21 is a bottom view of the footwear of FIG. [Figure 22] Schematic diagram showing a set of segments [Figure 23] Schematic diagram of a set of segments with reduced height [Figure 24] Schematic diagram of a set of segments with reduced width [Diagram 25] Schematic of a set of segments with reduced height and width [Figure 26] Schematic diagram of a set of variable height segments [Figure 27] Schematic of a set of segments with intermediate peak heights [Figure 28] Schematic diagram of a set of segments with variable widths [Figure 29] Schematic of a set of segments with a peak width in between [Diagram 30] Schematic of a set of shape-changing segments DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] The following discussion and accompanying figures disclose various embodiments or configurations of shoes or footwear. Although the embodiments are disclosed with reference to shoes such as running shoes, tennis shoes, basketball shoes, etc., the concepts related to the shoe embodiments can be applied to a wide range of footwear and footwear formats, including, for example, basketball shoes, cross-training shoes, football shoes, golf shoes, hiking shoes, hiking boots, ski and snowboard boots, soccer shoes and spikes, walking shoes, and track spikes. The shoe concepts can also be applied to footwear that is considered non-athletic shoes, such as dress shoes, sandals, loafers, slippers, heels, etc. Thus, the concepts described herein can be utilized in a variety of products.

[0015] The term "about" as used herein refers to variations in numerical quantities that may occur, for example, through typical measuring and manufacturing procedures used for footwear or other articles that may include embodiments disclosed herein, through inadvertent errors in these procedures, through differences in manufacture, source, or purity of ingredients used to make a composition or mixture or to practice a method, etc. Throughout this disclosure, the terms "approximately" and "about" refer to a range of values ​​of ±5% of the numerical value that the term precedes.

[0016] The present disclosure is directed to footwear and / or specific parts or portions of footwear, such as midsoles, outsoles, or sole structures. Footwear can include knitted materials, woven fabrics, braided components, and / or uppers, sleeves, or socks formed at least in part from one or more combinations of the foregoing materials. Knitted materials can be produced by knitting yarns, woven fabrics by knitting yarns, and braided components by braiding. Knitted fabrics or materials include fabrics formed by warp knitting, weft knitting, flat knitting, circular knitting, and / or other suitable knitting operations. Knitted fabrics can have, for example, a plain knit construction, a mesh knit construction, and / or a rib knit construction. Woven fabrics include fabrics formed by any of a number of weaving configurations, such as, but not limited to, plain weave, twill weave, satin weave, dobbin weave, jacquard weave, double weave, and / or double cloth weave. The upper, sleeve, or sock may be constructed from different materials, such as a first knitted material or yarn, a second knitted material or yarn, and / or a third knitted material or yarn, which may have different properties or different visual characteristics.

[0017] 1 illustrates a method 100 for manufacturing footwear (e.g., a shoe) according to one embodiment of the present disclosure. In some embodiments, portions of the method may be performed using a controller including a processor and memory, and portions of the method may be performed by an additive manufacturing system (e.g., a 3D printer). In some embodiments, the controller may be integrated into the additive manufacturing system. In other embodiments, the controller may be located remotely from the additive manufacturing system and may be in wireless communication with the additive manufacturing system.

[0018] Method 100 may begin at step 102 by forming a sleeve or upper. The sleeve or upper may be formed or manufactured from knit, woven, or braided materials by a knitting, weaving, or braiding process. In some embodiments, the sleeve or upper may be formed entirely from one or more knit materials. Generally, the sleeve or upper may be formed into the general shape of a sock that can be worn by a user.

[0019] In some embodiments, the sleeve or upper can define a forward distal end, a rearward distal end, an exterior surface, an interior surface, and an opening. The interior surface can form an interior cavity capable of receiving a user's foot. The opening provides access to the interior cavity. The sleeve can include an upper portion and a midsole portion. The midsole portion can extend at least partially over a bottom portion of the exterior surface. In some embodiments, the sleeve or upper can be formed from a single knit material. In some embodiments, the sleeve or upper can be formed from two or more materials. For example, the knit material of the sleeve or upper can include a first knit material spanning the upper portion and a second knit material spanning the midsole portion. Thus, forming the sleeve or upper in step 102 can include forming the upper portion of the sleeve or upper from a first knit material and forming the midsole portion of the upper or sleeve from a second knit material.

[0020] In general, the sleeve or upper may be formed to at least partially expose a midsole that may be inserted into the interior cavity during manufacture of the footwear. For example, in some embodiments, the second knit material may be at least partially transparent such that a portion of the midsole received within the sleeve or upper is externally visible through the midsole portion of the sleeve. In some embodiments, the second knit material may be a transparent monofilament knit or yarn material. In some embodiments, the sleeve or upper may include a hole through which a portion of the midsole is visible.

[0021] After the sleeve or upper is formed in step 102, a last is inserted into the interior cavity of the sleeve or upper in step 104 (see, e.g., FIG. 5). The last may be inserted into the interior cavity of the sleeve or upper such that the last mates with the interior surface of the sleeve or upper and supports the exterior surface of the sleeve or upper. For example, the volume defined by the last may be equal to or greater than the static or unsupported interior volume of the interior cavity (e.g., the volume without any parts inserted into or mating with the upper), thereby ensuring that the last fills the interior cavity and mates with the interior surface when inserted into the interior cavity. In some embodiments, the volume and shape of the last may define the size and shape of the footwear intended to be manufactured.

[0022] Generally, forming the sleeve or upper from one or more knitted materials may result in more efficient manufacturing compared to traditional upper manufacturing, and batch size (i.e., the number of uppers manufactured in one batch) is not limited by the manufacturing process. While the use of one or more knitted materials provides several manufacturing advantages, the structural integrity of the upper or sleeve may require reinforcement to form a stabilized sleeve or upper. For example, in step 106, a scaffold is printed layer-by-layer on the exterior surface of the upper or sleeve. In some embodiments, the scaffold may be printed layer-by-layer on the exterior surface by an additive manufacturing system (e.g., a 3D printer). Various methods of additive manufacturing used to fabricate a framework for a portion of a sleeve or upper according to the present disclosure may include binder jetting, direct energy deposition, selective laser melting (SLM), fused deposition modeling (FDM), electron beam melting, laser powered bed fusion (LPBF) ultrasonic additive manufacturing, material extrusion, material jetting, joule printing, electrochemical deposition, cold spray metal printing, DLP metal printing, ultrasonic consolidation or ultrasonic additive manufacturing (UAM), LENS laser-based printing, vat photopolymerization, sheet lamination, or electron beam freeform manufacturing (EBF3).

[0023] Generally, the scaffolding can be selectively printed on a portion of the exterior surface of the sleeve or upper to reinforce and stabilize the sleeve or upper. In some embodiments, the scaffolding can define a matrix pattern including a plurality of segments. The plurality of segments can extend along the exterior surface of the sleeve or upper from the anterior distal end to the posterior distal end. In some embodiments, the plurality of segments can be disposed on both the interior of the exterior of the sleeve or upper and the exterior of the sleeve or upper.

[0024] The plurality of segments may include row segments or a first set of lines, and column segments or a second set of lines. In some embodiments, the row segments may be disposed along a portion of the exterior surface such that the row segments are generally parallel to one another, and the column segments may be disposed along a portion of the exterior surface such that the column segments are generally parallel to one another. The generally parallel arrangement of the row and column segments does not limit the shapes of the row and column segments to straight line segments. For example, the row and / or column segments may define straight line segments, curved segments, wavy segments, or other shapes. In some embodiments, the row segments may not be generally parallel to one another, but may be aligned or extend in a common direction. For example, the row segments may extend in a general direction from the anterior distal end to the posterior distal end (e.g., in a heel-to-toe direction). Similarly, in some embodiments, the column segments may not be generally parallel to one another, but may be aligned or extend in a common direction. For example, the column segments may extend in a general direction intersecting the row segments or in a general direction from the medial side of the exterior to the lateral side of the exterior. In some embodiments, the row segments are interconnected and intersect with the column segments to form a cross pattern.

[0025] In general, the row segments may be spaced apart from one another and the column segments may be spaced apart from one another. In some embodiments, the row spacing defined between adjacent pairs of row segments may be approximately equal. In some embodiments, the row spacing defined between adjacent pairs of row segments may vary from a minimum row spacing to a maximum row spacing. In some embodiments, the ratio between the maximum row spacing and the minimum row spacing may be between about 1 and about 5, or between about 1 and about 4, or between about 1 and about 3, or between about 2 and about 4. In some embodiments, the row spacing defined between individual row segments in adjacent pairs of row segments may vary in addition to or as an alternative to the row spacing varying between adjacent pairs of row segments.

[0026] In some embodiments, the column spacing defined between adjacent pairs of column segments may be approximately equal. In some embodiments, the column spacing defined between adjacent pairs of column segments may vary from a column spacing minimum to a column spacing maximum. In some embodiments, the ratio between the column spacing maximum and the column spacing minimum may be between about 1 and about 5, or between about 1 and about 4, or between about 1 and about 3, or between about 2 and about 4. In some embodiments, the column spacing defined between individual column segments in adjacent pairs of column segments may vary in addition to or as an alternative to the column spacing varying between adjacent pairs of column segments.

[0027] In some embodiments, each of the plurality of segments defines a shape and size that may remain substantially constant across the framework. For example, each of the plurality of segments may define a segment height and a segment width. In some embodiments, the segment height and segment width may be substantially equal.

[0028] In some embodiments, the segment height, segment width, and / or segment shape may vary over select portions of the exterior surface to provide increased or decreased stability / reinforcement to the sleeve or upper. For example, the segment height and / or segment width may be increased over a portion of the exterior surface to provide increased stability / reinforcement. Alternatively, or in addition, the shape of the segment may be changed (e.g., transitioning from a triangular to a circular or semicircular cross section) to provide increased stability / reinforcement. In some embodiments, the segment height may vary from a minimum segment height to a maximum segment height. For example, the maximum segment height may be between about 1 and about 5 times the minimum segment height, or between about 1 and about 4 times the minimum segment height, or between about 1 and about 3 times the minimum segment height, or between about 2 and about 4 times the minimum segment height. The ranges between the maximum and minimum segment heights described herein maintain an important balance between increased and / or decreased stability / reinforcement while maintaining a desirable aesthetic for the footwear.

[0029] In some embodiments, the segment width may vary from the minimum segment width to the maximum segment width. For example, the maximum segment width is between about 1 and about 5 times the minimum segment width, or between about 1 and about 4 times the minimum segment width, or between about 1 and about 3 times the minimum segment width, or between about 2 and about 4 times the minimum segment width. The ranges between the maximum and minimum segment widths described herein maintain an important balance between increased and / or decreased stability / reinforcement while maintaining a desirable aesthetic for the footwear.

[0030] In some embodiments, the plurality of segments may include a first segment having a first segment height at a first location on the exterior surface, a second segment having a second segment height at a second location on the exterior surface, and a third segment having a third segment height at a third location on the exterior surface. In some embodiments, the first segment height is greater than the first segment height and the third segment height. In some embodiments, the third segment height is greater than the second segment height, and the second segment height is greater than the first segment height.

