Article of footwear with reinforcement

Abstract

To provide an article of footwear with reinforcement for stability, energy return, comfort, and weight reduction, and an efficient method of manufacturing the article of footwear with such reinforcement.SOLUTION: A method of manufacturing an article of footwear includes forming a sole structure using an additive manufacturing system. The sole structure includes a conduit extending within a region of the sole structure. The conduit includes an end projecting outward from a surface of the sole structure and a channel defined through the conduit. The method also includes connecting an end of the conduit to an injection device and injecting a reinforcement material into the channel of the conduit to form the reinforcement. The method further includes removing a portion of the end of the conduit.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates generally to footwear including reinforcements, and more particularly to sole structures including reinforcements within a midsole. [Background technology]

[0002] Conventional shoes and other footwear typically include an upper and a sole attached to the lower end of the upper. Conventional shoes also include an interior space, i.e., a void or cavity, formed by the upper and the inner surface of the sole, which accommodates the user's foot before fastening the shoe to the foot. The sole is attached to the underside or boundary of the upper and is positioned between the upper and the ground. As a result, the sole typically provides flexibility and cushioning to the user while wearing the shoe. In some cases, the sole may include multiple components, such as an outsole, a midsole, and an upper. The outsole may provide traction to the bottom surface of the sole, and the midsole may be attached to the inner surface of the outsole and provide cushioning or additional stability to the sole. For example, the sole may include a specific foam material that increases stability at one or more desired locations along the sole or a foam material that reduces stress or impact energy on the foot or leg when the user runs, walks, or engages in other activities. The sole may also include additional components, such as a plate, which is embedded in the sole to increase the overall rigidity of the sole and reduce energy during use.

[0003] The upper generally extends upward from the sole and defines an interior cavity that completely or partially encases the foot. Often, the upper extends over the instep and toe areas of the foot, across the medial and lateral surfaces of those areas. Many articles of footwear also include a tongue that extends across the instep area, bridging the gap between the edges of the medial and lateral surfaces of the upper and defining an opening to the cavity. The tongue is also positioned below the lacing system and between the medial and lateral surfaces of the upper, allowing for adjustment of the tightness of the shoe. The tongue can also be manipulated by the user to allow the foot to move in and out of the interior space or cavity. The lacing system also allows the user to adjust certain dimensions of the upper or sole, thereby allowing the upper to fit a wide variety of foot types having different sizes and shapes.

[0004] Many shoe sole structures include a wide variety of materials that may be utilized to form the sole structure and selected for use based on one or more intended uses of the shoe. The sole structure may also include various materials specific to particular regions of the sole structure. For example, reinforcements may be included in the forefoot or heel regions of the sole structure to provide greater resistance or stiffness, improving stability and energy return, while other portions of the shoe may include greater flexibility or cushioning. Summary of the Invention [Problem to be solved by the invention]

[0005] There is a continuing need for footwear with reinforcements for stability, energy return, comfort, and light weight, as well as efficient methods for manufacturing footwear with such reinforcements. [Means for solving the problem]

[0006] The footwear described herein can have a variety of configurations.

[0007] In some aspects, a method of manufacturing footwear includes forming a sole structure using an additive manufacturing system. The sole structure includes a conduit extending within a region of the sole structure. The conduit includes an end projecting outwardly from a surface of the sole structure and a channel extending therethrough. The method further includes connecting the end of the conduit to an injection device, injecting a reinforcing material into the channel of the conduit to form a reinforcing member, and removing a portion of the end of the conduit.

[0008] In some embodiments, the sole structure includes a lattice region having a lattice structure including a plurality of beams interconnected by a plurality of nodes to define a plurality of voids. In some embodiments, the sole structure includes a midfoot region located between the forefoot region and the heel region, a top surface opposite the bottom surface, and a lateral surface opposite the medial surface, and the conduit is disposed within each of the forefoot region, midfoot region, and heel region, with an end of the conduit adjacent to at least one of the top surface or the bottom surface. In some embodiments, the sidewall extends from the lateral surface to the medial surface and from the forefoot region to the heel region, and the end of the conduit is disposed along at least one sidewall of the heel region or the forefoot region.

[0009] In some embodiments, the method further includes creating a design model of the sole structure including the arrangement of the conduits. An additive manufacturing system can be configured to receive the design model and form the sole structure. In some embodiments, the method further includes curing the reinforcing material in the sole structure. Curing can include applying at least one of heat, light, or electricity to harden the material. In some embodiments, the sole structure is composed of a material different from the reinforcing material injected into the conduits to form the reinforcing material. In some embodiments, the conduits extend continuously between opposite first and second ends, and the injection device is configured to connect to both the first and second ends. In some embodiments, the reinforcing material includes continuous fiber bundles and a resin material. In some embodiments, the injection device is configured to generate a pressure differential across the channels of each conduit. In some embodiments, the channels are at least partially filled with the reinforcing material. In some embodiments, the channels are completely filled with the reinforcing material.

[0