[0031] In some embodiments, the plurality of segments includes a first segment having a first segment width at a first location on the exterior surface, a second segment having a second segment width at a second location on the exterior surface, and a third segment having a third segment width at a third location on the exterior surface. In some embodiments, the second segment width is greater than the first segment width and the third segment width. In some embodiments, the third segment width is greater than the second segment width and the second segment width is greater than the first segment width.

[0032] In some embodiments, the framework may include an outsole that is printed layer by layer on the bottom or sole side of the exterior surface of the sleeve or upper. Thus, step 106 may include printing the framework layer by layer on the sleeve or upper and printing the outsole layer by layer on the bottom or sole side of the exterior surface of the sleeve or upper. In some embodiments, the outsole may be formed from the same material as the multiple segments. For example, the outsole may be integrally formed with the framework. In some embodiments, the outsole may be formed from a different material than the multiple segments. In some embodiments, the outsole may be connected to the framework on the inside of the exterior and on the outside of the exterior of the sleeve or upper.

[0033] In some embodiments, the scaffold as a whole may be printed layer-by-layer in step 106. For example, one layer of the entire scaffold (e.g., the outsole and segments) may be printed at a time until all layers of the scaffold are printed on a portion of the exterior surface. In some embodiments, a portion of the scaffold may be printed layer-by-layer before another portion of the scaffold is printed layer-by-layer. For example, the outsole may be printed layer-by-layer, and then the segments may be printed layer-by-layer, or vice versa.

[0034] 1, once the skeleton is printed at step 106, the last may be removed from the interior cavity of the sleeve or upper, and a midsole may be inserted into the interior cavity at step 108. The combination of the sleeve or upper and the midsole disposed therein may form footwear. In some embodiments, in addition to the midsole, an insole or sockliner may be inserted into the interior cavity.

[0035] Generally, the reinforced sleeve or upper is formed separately from the midsole, allowing various sleeves / upper to be paired with different midsoles to provide selective cushioning properties. The only requirement is that the midsole be sized to match (e.g., made for the same size shoe) the reinforced sleeve or upper.

[0036] 2 illustrates a method 200 for manufacturing an article of footwear (e.g., a shoe) according to one embodiment of the present disclosure. Similar to method 100, method 200 may begin in step 202 by forming a sleeve or upper. The sleeve or upper may be formed or manufactured from knit, woven, or braided materials by a knitting, weaving, or braiding process. In some embodiments, the sleeve or upper may be formed entirely from one or more knit materials. Generally, the sleeve or upper may be formed into the general shape of a sock that can be worn by a user.

[0037] In some embodiments, the sleeve or upper may define a forward distal end, a rearward distal end, an exterior surface, an interior surface, and an opening. The interior surface may form an interior cavity capable of receiving a user's foot. The opening provides access to the interior cavity. The sleeve may include an upper portion and a midsole portion. The midsole portion may extend at least partially over a bottom portion of the exterior surface. In some embodiments, the sleeve or upper may be formed from a single knit material. In some embodiments, the sleeve or upper may be formed from two or more materials. For example, the knit material of the sleeve or upper may include a first knit material spanning the upper portion and a second knit material spanning the midsole portion. Thus, forming the sleeve or upper in step 202 may include forming the upper portion of the sleeve or upper from a first knit material and forming the midsole portion of the upper or sleeve from a second knit material.

[0038] In general, the sleeve or upper may be formed to at least partially expose a midsole that may be inserted into the interior cavity during manufacture of the footwear. For example, in some embodiments, the second knit material may be at least partially transparent such that a portion of the midsole received within the sleeve or upper is externally visible through the midsole portion of the sleeve. In some embodiments, the second knit material may be a transparent monofilament knit or yarn material. In some embodiments, the sleeve or upper may include a hole through which a portion of the midsole is visible.

[0039] After the sleeve or upper is formed in step 202, a last is inserted into the interior cavity of the sleeve or upper in step 204 (see, e.g., FIG. 5). The last may be inserted into the interior cavity of the sleeve or upper such that the last engages with the interior surface of the sleeve or upper and supports the exterior surface of the sleeve or upper. For example, the volume of the last may be larger than the rest or unsupported volume of the sleeve or upper (e.g., the volume of the sleeve or upper with no parts inserted or engaged with it) to ensure that the last expands and stretches the sleeve or upper when inserted into the interior cavity. In some embodiments, the volume and shape of the last may define the size and shape of the footwear intended to be manufactured.

[0040] Generally, forming the sleeve or upper from one or more knitted materials may result in more efficient manufacturing and batch size (i.e., the number of uppers produced in one batch) may not be limited by the manufacturing process as compared to traditional upper manufacturing. While the use of one or more knitted materials provides several manufacturing advantages, the structural integrity of the upper or sleeve may require reinforcement to form a stable sleeve or upper. For example, in step 206, a scaffold is printed layer by layer on the exterior surface of the upper or sleeve. In some embodiments, the scaffold may be printed layer by layer on the exterior surface by an additive manufacturing system (e.g., a 3D printer). Various methods of additive manufacturing used to fabricate a framework in a portion of a sleeve or upper in accordance with the present disclosure may include binder jetting, direct energy deposition, selective laser melting (SLM), fused deposition modeling (FDM), electron beam melting, laser powered bed fusion (LPBF), ultrasonic additive manufacturing, material extrusion, material jetting, joule printing, electrochemical deposition, cold spray metal printing, DLP metal printing, ultrasonic consolidation or ultrasonic additive manufacturing (UAM), LENS laser-based printing, vat photopolymerization, sheet lamination, or electron beam freeform manufacturing (EBF3).

[0041] Generally, the scaffolding may be printed on selective portions of the exterior surface of the sleeve or upper to reinforce and stabilize the sleeve or upper. In some embodiments, the scaffolding may define a matrix pattern including a plurality of segments. The plurality of segments may extend along the exterior surface of the sleeve or upper from the anterior distal end to the posterior distal end. In some embodiments, the plurality of segments may be disposed on both the interior and exterior sides of the sleeve or upper.

[0042] The plurality of segments may include row segments or a first set of lines and column segments or a second set of lines. In some embodiments, the row segments may be arranged along a portion of the exterior surface such that the row segments are generally parallel to one another, and the column segments may be arranged along a portion of the exterior surface such that the column segments are generally parallel to one another. The generally parallel arrangement of the row and column segments does not limit the shapes of the row and column segments to straight segments. For example, the row and / or column segments may define straight segments, curved segments, wavy segments, or other shapes. In some embodiments, the row segments may not be generally parallel to one another, but may be aligned or extend in a common direction. For example, the row segments may extend in a general direction from the anterior distal end to the posterior distal end (e.g., in a heel-to-toe direction). Similarly, in some embodiments, the column segments may not be generally parallel to one another, but may be aligned or extend in a common direction. For example, the column segments may extend in a general direction intersecting the row segments or in a general direction from the medial side of the exterior to the lateral side of the exterior. In some embodiments, the row segments may interconnect and intersect with the column segments to form a cross pattern.

[0043] In general, the row segments may be spaced apart from one another and the column segments may be spaced apart from one another. In some embodiments, the row spacing defined between adjacent pairs of row segments may be approximately equal. In some embodiments, the row spacing defined between adjacent pairs of row segments may vary from a minimum row spacing to a maximum row spacing. In some embodiments, the ratio of the maximum row spacing to the minimum row spacing may be between about 1 and about 5, or between about 1 and about 4, or between about 1 and about 3, or between about 2 and about 4. In some embodiments, the row spacing defined between individual row segments of adjacent pairs of row segments may vary in addition to or as an alternative to the row spacing varying between adjacent pairs of row segments.

[0044] In some embodiments, the column spacing defined between adjacent pairs of column segments may be approximately equal. In some embodiments, the column spacing defined between adjacent pairs of column segments may vary from a column spacing minimum to a column spacing maximum. In some embodiments, the ratio of the column spacing maximum to the column spacing minimum may be between about 1 and about 5, or between about 1 and about 4, or between about 1 and about 3, or between about 2 and about 4. In some embodiments, the column spacing defined between individual column segments in adjacent pairs of column segments may vary in addition to or as an alternative to the column spacing varying between adjacent pairs of column segments.

[0045] In general, each of the plurality of segments defines a shape and size that may be approximately constant across the framework. For example, each of the plurality of segments may define a segment height and a segment width. In some embodiments, the segment height and segment width are approximately equal.

[0046] In some embodiments, the segment height, segment width, and / or segment shape may vary over select portions of the exterior surface to increase or decrease the stability / reinforcement of the sleeve or upper. For example, the segment height and / or segment width may be increased over a portion of the exterior surface to increase stability / reinforcement. Alternatively, or in addition, the shape of the segment may be changed (e.g., transitioning from a triangular to a circular or semicircular cross section) to increase stability / reinforcement. In some embodiments, the segment height may vary from a minimum segment height to a maximum segment height. For example, the maximum segment height is between about 1 and about 5 times the minimum segment height, or between about 1 and about 4 times the minimum segment height, or between about 1 and about 3 times the minimum segment height, or between about 2 and about 4 times the minimum segment height. The ranges between the maximum and minimum segment heights described herein maintain an important balance between increased and / or decreased stability / reinforcement while maintaining a desirable aesthetic for the footwear.

[0047] In some embodiments, the segment width may vary from the minimum segment width to the maximum segment width. For example, the maximum segment width is between about 1 and about 5 times the minimum segment width, or between about 1 and about 4 times the minimum segment width, or between about 1 and about 3 times the minimum segment width, or between about 2 and about 4 times the minimum segment width. The ranges between the maximum and minimum segment widths described herein maintain an important balance between increased and / or decreased stability / reinforcement while maintaining a desirable aesthetic for the footwear.

[0048] In some embodiments, the plurality of segments may include a first segment having a first segment height at a first location on the exterior surface, a second segment having a second segment height at a second location on the exterior surface, and a third segment having a third segment height at a third location on the exterior surface. In some embodiments, the second segment height is greater than the first segment height and the third segment height. In some embodiments, the third segment height is greater than the second segment height and the second segment height is greater than the first segment height.

[0049] In some embodiments, the plurality of segments includes a first segment having a first segment width at a first location on the exterior surface, a second segment having a second segment width at a second location on the exterior surface, and a third segment having a third segment width at a third location on the exterior surface. In some embodiments, the second segment width is greater than the first segment width and the third segment width. In some embodiments, the third segment width is greater than the second segment width and the second segment width is greater than the first segment width.

[0050] In some embodiments, the framework may include an outsole that is printed layer by layer on the bottom or sole side of the exterior surface of the sleeve or upper. Thus, step 206 may include printing the framework layer by layer on the sleeve or upper and printing the outsole layer by layer on the bottom or sole side of the exterior surface of the sleeve or upper. In some embodiments, the outsole may be made from the same material as the multiple segments. For example, the outsole may be integrally formed with the framework. In some embodiments, the outsole may be formed from a different material than the multiple segments. In some embodiments, the outsole may be connected to the framework on the inside of the exterior and on the outside of the exterior of the sleeve or upper.

[0051] In some embodiments, the scaffold as a whole may be printed layer-by-layer in step 106. For example, one layer of the entire scaffold (e.g., the outsole and segments) may be printed at a time until all layers of the scaffold are printed on a portion of the exterior surface. In some embodiments, a portion of the scaffold may be printed layer-by-layer before another portion of the scaffold is printed layer-by-layer. For example, the outsole may be printed layer-by-layer, and then the segments may be printed layer-by-layer, or vice versa.

[0052] After printing the framework layer by layer on the formed sleeve or upper in step 206, the midsole may be printed layer by layer in step 208. In some embodiments, the midsole may be manufactured by an additive manufacturing system (e.g., a 3D printer). By manufacturing the midsole from an additive manufacturing system, midsoles with complex and customizable geometric features can be formed or manufactured using molding processes that are not limited by the design of the midsole. In some embodiments, the formed midsole may include geometric structures such as holes, openings, channels, tunnels, voids, or lattice structures formed in the midsole by the additive manufacturing system.

[0053] The use of the term "lattice portion" or "lattice structure" herein refers to a portion of a negative mold and / or a portion of footwear (e.g., a midsole) formed by one of a plurality of interconnected segments, interconnected shapes, interconnected channels, interconnected openings, and / or interconnected surfaces. In some embodiments, the lattice structure or lattice portion may be integrally formed with the negative mold or the portion of footwear by an additive manufacturing process. In some embodiments, the lattice structure or lattice portion may define at least one cutout, opening, hole, or absence of material formed within a unit cell (e.g., a repeating pattern defined by the lattice structure). By using a lattice structure within the negative mold and / or the portion of footwear, various manufacturing and performance characteristics can be modified, improved, and / or customized. For example, the lattice structure or lattice portion can define a substantially reduced weight or density compared to a solid material. Thus, incorporating a lattice structure or lattice portion into a shoe or sole can reduce the overall volume or mass of material required to manufacture the footwear. Additionally, the lattice structure or lattice portion may include geometric features that have improved cushioning properties when compared to solid materials, such that incorporating the lattice structure or lattice portion into the midsole can reduce the overall weight and improve cushioning performance in the footwear.

[0054] In some embodiments, the lattice structure may define unit cells formed by cutouts, voids, or absence of material defined between interconnected nodes. For example, the lattice structure may define triangular, spherical, square, rectangular, or diamond shaped unit cells. Alternatively or additionally, in some embodiments, at least a portion of the unit cells in a lattice structure according to the present disclosure may define a pentagonal, hexagonal, or any other polygonal shape.

[0055] In some embodiments, the unit cells defined by the lattice structures of the present disclosure may be formed by interconnected shapes (e.g., ellipses, circles, or other geometric shapes) with various orientations to form a repeating pattern or unit cell. In some embodiments, the lattice structures of the present disclosure may define an expansive cutout or pattern. In some embodiments, the lattice structures of the present disclosure may be formed by differential geometry structures. For example, the lattice structures of the present disclosure may be formed by gyroid structures that include a plurality of interconnected periodic minimal surfaces. The gyroid structures may form the lattice structures of the present disclosure by defining unit cells that are repeated in a pattern over a particular volume. In general, the use of differential geometry structures (e.g., gyroids) may reduce the sharp edges formed on the lattice structures, thereby reducing stress concentrations formed along the lattice structures, which may improve cushioning performance, for example, in footwear midsoles, compared to solid materials used in conventional midsoles.

[0056] After the midsole is printed layer by layer in step 208, the midsole is inserted into the interior cavity of the sleeve or upper in step 210, thereby forming the footwear. In some embodiments, in addition to the midsole, an insole or sock liner may be inserted into the interior cavity.

[0057] Generally, by forming the reinforced sleeve or upper separately from the midsole, various sleeves / upper can be paired with different midsoles to provide selective cushioning properties. The only requirement is that the midsole be sized to match (e.g., made for the same size shoe) the reinforced sleeve or upper. Additionally, additive manufacturing of the framework and midsole allows for increased customization of the support and cushioning properties of the resulting footwear.

[0058] 3 and 4 illustrate one embodiment of a sleeve or upper 300 that can be formed, for example, by method 100 or method 200. In the illustrated embodiment, upper 300 includes an exterior surface 302, an interior surface 304, and an opening 306. Upper 300 defines a front distal end 308, a rear distal end 310, an exterior medial side 312, and an exterior lateral side 315. Generally, exterior surface 302 extends outside of upper 300, and interior surface 304 forms an interior cavity 314 within which a user's foot can be received. Opening 306 can provide access to interior cavity 314.

[0059] In the illustrated embodiment, the upper 300 includes an upper portion 316 and a midsole portion 318. In the illustrated embodiment, the upper portion 316 extends in a heel-to-toe direction 320 from a forward distal end 308 to a rear distal end 310 of the upper 300. The upper portion 316 extends upwardly (e.g., from the perspective of FIG. 3 ) in a sole-to-instep direction 322 from an interface or boundary 324 defined between the upper portion 316 and the midsole portion 318 to cover the remainder of the exterior surface 302. The midsole portion 318 may extend at least partially above a bottom portion 326 of the exterior surface 302. In other words, the midsole portion 318 may be disposed on a sole side 323 of the upper 300. The midsole portion 318 may extend upwardly from a bottom 326 of the exterior surface 302 in a sole-to-instep direction 322 (e.g., from the perspective of FIG. 3 ) and at least partially on the exterior medial side 312 and the exterior lateral side 315 of the upper 300. In this manner, for example, at least a portion of the midsole portion 318 may be externally visible on the exterior medial side 312 and the exterior lateral side 315, thereby allowing the midsole portion 318 to be at least partially visible when the upper 300 is worn by a user. In some embodiments, the midsole portion 318 may extend in a heel-to-toe direction 320 from the rear distal end 310 to the front distal end 308. In some embodiments, the midsole portion 318 may extend in a heel-to-toe direction 320 from the rear distal end 310 to a position between the rear distal end 310 and the front distal end 308 (see, e.g., FIG. 9 ).

[0060] In some embodiments, the upper 300 may be formed from a single knit material. That is, the upper portion 316 and the midsole portion 318 may be formed from the same knit material. In the illustrated embodiment, the upper portion 316 may be formed from a first knit material, and the midsole portion 318 may be formed from a second knit material that differs from the first knit material in at least one of color, transparency, or chemical composition. For example, the second knit material may be at least partially transparent such that a portion of the midsole is externally visible through the midsole portion 318 of the upper 300 (see, e.g., FIGS. 7-9). In some embodiments, the second knit material may be a transparent monofilament knit or yarn material.

[0061] In general, the particular properties that a particular type of yarn or knit material imparts to an area of ​​a knitted component may depend, at least in part, on the materials forming the various filaments and fibers of the yarn. For example, cotton can impart a soft effect, biodegradability, and natural beauty to a knitted material. Elastane and stretch polyester can both impart desirable stretch and recovery properties to a knitted component. Rayon can provide a high shine and moisture wicking material, wool can provide a highly moisture wicking material, nylon can provide a durable material that is abrasion resistant, and polyester can provide a hydrophobic and durable material.

[0062] Other aspects of the knitted component can also be varied to affect the properties of the knitted component and provide desired properties. For example, the yarns forming the knitted component or material can include monofilament yarns or multifilament yarns, or the yarns may each include filaments formed from two or more different materials. Additionally, the knitted component may be formed using a particular knitting process to impart specific properties to regions of the knitted component. Thus, both the materials forming the yarns or knitted material and other aspects of the yarns or knitted material may be selected to impart different properties to specific regions of the upper 300.

[0063] In some embodiments, the elasticity of a knitted material or a structure made from a knitted material may be measured based on a comparison of the width or length of the knitted structure in a first, unstretched state to the width or length of the knitted structure in a second, stretched state after a lateral force is applied to the knitted structure. As described herein, the upper 300 may include additional structural elements to reinforce and / or stabilize select portions of the upper 300. In some embodiments, properties associated with the upper 300 may be varied, such as stitch type or yarn type, or properties associated with different stitch or yarn types, such as stretch, aesthetics, thickness, breathability, transparency, or scuff resistance.

[0064] 5, in a method or process in which upper 300 is reinforced with a skeleton (see, e.g., method 100 or method 200), last 330 may be inserted into upper 300. Last 330 may be inserted into interior cavity 314 of upper 300 such that last 330 mates with interior surface 304 of upper 300 and supports exterior surface 302 of upper 300. For example, the volume defined by last 330 may be greater than or equal to the static or unsupported interior volume of interior cavity 314 (e.g., the volume when nothing is inserted into or mated with upper 300), thereby ensuring that last 330 fills interior cavity 314 and mates with interior surface 304 when last 330 is inserted into interior cavity 314. Thus, for example, the last 330 can be used as a mold for the intended size and shape of the upper 300 and can provide a rigid support for the upper 300 as the framework is printed thereon. In some embodiments, the volume and shape of the last 330 can define the intended size and shape of the upper 300. In some embodiments, the last 330 and corresponding upper 300 can be formed smaller than the intended size and shape of the upper 300. For example, in some embodiments, the last 330 and corresponding upper 300 can be formed about 25%, preferably about 20%, more preferably about 15%, and in one example about 10% smaller than the intended size and shape of the upper 300. Thus, for example, the upper 300 can stretch and automatically tighten around the user's foot upon receiving the foot.

[0065] 6 illustrates one embodiment of upper 300 with skeleton 340 printed on exterior surface 302. After skeleton 340 is printed on upper 300, midsole 342 is inserted into interior cavity 314. In some embodiments, midsole 342 may be formed from a thermoplastic material or foam (e.g., expanded thermoplastic urethane (ETPU), polyurethane, ethylene-vinyl acetate, or the like). Midsole 342 may be inserted through opening 306 and positioned within interior cavity 314 such that a portion of midsole 342 protrudes through and / or is visible through midsole portion 318 of upper 300 (see, e.g., FIGS. 7-9).

[0066] In the illustrated embodiment, the midsole 342 includes a body 344 defining an upper surface 346 and a peripheral boundary 350 formed around the periphery of the midsole 342. In the illustrated embodiment, the body 344 includes a lattice structure 352 having unit cells 354 formed by interconnected surfaces or segments 356. In general, the lattice structure 352 formed in the midsole 342 may define one or more openings, voids, holes, channels, and / or passages 358 formed by the interconnected surfaces or segments 356 and extending throughout the midsole 342. In some embodiments, the lattice structure 352 may define a gyroid structure including three periodic minimal surfaces. In general, the use of the lattice structure 352 may reduce stress concentrations formed along the midsole 342 due to the reduction in sharp edges formed in the lattice structure 352, which may improve cushioning performance in the midsole 342, for example.

[0067] In the illustrated embodiment, lattice structure 352 extends from top surface 346 and extends outwardly to peripheral boundary 350. As such, for example, lattice structure 352 may be externally visible through midsole portion 318 of upper 300 when the footwear is assembled.

[0068] 7-11 show one embodiment of footwear 360 including upper 300, framework 340, and midsole 342 disposed within interior cavity 314. In some embodiments, midsole 342 may be disposed within interior cavity 314 and interlock with interior surface 304. Midsole 342 may be secured within interior cavity 314 without the need for adhesives or other chemical or structural attachment mechanisms. As described herein, midsole portion 318 may be transparent such that at least a portion of midsole 342 is externally visible through midsole portion 318 of upper 300 (see, e.g., FIGS. 7-9). In the illustrated embodiment, dashed / dotted lines or grayscale shading in the close-up views of FIGS. 7-9 represent that midsole portion 318 of upper 300 is transparent such that, for example, lattice structure 352 of midsole 342 is visible through midsole portion 318 (e.g., in areas where framework 340 does not cover midsole portion 318).

[0069] Footwear 360 may be manufactured by, for example, method 100 or method 200. Footwear 360 may be included in a footwear assembly that includes a pair of shoes (e.g., a left foot version of footwear 360 and a right foot version of footwear 360). For ease of disclosure, aspects of the disclosure will be described with reference to a single shoe or footwear 360. In some figures, the footwear is depicted as a right shoe and in some figures, the footwear is depicted as a left shoe.

[0070] For reference, footwear 360 defines a forefoot region 362, a midfoot region 364, and a heel region 366 (see, e.g., FIG. 10). Forefoot region 362 corresponds to a portion of footwear 360 that generally encases a portion of the foot including the toes, ball of the foot, and joints connecting the metatarsals to the toes or phalanges. Midfoot region 364 is closely adjacent to forefoot region 362 and generally corresponds to a portion of footwear 360 that encases the arch of the foot along with the bridge of the foot. Heel region 366 is closely adjacent to midfoot region 364 and generally corresponds to a portion of footwear 360 that encases a rear portion of the foot including the heel or calcaneus, ankle, and / or Achilles tendon.

[0071] Footwear 360 defines a lateral side 368 (which generally corresponds to the exterior lateral side 315 of upper 300) and a medial side 370 (which generally corresponds to the exterior medial side 312 of upper 300). Lateral side 368 corresponds to the portion of footwear 360 that faces outwardly and medial side 370 corresponds to the portion of footwear 360 that faces inwardly when the shoe is worn by a user. Thus, the left shoe and the right shoe have opposing lateral and medial sides, with the medial sides being defined as the sides that are closest to each other when the shoe is worn by a user, while the lateral sides are defined as the sides that are furthest from each other when the shoe is worn.

[0072] The medial side 370 and the lateral side 368 are adjacent to one another along a longitudinal medial plane or axis 372 of the footwear 360 (see, e.g., FIG. 10 ). The longitudinal medial plane or axis 372 may define a central, intermediate axis between the medial side 370 and the lateral side 368 of the footwear 360. Stated another way, the longitudinal plane or axis 372 may extend between the rear distal end 310 and the forward distal end 308 of the footwear 360 and may continuously define the middle of the midsole 342, framework 340, and / or upper 300 of the footwear 360 (e.g., the longitudinal plane or axis 372 is a linear axis that extends through the rear distal end 310 of the heel region 366 to the forward distal end 308 of the forefoot region 362).

[0073] Forefoot region 362 may correspond to a portion of footwear 360 that generally encases a portion of foot 374 including toes or phalanges 376, ball of foot 374, and one or more of joints 380 connecting metatarsals 382 and toes or phalanges 376 of foot 374 (see, e.g., FIG. 5 ). Midfoot region 364 is proximate to and adjacent to forefoot region 362. Midfoot region 364 generally corresponds to a portion of footwear 360 that encases the arch of foot 374 as well as the bridge of foot 374. Heel region 366 is proximate to and adjacent to midfoot region 364. Heel region 366 generally corresponds to a portion of footwear 360 that encases a rear portion of foot 374 including heel or calcaneus 384, ankle (not shown), and / or Achilles tendon (not shown).

[0074] Forefoot region 362, midfoot region 364, heel region 366, medial side 370, and lateral side 368 are intended to define boundaries or regions of footwear 360. As such, forefoot region 362, midfoot region 364, heel region 366, medial side 370, and lateral side 368 generally characterize sections of footwear 360. Certain embodiments of the present disclosure may refer to portions or elements coextensive with one or more of forefoot region 362, midfoot region 364, heel region 366, medial side 370, and lateral side 368. Additionally, both upper 300, midsole 342, and / or framework 340 may be characterized as having portions within forefoot region 362, midfoot region 364, heel region 366, medial side 370, and / or lateral side 368. Thus, the upper 300, midsole 342, and / or framework 340, or parts of the upper 300, midsole 342, and / or framework 340, may include portions disposed in the forefoot region 362, the midfoot region 364, the heel region 366, the medial side 370, and / or the lateral side 368.

[0075] In some embodiments, the forefoot region 362 extends from the forward distal end 308 to a widest portion 386 of the footwear 360. The widest portion 386 is defined or measured along a first line 388 perpendicular to the longitudinal axis 372 that extends from the forward distal end 308 to a rear distal end 310 opposite the forward distal end 308. The midfoot region 364 extends from the widest portion 386 of the footwear 300 to a thinnest portion 390. The thinnest portion 390 of the footwear 360 is defined as the thinnest portion of the footwear 360 measured across a second line 392 perpendicular to the longitudinal axis 372. The heel region 366 extends from the thinnest portion 390 to the rear distal end 310 of the footwear 360.

[0076] The medial side 370 begins at the forward distal end 308 and curves outward along the medial side of the footwear 360 along the forefoot region 362 toward the midfoot region 364. The medial side 370 reaches a first line 388, at which point the medial side 370 curves inward toward the central longitudinal axis 372. The medial side 370 extends from the first line 388, or widest portion 386, to a second line 392, or thinnest portion 390, at which point, or in crossing the first line 388, the medial side 370 enters the midfoot region 364. Upon reaching the second line 392, the medial side 370 curves outward away from the central longitudinal axis 372, at which point, or in crossing the second line 392, the medial side 370 extends into the heel region 366. The inner side 370 then curves outward and then inward toward the rear distal end 310 , terminating at a point where the inner side 370 meets a central longitudinal axis 372 .

[0077] The lateral side 368 begins at the forward distal end 308 and curves along the outside of the footwear 360, along the forefoot region 362 and toward the midfoot region 364. The lateral side 368 reaches a first line 388, at which point the lateral side 368 curves inward toward the longitudinal central axis 372. The lateral side 368 extends from the first line 388, or widest portion 386, to a second line 392, or thinnest portion 390, at which point, or when it crosses the first line 388, the lateral side 368 enters the midfoot region 364. Upon reaching the second line 392, the lateral side 368 curves outward, away from the longitudinal central axis 372, at which point, or when it crosses the second line 392, the lateral side 368 extends into the heel region 366. The outer side 368 then curves outward and then inward toward the rear distal end 310 , terminating at a point where the outer side 368 meets the central longitudinal axis 372 .

[0078] It should be understood that numerous variations will be apparent to those skilled in the art in light of the foregoing description, and that individual components thereof may be incorporated into numerous articles of footwear. Accordingly, embodiments of footwear 360 and components thereof may be described with reference to general areas or portions of footwear 360, with the understanding that boundaries of forefoot region 362, midfoot region 364, heel region 366, medial side 370, and / or lateral side 368 described herein may vary from article to article of footwear.

[0079] However, embodiments of footwear 360 and individual components thereof may be described with reference to precise areas or portions of footwear 360, and the appended claims herein may incorporate limitations related to those boundaries of forefoot region 362, midfoot region 364, heel region 366, medial side 370, and / or lateral side 368 as discussed herein.

[0080] In the illustrated embodiment, the upper 300 extends across the forefoot region 362, midfoot region 364, and heel region 366 along a lateral side 368 and medial side 370 to receive and cradle the midsole 342 and the user's foot. In some embodiments, the upper 300 can further include an instep region 394 (see FIGS. 7 and 8 ) that extends from the opening 306 in the heel region 366 across an area corresponding to the instep of the foot to an area adjacent the forefoot region 362. The instep region 394 can include an area similar to an area in which a thong is located. In the illustrated embodiment, the upper 300 does not include a thong, i.e., the upper 300 is thongless.

[0081] Laces 396 may be threaded through a number of eyelets 397, framework 340, and / or upper portion 316 of upper 300 itself. Laces 396 may be operated by a user, allowing the user to change the dimension of upper 300 around the foot as desired by the user, for example, tightening or loosening a portion of upper 300. In some embodiments, footwear 360 may not include manually operated laces 396, but instead may include an electronically operated automatic lacing system. In some embodiments, upper 300 may be manufactured smaller than the size and shape intended for manufacture, as described herein, allowing footwear 360 to automatically tighten around the user's foot when the user inserts the foot into upper 300. In these embodiments, framework 340 may be formed from a stretchable material. In some embodiments, upper 300 can include a variable connection (e.g., elastic bands, lacing, disc lacing, or the like) connecting an upper region on the lateral side 368 to an upper region on the medial side 370, which ensures that upper 300 is positioned as close as possible to the wearer's metatarsals.

[0082] In some embodiments, selective segments, portions, or areas of the framework 340 may be movable relative to the upper 300 to allow a user to thread the laces through different portions of the framework 340. For example, in some embodiments, selective segments of the framework 340 may be printed on the upper 300 over areas of a release agent (e.g., release paper, release spray or coating, etc.) such that the selective segments of the framework 340 may be picked up or moved relative to the upper 300 to allow the laces to be threaded under the selective segments of the framework 340. In the illustrated embodiment of Figures 7 and 8, the laces 396 are threaded under the framework 340 at two or more points along the framework 340.

[0083] 7-11 , in the illustrated embodiment, the framework 340 is printed layer-by-layer on the exterior surface 302 of the upper 300. In the illustrated embodiment, the framework 340 includes a plurality of segments 400 and an outsole 402. In some embodiments, the plurality of segments 400 and the outsole 402 may be formed from the same material (e.g., a plastic material, a resin material, a polymeric material, a wax material, or the like). In some embodiments, the plurality of segments 400 and the outsole 402 may be formed from different materials, e.g., the plurality of segments 400 may be formed from a first material and the outsole 402 may be formed from a second material.

[0084] In some embodiments, scaffold 340 may be printed layer-by-layer on exterior surface 302 by an additive manufacturing system (e.g., a 3D printer). Various methods of additive manufacturing used to manufacture scaffold 340 in portions of upper 300 according to the present disclosure may include binder jetting, direct energy deposition, selective laser melting (SLM), fused deposition modeling (FDM), electron beam melting, laser powered bed fusion (LPBF), ultrasonic additive manufacturing, material extrusion, material jetting, joule printing, electrochemical deposition, cold spray metal printing, DLP metal printing, ultrasonic consolidation or ultrasonic additive manufacturing (UAM), LENS laser-based printing, vat photopolymerization, sheet lamination, or electron beam freeform manufacturing (EBF3).

[0085] In general, the framework 340 may be printed on selective portions of the exterior surface 302 of the upper 300 to reinforce and stabilize the upper 300. In some embodiments, the framework 340 may be symmetrical about a longitudinal axis 372. In some embodiments, the framework 340 may define a different shape, pattern, and / or footprint on the lateral side 368 as compared to the medial side 370. In some embodiments, the framework 340 may define a matrix pattern including a plurality of segments 400. In the illustrated embodiment, the plurality of segments 400 extend along the exterior surface 302 of the upper 300 between the forward distal end 308 and the rearward distal end 310. For example, the plurality of segments 400 may extend in a heel-to-toe direction 320 through the forefoot region 362, the midfoot region 364, and the heel region 366. In the illustrated embodiment, the plurality of segments 400 are disposed on both the medial side 370 and the lateral side 368.

[0086] In the illustrated embodiment, the plurality of segments 400 extend upward in a sole-to-instep direction 322 from the bottom 326 or sole side 323. In some embodiments, the plurality of segments 400 may extend upward in the sole-to-instep direction 322 from the bottom 326 to a location between the bottom 326 and the top along the exterior surface 302 (e.g., a point or line along the exterior surface 302 located the greatest distance from the bottom 326). In the illustrated embodiment, the plurality of segments 400 extend upward in the sole-to-instep direction 322 along the exterior surface 302 from the bottom 326 to a location between the top in the forefoot region 362 and the heel region 366. In other words, the plurality of segments 400 extend completely around the exterior surface 302 from the medial side 370 to the lateral side 368. Thus, for example, the plurality of segments 400 provide reinforcement and stability to the upper 300 while allowing flexibility as the wearer walks or runs.

[0087] In the illustrated embodiment, the plurality of segments 400 includes row segments or a first set of lines 404 and column segments or a second set of lines 406. Generally, the row segments 404 extend in a first direction along the exterior surface 302 and the column segments 406 extend in a second direction along the exterior surface 302 that is orthogonal to the first direction. For example, the column segments 406 may extend in a general direction that intersects with the row segments 404 such that the row segments 404 interconnect and intersect with the column segments 406 to form a cross pattern.

[0088] In general, the row segments 404 may be disposed along a portion of the exterior surface 302 such that the row segments 404 are generally parallel to one another, and the column segments 406 may be disposed along a portion of the exterior surface 302 such that the column segments 406 are generally parallel to one another. The generally parallel arrangement of the row segments 404 and column segments 406 does not limit the shapes of the row segments 404 and column segments 406 to straight segments. For example, in the illustrated embodiment, the row segments 404 and column segments 406 are curved segments.

[0089] Generally, the row segments 404 are spaced apart from one another and the column segments 406 are spaced apart from one another. In some embodiments, the row spacing 408 defined between adjacent pairs of row segments 404 may be approximately equal. In the illustrated embodiment, the row spacing 408 defined between adjacent pairs of row segments 404 varies from a minimum row spacing to a maximum row spacing. In some embodiments, the ratio between the maximum row spacing and the minimum row spacing may be between about 1 and about 5, or between about 1 and about 4, or between about 1 and about 3, or between about 2 and about 4. Generally, varying the row spacing 408 can vary the amount of reinforcement and / or stability provided to the upper 300 in a portion of the exterior surface 302. The ratio between the maximum row spacing and the minimum row spacing can maintain a critical balance between increased and / or decreased stability / reinforcement while maintaining the aesthetics of the footwear 360. In some embodiments, the line spacing 408 defined between individual row segments 404 of an adjacent pair of row segments 404 may vary in addition to or as an alternative to the line spacing 408 varying between adjacent pairs of row segments 404.

[0090] In some embodiments, the row spacing 410 defined between adjacent pairs of row segments 406 may be approximately equal. In the illustrated embodiment, the row spacing 410 defined between adjacent pairs of row segments 406 varies from a row spacing minimum to a row spacing maximum. In some embodiments, the ratio between the row spacing maximum and the row spacing minimum may be between about 1 and about 5, or between about 1 and about 4, or between about 1 and about 3, or between about 2 and about 4. In general, varying the row spacing 410 can vary the amount of reinforcement and / or stability provided to the upper 300 in a portion of the exterior surface 302. The ratio between the row spacing maximum and the row spacing minimum can maintain a critical balance between increased and / or decreased stability / reinforcement while maintaining the aesthetics of the footwear 360. In some embodiments, the column spacing 410 defined between individual column segments 406 in adjacent pairs of column segments 406 may vary in addition to or as an alternative to the column spacing 410 varying between adjacent pairs of column segments 406.

[0091] Generally, each of the plurality of segments 400 defines a shape and a size. In some embodiments, the shape and size of each of the plurality of segments 400 may remain substantially constant across the framework 340. For example, each of the plurality of segments 400 may define a segment height and a segment width. In some embodiments, the segment height and segment width may be substantially equal.

[0092] In some embodiments, the segment height (e.g., the maximum height defined by a segment in a direction perpendicular to the exterior surface 302), the segment width (e.g., the maximum width defined in a direction parallel to the exterior surface 302), and / or the shape of the segments may vary across select portions of the exterior surface 302 to provide increased or decreased stability / reinforcement to the upper 300. Alternatively or additionally, the shape of the plurality of segments 400 may vary (e.g., transitioning from a triangular or conical cross-section to a circular or semicircular cross-section) to provide increased stability / reinforcement.

[0093] For example, the segment height and / or segment width may be increased in a portion of the exterior surface 302 to provide increased stability / reinforcement. For example, the segment height and / or segment width may be increased in the heel region 366 relative to the midfoot region 364 and / or forefoot region 362 to provide increased stability in the heel region 366 where the upper 300 flexes less during walking or running. In some embodiments, the segment height and / or segment width may increase adjacent the base 326. For example, the segment height and / or segment width may increase as the plurality of segments 400 extend in the sole-to-instep direction 322 toward the base 326.

[0094] In some embodiments, the segment height may vary from a minimum segment height to a maximum segment height. For example, the maximum segment height is between about 1 and about 5 times the minimum segment height, or between about 1 and about 4 times the minimum segment height, or between about 1 and about 3 times the minimum segment height, or between about 2 and about 4 times the minimum segment height. The ranges between the maximum and minimum segment heights described herein maintain an important balance between increased and / or decreased stability / reinforcement while maintaining a desirable aesthetic for the footwear.

[0095] In some embodiments, the segment width may vary from the minimum segment width to the maximum segment width. For example, the maximum segment width is between about 1 and about 5 times the minimum segment width, or between about 1 and about 4 times the minimum segment width, or between about 1 and about 3 times the minimum segment width, or between about 2 and about 4 times the minimum segment width. The ranges between the maximum and minimum segment widths described herein maintain an important balance between increased and / or decreased stability / reinforcement while maintaining a desirable aesthetic for the footwear.

[0096] The outsole 402 is printed layer by layer on the bottom 326 of the exterior surface 302 (see, e.g., FIG. 9). In the illustrated embodiment, a portion of the plurality of segments 400 (e.g., at least one segment in the forefoot region 362, the midfoot region 364, or the heel region 366) extends from the lateral side 368 and the medial side 370 and at least partially covers the bottom 326 and connects to the outsole 402. The outsole 402 may cover an area of ​​the bottom 326. In the illustrated embodiment, the outsole 402 includes a plurality of outsole recesses 412 recessed into the outsole 402 (see, e.g., FIG. 11). The outsole recesses 412 may be at least partially recessed into the outsole 402 or may extend laterally between opposing sides of the outsole 402. The outsole recesses 412 may be spaced apart from one another in the heel-to-toe direction 320 and may be disposed along the outsole 402 in the heel-to-toe direction 320.

[0097] In some embodiments, the scaffold 340 as a whole may be printed layer-by-layer on the exterior surface 302. For example, the entire scaffold 340 (e.g., the outsole 402 and the segments 400) may be printed one layer at a time until all layers of the scaffold 340 are printed on the portion of the exterior surface 302. In some embodiments, a portion of the scaffold 340 may be printed layer-by-layer before another portion of the scaffold 340 is printed layer-by-layer. For example, the outsole 402 may be printed layer-by-layer and then the segments 400 may be printed layer-by-layer, or vice versa.

[0098] As described herein, the scaffold may be printed layer-by-layer on the upper by an additive manufacturing system (e.g., a 3D printer). FIG. 12 illustrates one embodiment of an additive manufacturing system 450 that may be used to design and print the scaffold and / or midsole according to the present disclosure. The additive manufacturing system 450 may include a controller 452, a print head 454, one or more motors 456, and a monitor or display 458. The controller 452 may include a processor having a memory including instructions executed by the processor. The controller 452 may be in communication with the print head 454, the one or more motors 456, and the monitor 458. The controller 452 may be configured to instruct the print head 454 to deposit material layer-by-layer in a predetermined pattern at specific locations. In some embodiments, the controller 452 may be separate from the print head 454, but is in communication with the print head 454.

[0099] In some embodiments, the controller 452 may be configured to design or receive a file including a midsole or skeleton. For example, the controller 452 may be in communication with a monitor 458 to allow a user to visualize and design the midsole or skeleton. In some embodiments, the print head 454 may be coupled to one or more motors 456, and the print head 454 may be configured to move about all sides and axes defined by the footwear 360 to print the skeleton 340 on a portion of the exterior surface 302 (see, e.g., FIG. 13 ).

[0100] In some embodiments, the print head 454 may be packaged within a housing 460 that supports footwear 360 on posts 462. The posts 462 may be coupled to one or more motors 456, which may rotate the footwear 360 as the framework 340 is printed on the exterior surface 302 (see, e.g., FIG. 14 ).

[0101] The freedom of customization and design afforded by the manufacture of the upper and the use of additive manufacturing systems provides a variety of design possibilities for the footwear. For example, FIGS. 15-17 show an embodiment of footwear 500 that can be formed, for example, by method 100 or method 200. In the illustrated embodiment, footwear 500 includes upper 501 with exterior surface 502, interior surface 504, first lace support 505, opening 506, and second lace support 507 disposed proximate opening 506. Upper 501 defines forward distal end 508, rear distal end 510, exterior medial side 512, and exterior lateral side 515. In general, exterior surface 502 extends over the exterior of upper 501, and interior surface 504 forms interior cavity 514 in which a user's foot is received. Opening 506 can provide access to interior cavity 514.

[0102] In the illustrated embodiment, the upper 501 may be formed from a single knit material. In general, the particular properties that a particular type of yarn or knit material imparts to a region of a knitted component may depend, at least in part, on the materials forming the various filaments and fibers of the yarn. For example, cotton may impart a soft effect, biodegradability, or natural aesthetics to the knitted material. Elastane and stretch polyester may provide the desired stretch and recovery properties to the knitted material, respectively. Rayon may provide a high shine and moisture wicking material, wool a highly moisture wicking material, nylon a durable material with abrasion resistance, and polyester a hydrophobic and durable material.

[0103] Other properties of the knitted component may be varied to affect the properties of the knitted component and provide desired properties. For example, the yarns forming the knitted component or material may include monofilament yarns or multifilament yarns, or the yarns may include filaments each formed from two or more different materials. Additionally, the knitted component may be formed using a particular knitting process to impart specific properties to regions of the knitted component. Thus, different properties may be imparted to specific regions of the upper 501 by selecting both the material forming the yarn or knitted material and other properties of the yarn or knitted material.

[0104] In some embodiments, the elasticity of a knitted material or a structure made from a knitted material can be measured based on a comparison of the knitted structure width or length in a first, unstretched state to the knitted structure width or length in a second, stretched state after a lateral force is applied to the knitted structure. As described herein, the upper 501 can also include additional structural elements to reinforce and / or stabilize select portions of the upper 501. In some embodiments, properties associated with the upper 501, such as stitch type, yarn type, or properties associated with different stitch or yarn types, such as stretch, aesthetics, thickness, breathability, transparency, or scuff resistance, can be varied.

[0105] In general, the descriptions relating to the forefoot region 362, midfoot region 364, heel region 366, lateral side 368, medial side 370, and longitudinal axis 372 of footwear 360 also apply to footwear 500 as appropriate, and like features are identified with like reference numerals in the 500 range. Additionally, the views and descriptions relating to FIG. 10 may be correspondingly applied to footwear 500.

[0106] In the illustrated embodiment, the upper 501 extends across the forefoot region 562, midfoot region 564, and heel region 566 along the lateral side 568 (see FIG. 16) and medial side 570 to receive and encase the midsole 542 and the user's foot. In some embodiments, the upper 501 can also include an instep region 594 that extends from the opening 506 in the heel region 566 across an area corresponding to the instep of the foot to an area adjacent the forefoot region 562. The instep region 594 can include an area similar to an area where a thong is located. In the illustrated embodiment, the upper 501 does not include a thong, i.e., the upper 501 is thongless.

[0107] In the illustrated embodiment, the upper 501 includes a cutout, window, or hole 503 formed on an inner side 570 of the upper adjacent the bottom 526 of the upper 501 in the heel region 566. In some embodiments, another hole may be formed symmetrically (e.g., about the longitudinal axis) on the outer side 568. With the midsole 342 disposed within the interior cavity 514, at least a portion of the midsole 542 may be visible through the hole 503. Thus, such portion of the midsole 542 protrudes through the hole 503 formed in the upper 501.

[0108] The lace 596 may be threaded through a number of eyelets 597 formed in the first lace support 505 and the second lace support 507. In some embodiments, the eyelets 597 may be formed by selective segments of the framework 540 that are movable relative to the upper 501, rather than the first lace support 505 and / or the second lace support 507. In the illustrated embodiment of FIG. 16, the second lace support 507 is at least partially disposed between the first lace support 505 and the opening 506, although other configurations are possible. The lace 596 may be manipulated around the foot as desired by the user to allow the user to change the dimensions of the upper 501, for example, to tighten or loosen a portion of the upper 501. In the illustrated embodiment, an arch-joint lacing 598 is included in the upper 501 to provide 360 ​​degrees of lacing.

[0109] In the illustrated embodiment, upper 501 includes a framework 540 that is printed layer-by-layer on exterior surface 502 by an additive manufacturing system (e.g., a 3D printer). Framework 540 includes a plurality of segments 600 and an outsole 602. In some embodiments, segments 600 and outsole 602 may be formed from the same material (e.g., a plastic material, a resin material, a polymer material, a wax material, or the like). In some embodiments, segments 600 and outsole 602 may be formed from different materials, e.g., segments 600 may be formed from a first material and outsole 602 may be formed from a second material.

[0110] Various methods of additive manufacturing used to fabricate the framework 540 in a portion of the upper 501 in accordance with the present disclosure may include binder jetting, direct energy deposition, selective laser melting (SLM), fused deposition modeling (FDM), electron beam melting, laser powered bed fusion (LPBF), ultrasonic additive manufacturing, material extrusion, material jetting, joule printing, electrochemical deposition, cold spray metal printing, DLP metal printing, ultrasonic consolidation or ultrasonic additive manufacturing (UAM), LENS laser-based printing, vat photopolymerization, sheet lamination, or electron beam freeform manufacturing (EBF3).

[0111] In general, the framework 540 may be printed on select portions of the exterior surface 502 of the upper 501 to reinforce and stabilize the upper 501. In some embodiments, the framework 540 may be symmetrical about a longitudinal axis defined by the footwear 500. In some embodiments, the framework 540 may define a different shape, pattern, and / or footprint on the lateral side 568 as compared to the medial side 570. In some embodiments, the framework 540 may define a matrix pattern including a plurality of segments 600. In the illustrated embodiment, the plurality of segments 600 extends along the exterior surface 502 of the upper 501 between the forward distal end 508 and the rear distal end 510. For example, the plurality of segments 600 may extend in a heel-to-toe direction 520 through the forefoot region 562, the midfoot region 564, and at least partially through the heel region 566. In the illustrated embodiment, the plurality of segments 600 are disposed on both the medial side 570 and the lateral side 568.

[0112] In the illustrated embodiment, the plurality of segments 600 extend upward in the sole-instep direction 522 from the bottom 526 or sole side 603 (see FIG. 15 ). In some embodiments, the plurality of segments 600 may extend upward in the sole-instep direction 522 from the bottom 526 to a location between the bottom 526 and the top along the exterior surface 502 (e.g., a point or line along the exterior surface 502 located the greatest distance from the bottom 526). In the illustrated embodiment, the plurality of segments 600 extend upward in the sole-instep direction 522 from the bottom 526 to a location between the bottom 526 and the top along the exterior surface 502 in the midfoot region 564. The plurality of segments 600 extend upward in the sole-instep direction 522 from the bottom 526 to a top along the exterior surface 502 in a portion of the forefoot region 562. In other words, the plurality of segments 600 extends completely around the exterior surface 502 from the medial side 570 to the lateral side 568 in at least a portion of the forefoot region 562. In this manner, for example, the plurality of segments 600 provides reinforcement and stability to the upper 501 while allowing flexibility as the wearer walks or runs.

[0113] In the illustrated embodiment, the plurality of segments 600 includes row segments or a first set of lines 604 and column segments or a second set of lines 606. In general, the row segments 604 extend in a first direction along the exterior surface 502, and the column segments 606 extend in a second direction along the exterior surface 502 that is orthogonal to the first direction. For example, the column segments 606 may extend in a general direction that intersects the row segments 604, such that the row segments 604 interconnect and intersect with the column segments 606 to form a cross pattern. In other words, the plurality of segments 600 defines a matrix pattern including interconnected row segments 604 and column segments 606.

[0114] In general, the row segments 604 may be arranged along a portion of the exterior surface 502 such that the row segments 604 are generally parallel to one another, and the column segments 606 may be arranged along a portion of the exterior surface 502 such that the column segments 606 are generally parallel to one another. The generally parallel arrangement of the row segments 604 and column segments 606 does not limit the shapes of the row segments 604 and column segments 606 to straight line segments. For example, in the illustrated embodiment, the row segments 604 and column segments 606 are curved or wavy segments.

[0115] In general, the row segments 604 may be spaced apart from one another and the column segments 606 may be spaced apart from one another. In some embodiments, the row spacing 608 defined between adjacent pairs of row segments 604 may be approximately equal. In the illustrated embodiment, the row spacing 608 defined between adjacent pairs of row segments 604 varies from a row spacing minimum to a row spacing maximum. In some embodiments, the ratio between the row spacing maximum and the row spacing minimum may be between about 1 and about 5, or between about 1 and about 4, or between about 1 and about 3, or between about 2 and about 4. In general, varying the row spacing 608 may vary the amount of reinforcement and / or stability provided to the upper 501 in a portion of the exterior surface 502. The ratio between the row spacing maximum and the row spacing minimum may maintain a critical balance between increased and / or decreased stability / reinforcement while maintaining the aesthetics of the footwear 500. In some embodiments, the line spacing 608 defined between individual row segments 604 in adjacent pairs of row segments 604 may vary in addition to or as an alternative to the line spacing 608 varying between adjacent pairs of row segments 604.

[0116] In some embodiments, the row spacing 610 defined between adjacent pairs of row segments 606 may be approximately equal. In the illustrated embodiment, the row spacing 610 defined between adjacent pairs of row segments 606 varies from a row spacing minimum to a row spacing maximum. In some embodiments, the ratio between the row spacing maximum and the row spacing minimum may be between about 1 and about 5, or between about 1 and about 4, or between about 1 and about 3, or between about 2 and about 4. In general, varying the row spacing 610 can vary the amount of reinforcement and / or stability provided to the upper 501 in a portion of the exterior surface 502. The ratio between the row spacing maximum and the row spacing minimum can maintain a critical balance between increased and / or decreased stability / reinforcement while maintaining the aesthetics of the footwear 500. In some embodiments, the row spacing 610 defined between individual row segments 606 in adjacent pairs of row segments 606 may vary in addition to or as an alternative to the row spacing 610 varying between adjacent pairs of row segments 606.

[0117] In general, each of the plurality of segments 600 defines a shape and a size. In some embodiments, the shape and size of each of the plurality of segments 600 may remain substantially constant across the framework 540. For example, each of the plurality of segments 600 may define a segment height and a segment width. In some embodiments, the segment height and segment width may be approximately equal.

[0118] In some embodiments, the segment height (e.g., the maximum height defined by a segment in a direction perpendicular to the exterior surface 502), the segment width (e.g., the maximum width defined in a direction parallel to the exterior surface 502), and / or the shape of the segments may vary across select portions of the exterior surface 502 to provide increased or decreased stability / reinforcement to the upper 501. Alternatively or additionally, the shape of the plurality of segments 600 may vary (e.g., transitioning from a triangular or conical cross-section to a circular or semicircular cross-section) to provide increased stability / reinforcement.

[0119] For example, the segment height and / or segment width may be increased in a portion of the exterior surface 502 to provide increased stability / reinforcement. For example, the segment height and / or segment width may be increased in the heel region 566 relative to the midfoot region 564 and / or forefoot region 562 to provide increased stability in the heel region 566 where the upper 501 flexes less during walking or running. In some embodiments, the segment height and / or segment width may increase adjacent the base 526. For example, the segment height and / or segment width may increase as the plurality of segments 600 extend in the sole-to-instep direction 522 toward the base 526.

[0120] In some embodiments, the segment height may vary from a minimum segment height to a maximum segment height. For example, the maximum segment height is between about 1 and about 5 times the minimum segment height, or between about 1 and about 4 times the minimum segment height, or between about 1 and about 3 times the minimum segment height, or between about 2 and about 4 times the minimum segment height. The ranges between the maximum and minimum segment heights described herein maintain an important balance between increased and / or decreased stability / reinforcement while maintaining a desirable aesthetic for the footwear.

[0121] In some embodiments, the segment width may vary from the minimum segment width to the maximum segment width. For example, the maximum segment width is between about 1 and about 5 times the minimum segment width, or between about 1 and about 4 times the minimum segment width, or between about 1 and about 3 times the minimum segment width, or between about 2 and about 4 times the minimum segment width. The ranges between the maximum and minimum segment widths described herein maintain an important balance between increased and / or decreased stability / reinforcement while maintaining a desirable aesthetic for the footwear.

[0122] In the illustrated embodiment, the footwear 500 includes additional structures that can supplement the framework 540 to reinforce and stabilize the upper 501. For example, the footwear 500 includes a first lace support plate 505 disposed on both the lateral side 568 and the medial side 570, a second lace support plate 507 disposed on both the lateral side 568 and the medial side 570, and a heel support plate 509. The first lace support plate 505 generally defines a zigzag pattern and extends along the upper through at least a portion of the midfoot region 564. The first lace support 505 includes a portion of a plurality of eyelets 597 formed therein. The second support plate 507 is spaced apart from the first support plate 505 in the heel-toe direction 520, and the second support plate can include a portion of the plurality of eyelets 597 formed therein. The second support plate 507 can be disposed in the midfoot region 564 and / or the heel region 566. The heel support plate 509 extends from a lateral side 568 to a medial side 570 around at least a portion of the heel region 566 .

[0123] With specific reference to FIG. 17 , the midsole 542 includes an upper side 614, a lower side 616, and a body 612 defining a lattice structure 618 extending between a top surface 620 and a bottom surface 622 throughout the body 612. The body 612 further defines a medial side 624, a lateral side 626, a rear distal end 628, and a front distal end 630. In the illustrated embodiment, the upper surface 620 defines a variable geometric structure including a first portion 632, a second portion 634, and a third portion 636. The second portion 634 is disposed between the first portion 632 and the third portion 636. The first portion 632 extends from the front distal end 630 to an intersection between the first portion 632 and the second portion 634. The third portion 636 extends from the rear distal end 628 to an intersection between the third portion and the second portion 634. In some embodiments, first portion 632 may extend at least partially over the forefoot region into a midfoot region defined by body 612. In some embodiments, second portion 634 may extend at least partially over the midfoot region and into a heel region defined by body 612. In some embodiments, third portion 636 may extend at least partially over the heel region defined by body 612.

[0124] The first portion 632 and the third portion 636 define a different geometric structure than the second portion 634. For example, the first portion 632 may include a first support surface 640 having a first plurality of holes 638 extending at least partially through the first support surface 640. The plurality of holes 638 are arranged in an array pattern on the first support surface 640. Similar to the first portion 632, the third portion 636 includes a second support surface 642 having a second plurality of holes 644 extending at least partially through the second support surface 642. The second plurality of holes 644 are arranged in an array pattern on the second support surface 642. The second portion 634 defines a generally open structure formed by the lattice structure 618. In other words, the first support surface 640 extending on the first portion 632 and the second support surface 642 extending on the third portion 636 may not extend onto the second portion 634, and the lattice structure 618 may be visible through the upper side 614 of the body 612 at the second portion 634.

[0125] In the illustrated embodiment, the lattice structure 618 includes unit cells 646 formed by interconnected surfaces or segments 648 that define one or more openings, voids, holes, channels, tunnels, or passages 650 extending through the body 612. In some embodiments, the interconnected surfaces 648 can define a minimal surface. In some embodiments, the interconnected surfaces 648 may define a tri-periodic minimal surface (e.g., a gyroid). In general, the use of differential geometry (e.g., a gyroid) reduces the acute angles formed in the body 612, thereby reducing stress concentrations formed along the midsole 542, thereby providing the midsole 542 with improved cushioning performance. Additionally, the variable shape defined along the upper side 614 provides additional support in areas of high force / pressure along the midsole 542. For example, first support surface 640 may provide additional support in a forefoot region (e.g., under the ball of the user's foot and / or under the user's toes) and second support surface 642 may provide additional support in a heel region (e.g., under the user's heel). The additional support provided by first support surface 640 and second support surface 642 may help spread or distribute pressure / forces exerted across lattice structure 618, further leveraging the improved cushioning properties of lattice structure 618.

[0126] 18-21 illustrate an embodiment of footwear 700 that can be formed, for example, by method 100 or method 200. In the illustrated embodiment, footwear 700 includes an upper 701 having an exterior surface 702, an interior surface 704, and an opening 706. Upper 701 defines a front distal end 708, a rear distal end 710, an exterior medial side 712, and an exterior lateral side (not shown). Generally, exterior surface 702 extends on an exterior side of upper 701, and interior surface 704 forms an interior cavity 714 in which a user's foot is received. Opening 706 can provide access to interior cavity 714.

[0127] In the illustrated embodiment, the upper 701 may be formed from a single knit material. In general, the particular properties that a particular type of yarn or knit material imparts to a region of a knitted component may depend, at least in part, on the materials forming the various filaments and fibers of the yarn. For example, cotton may impart a soft effect, biodegradability, or natural aesthetics to the knitted material. Elastane and stretch polyester may provide the desired stretch and recovery properties to the knitted material, respectively. Rayon may provide a high shine and moisture wicking material, wool a highly moisture wicking material, nylon a durable material that is abrasion resistant, and polyester a hydrophobic and durable material.

[0128] Other aspects of the knitted component can also be varied to affect the properties of the knitted component and provide desired properties. For example, the yarns forming the knitted component or material can include monofilament yarns or multifilament yarns, or the yarns may include filaments each formed from two or more different materials. Additionally, the knitted component may be formed using a particular knitting process to impart specific properties to regions of the knitted component. Thus, both the materials forming the yarns or knitted material and other aspects of the yarns or knitted material may be selected to impart various properties to specific regions of the upper 701.

[0129] In some embodiments, the elasticity of a knitted material or a structure made from a knitted material can be measured based on a comparison of the width or length of the knitted structure in a first, unstretched state to the width or length of the knitted structure in a second, stretched state after a lateral force is applied to the knitted structure. As described herein, the upper 701 can also include additional structural elements to reinforce and / or stabilize select portions of the upper 701. In some embodiments, properties associated with the upper 701, such as stitch type, yarn type, or properties associated with different stitch or yarn types, such as elasticity, aesthetics, thickness, breathability, transparency, or scuff resistance, may be varied.

[0130] In general, the descriptions herein relating to the forefoot region 362, midfoot region 364, heel region 366, lateral side 368, medial side 370, and longitudinal axis 372 of footwear 360 also apply to footwear 700 as appropriate, and like features are identified with like reference numerals in the 700 series. Additionally, the views and descriptions relating to FIG. 10 may be correspondingly applied to footwear 700.

[0131] In the illustrated embodiment, the upper 701 extends across the forefoot region 762, midfoot region 764, and heel region 766 along the lateral side 768 and medial side 770 to accommodate the midsole 742 and the user's foot. In some embodiments, the upper 701 may also include an instep region 794 that extends from the opening 706 in the heel region 766 across an area corresponding to the instep of the foot to an area adjacent the forefoot region 762. The instep region 794 can have an area similar to the area in which a thong is located. In the illustrated embodiment, the upper 701 does not include a thong, i.e., the upper 701 is thongless.

[0132] In the illustrated embodiment, the upper 701 includes a plurality of cutouts, windows, or holes 703 formed in a bottom 726 of the upper 701 through which a portion of the midsole 742 is externally visible. The plurality of holes 703 may each extend through the bottom 726 of the upper 701 and may define a variety of sizes. The plurality of holes 703 may be arranged in an array on the bottom 726 and may extend between a front distal end 708 and a rear distal end 710. In general, the holes 703 may be sized and arranged to allow a corresponding protrusion to extend therethrough.

[0133] Lace 796 may be threaded through a number of eyelets 797. In some embodiments, eyelet 797 may be formed by a portion of framework 740 that is movable relative to upper 701. Lace 796 may be manipulated by a user to allow the user to change the dimension of upper 701 around the foot, for example, to tighten or loosen a portion of upper 701.

[0134] In the illustrated embodiment, upper 701 includes a framework 740 that is printed layer-by-layer on exterior surface 702 by an additive manufacturing system (e.g., a 3D printer). Framework 740 includes a plurality of segments 800 and an outsole 802 (see, e.g., FIG. 20 ). In some embodiments, segments 800 and outsole 802 may be formed from the same material (e.g., a plastic material, a resin material, a polymer material, a wax material, or the like). In some embodiments, segments 800 and outsole 802 may be formed from different materials, e.g., segments 800 may be formed from a first material and outsole 802 may be formed from a second material.

[0135] Various methods of additive manufacturing that may be used to fabricate the framework 740 in a portion of the upper 701 in accordance with the present disclosure may include binder jetting, direct energy deposition, selective laser melting (SLM), fused deposition modeling (FDM), electron beam melting, laser powered bed fusion (LPBF), ultrasonic additive manufacturing, material extrusion, material jetting, joule printing, electrochemical deposition, cold spray metal printing, DLP metal printing, ultrasonic consolidation or ultrasonic additive manufacturing (UAM), LENS laser-based printing, vat photopolymerization, sheet lamination, or electron beam freeform manufacturing (EBF3).

[0136] In general, the framework 740 may be printed on select portions of the exterior surface 702 of the upper 701 to reinforce and stabilize the upper 701. In some embodiments, the framework 740 may be symmetrical about a longitudinal axis defined by the footwear 700. In some embodiments, the framework 740 may define a different shape, pattern, and / or footprint on the lateral side 768 as compared to the medial side 770. In the illustrated embodiment, the plurality of segments 800 extends along the exterior surface 702 of the upper 701 between the forward distal end 708 and the rear distal end 710. For example, the plurality of segments 800 may extend in the heel-to-toe direction 720 through at least a portion of the forefoot region 762, the midfoot region 764, and the heel region 766. In some embodiments, the plurality of segments 800 may be disposed on both the medial side 770 and the lateral side 768.

[0137] In the illustrated embodiment, the segments 800 are spaced apart from one another in the sole-to-instep direction 722 and extend various distances along the heel-to-toe direction 720. For example, a segment disposed adjacent to the lace 796 may extend a shorter distance in the heel-to-toe direction than a segment disposed adjacent to the sole 726. In the illustrated embodiment, at least one of the segments extends in the heel-to-toe direction 720 through the midfoot region 764 to the heel region 766. In the illustrated embodiment, the segments 800 are disposed generally parallel to one another, although a parallel arrangement does not limit the segments 800 to being straight. For example, in the illustrated embodiment, the segments 800 define generally wavy segments.

[0138] In general, the segments 800 may be spaced apart from one another (e.g., in the sole-to-instep direction 722). In the illustrated embodiment, the segment spacing 808 defined between adjacent pairs of the segments 800 may be approximately equal. In some embodiments, the segment spacing 808 defined between adjacent pairs of the segments 800 varies from a segment spacing minimum to a segment spacing maximum. In some embodiments, the ratio between the segment spacing maximum and the segment spacing minimum may be between about 1 and about 5, or between about 1 and about 4, or between about 1 and about 3, or between about 2 and about 4. In general, varying the segment spacing 808 can vary the amount of reinforcement and / or stability provided to the upper 701 in a portion of the exterior surface 702. The ratio between the segment spacing maximum and the segment spacing minimum can maintain an important balance between increased and / or decreased stability / reinforcement while maintaining the aesthetics of the footwear 700.

[0139] In general, each of the plurality of segments 800 defines a shape and a size. In some embodiments, the shape and size of each of the plurality of segments 800 may remain substantially constant across the framework 740. For example, each of the plurality of segments 800 may define a segment height and a segment width. In some embodiments, the segment height and segment width may be substantially equal.

[0140] In some embodiments, the segment height (e.g., the maximum height defined by a segment in a direction perpendicular to the exterior surface 702), segment width (e.g., the maximum width defined in a direction parallel to the exterior surface 702), and / or segment shape may vary over selective portions of the exterior surface 702 to provide increased or decreased stability / reinforcement to the upper 701. Alternatively or additionally, the shape of the plurality of segments 800 may vary (e.g., transitioning from a triangular or conical cross-section to a circular or semicircular cross-section) to provide increased stability / reinforcement.

[0141] For example, the segment height and / or segment width may be increased in a portion of the exterior surface 702 to provide increased stability / reinforcement. For example, the segment height and / or segment width may be increased in the heel region 766 relative to the midfoot region 764 and / or forefoot region 762 to provide increased stability in the heel region 766 where the upper 701 experiences less flexion during walking or running. In some embodiments, the segment height and / or segment width may increase adjacent the base 726. For example, the segment height and / or segment width may increase as the plurality of segments 800 extend in the sole-to-instep direction 722 toward the base 726.

[0142] In some embodiments, the segment height may vary from a minimum segment height to a maximum segment height. For example, the maximum segment height is between about 1 and about 5 times the minimum segment height, or between about 1 and about 4 times the minimum segment height, or between about 1 and about 3 times the minimum segment height, or between about 2 and about 4 times the minimum segment height. The ranges between the maximum and minimum segment heights described herein maintain an important balance between increased and / or decreased stability / reinforcement while maintaining a desirable aesthetic for the footwear.

[0143] In some embodiments, the segment width may vary from the minimum segment width to the maximum segment width. For example, the maximum segment width is between about 1 and about 5 times the minimum segment width, or between about 1 and about 4 times the minimum segment width, or between about 1 and about 3 times the minimum segment width, or between about 2 and about 4 times the minimum segment width. The ranges between the maximum and minimum segment widths described herein maintain an important balance between increased and / or decreased stability / reinforcement while maintaining a desirable aesthetic for the footwear.

[0144] In the illustrated embodiment, the midsole 742 may include a number of protrusions 816 extending outwardly from a bottom surface 818 of the midsole 742. When the midsole 742 is received within the interior cavity 714, a portion of the midsole 742 disposed above the bottom surface 818 may be encased within the interior cavity 714 of the upper 701, and each of the protrusions 816 may extend through a corresponding one of the holes 703 of the upper 701. Thus, for example, a portion of the midsole 742 may protrude through the upper 701 and be visible through the upper 701. In the illustrated embodiment, each of the protrusions 816 defines a generally hemispherical shape and is sized according to the corresponding hole 703 through which it passes. In the illustrated embodiment, the midsole 742 may include a number of recesses recessed toward the outer surface of the protrusions 816 and the periphery of the midsole 742.

[0145] 20 and 21 , the outsole 802 is printed layer-by-layer on the bottom 726 of the exterior surface 702. In the illustrated embodiment, the outsole 802 is printed around the holes 703 and the protrusions 816 extending therethrough. In some embodiments, the framework 740 may be printed layer-by-layer on the exterior surface 702 as a whole. For example, the entire framework 740 (e.g., the outsole 802 and the plurality of segments 800) may be printed one layer at a time until all layers of the framework 740 are printed on the portion of the exterior surface 702. In some embodiments, a portion of the framework 740 may be printed layer-by-layer before another portion of the framework 740 is printed layer-by-layer. For example, the outsole 802 may be printed layer-by-layer and then the plurality of segments 800 may be printed layer-by-layer, or vice versa.

[0146] As described herein, the segments on the framework can take on a variety of shapes and sizes across a particular portion of the upper. The following embodiments of segment shapes and sizes can be applied to any of the segments described herein. For example, the embodiments described with reference to Figures 22-34 can be applied to any of segments 400, 600, or 800, or to a subset of segments 400, 600, or 800. Additionally, differences between the embodiments of Figures 22-34 may be applied across different subsets of segments 400, 600, or 800. For example, the embodiment of Figure 22 may be applied to the heel region of segment 400, and the embodiment of Figure 25 may be applied to the midfoot region of segment 400. Any combination of the embodiments of Figures 22-34 may be incorporated into any portion or subset of segments 400, 600, or 800.

[0147] FIG. 22 illustrates one embodiment of a segment 400, 600, or 800. The segment may include a set of segments 902 that define a segment height H and a segment width W. The segment height H is defined as the maximum distance the segment extends in a direction perpendicular to the exterior surface (e.g., 302, 502, 702) on which the segment is printed. In the illustrated embodiment, the set of segments 902 each define a generally triangular shape in cross section and define approximately the same segment height H and segment width W. As described herein, the size of the segments within the framework may be varied to provide customized reinforcement in different portions of the upper. For example, as shown in FIG. 23, the segment 400, 600, or 800 may further include a set of segments 904, each defining a segment height H that is less than the segment height H of the set of segments 902 and approximately the same segment width W as the set of segments 902. Alternatively or additionally, segment 400, 600, or 800 may further include a set of segments 906 defining a segment width W smaller than the segment width W of the set of segments 902 and about the same segment height H as the set of segments 902, as shown in Figure 24. Alternatively or additionally, segment 400, 600, or 800 may further include a set of segments 908 defining a segment width W smaller than the segment width W of the set of segments 902 and a segment height H smaller than the set of segments 902, as shown in Figure 25.

[0148] Turning to FIG. 26, the segment 400, 600, or 800 may include a set of segments 910 with different heights. For example, the set of segments 910 may include a first segment 912 having a first segment height H1 at a first location on the exterior surface (e.g., 302, 502, 702), a second segment 914 having a second segment height H2 at a second location on the exterior surface, and a third segment 916 having a third segment height H3 at a third location on the exterior surface. In the illustrated embodiment, the third segment height H3 is greater than the second segment height H2, which is greater than the first segment height H1. In other embodiments, the second segment height H2 is greater than the first segment height H1 and the third segment height H3, as shown in FIG. 27.

[0149] Turning to FIG. 28, the segment 400, 600, or 800 may include a set of segments 918 that differ in width. For example, the set of segments 918 may include a first segment 920 having a first segment width W1 at a first location on the exterior surface (e.g., 302, 502, 702), a second segment 922 having a second segment width W2 at a second location on the exterior surface, and a third segment 924 having a third segment width W3 at a third location on the exterior surface. In the illustrated embodiment, the third segment width W3 is greater than the second segment width W2, which is greater than the first segment width W1. In other embodiments, the second segment width W2 is greater than the first segment width W1 and the third segment width W3, as shown in FIG. 29. In some embodiments, the segment 400, 600, or 800 may include segments that differ in both segment height and segment width.

[0150] In some embodiments, segments 400, 600, or 800 can include segments of various shapes. For example, FIG. 30 illustrates a set of segments 926 including a first segment 928 and a third segment 930 that define a generally triangular shape in cross section, and a second segment 932 that defines a generally rounded semicircular shape in cross section. It should be understood that variations in segment shape, height, and width can be applied in any combination to achieve a particular reinforcement of the upper. For example, variations in height and width can be applied to any shape or configuration of the segments (e.g., cone shape, polygon shape, arc shape, etc.).

[0151] Any of the embodiments described herein may be modified to include any of the structures or methodologies disclosed in connection with the different embodiments. Additionally, the disclosure is not limited to the types of footwear specifically shown. Additionally, the footwear aspects of any of the embodiments disclosed herein may be modified to work with any type of footwear, apparel, or other athletic equipment.

[0152] As mentioned above, although the present disclosure has been described in connection with specific embodiments and examples, those skilled in the art will appreciate that the present disclosure is not necessarily so limited, and that numerous other embodiments, examples, uses, modifications, and departures from the embodiments, examples, and uses are intended to be encompassed by the claims appended hereto. The entire disclosure of each patent and publication cited herein is incorporated by reference as if each such patent or publication were individually incorporated by reference herein. Various features and advantages of the present invention are set forth in the following claims. [Industrial Applicability]

[0153] Numerous modifications to the present disclosure will be apparent to those skilled in the art in light of the foregoing description. Accordingly, this specification is to be construed as illustrative only and is presented for the purpose of enabling any person skilled in the art to make and use the invention. The exclusive rights to all modifications that come within the scope of the appended claims are reserved.

Claims

1. A sleeve formed of a knit material, defining a front distal end and a rear distal end, and including an outer surface and an inner surface defining an inner cavity, a midsole disposed within the inner cavity, and a framework printed layer by layer on a part of the outer surface, the framework having a plurality of segments and an outsole, the outsole being disposed at the bottom of the outer surface, the plurality of segments extending along the outer surface of the sleeve between the front distal end and the rear distal end, the outer surface being located opposite to the inner surface, the outsole being directly attached to the outer surface, at least a part of the plurality of segments extending along the bottom of the outer surface and being in direct contact with the bottom of the outer surface, the bottom of the outer surface extending from the outside to the inside of the sleeve and being configured to extend under the foot when the user's foot is positioned within the inner cavity, a footwear.

2. The footwear according to claim 1, wherein the sleeve defines an upper part and a midsole part.

3. The footwear according to claim 2, wherein the knit material includes a first knit material spanning the upper part and a second knit material spanning the midsole part.

4. The footwear according to claim 3, wherein at least a part of the second knit material is transparent, and the midsole is at least partially visible from the outside through the midsole part of the sleeve.

5. The footwear according to claim 1, wherein the plurality of segments includes a first set of lines and a second set of lines.

6. The footwear according to claim 5, wherein the first set of lines are parallel to each other, and the second set of lines are parallel to each other.

7. The footwear according to claim 5, wherein the first set of lines intersects the second set of lines to form a cross pattern.

8. The footwear according to claim 1, wherein the plurality of segments are aligned with each other and extend in a heel-to-toe direction along the sleeve.

9. The footwear according to claim 1, wherein a part of the plurality of segments is movable relative to the sleeve so that a lace can be passed through the framework.

10. A sleeve formed of a knit material, defining a front distal end and a rear distal end, and including an outer surface and an inner surface defining an inner cavity, a midsole disposed within the inner cavity, and comprising a framework printed layer by layer on a part of the outer surface; the framework has a plurality of segments and an outsole, the outsole is disposed at the bottom of the outer surface, and the plurality of segments extend along the outer surface of the sleeve between the front distal end and the rear distal end; the sleeve has a hole through which a part of the midsole is visible, the footwear.

11. The part of the midsole protrudes through the hole formed in the sleeve, the footwear according to claim 10.

12. The outsole is printed around the hole formed in the sleeve, the footwear according to claim 11.

13. The plurality of segments include a first segment having a first segment height at a first position on the outer surface, a second segment having a second segment height at a second position on the outer surface, and a third segment having a third segment height at a third position on the outer surface, the footwear according to claim 10.

14. The second segment height is greater than the first segment height and the third segment height, the footwear according to claim 13.

15. An upper including an upper part formed of a first knit material and a midsole part formed of a second knit material, a midsole disposed in the internal cavity of the upper, a framework printed layer by layer on the upper, defining a matrix pattern including a plurality of row segments and a plurality of column segments extending along the inner side and the outer side of the outside of the upper, and an outsole printed layer by layer on the sole side of the upper, connected to the framework on the inner side and the outer side of the outside, at least a part of the plurality of row segments and the plurality of column segments extends along a bottom extending along the inner side and the outer side of the outside of the upper, in direct contact with the bottom, and the bottom is configured to extend under the foot when the user's foot is located in the internal cavity, the footwear.

16. The framework is integrally formed with the outsole, the footwear according to claim 15.

17. The row spacing defined between adjacent pairs of the row segments is the same, the footwear according to claim 15.

18. The footwear according to claim 15, wherein the row spacing defined between adjacent pairs of the row segments varies from a minimum row spacing to a maximum row spacing.

19. The footwear according to claim 15, wherein the column spacing defined between adjacent pairs of the column segments is the same.

20. The footwear according to claim 15, wherein the column spacing defined between adjacent pairs of the column segments varies from a minimum column spacing to a maximum column spacing.

Images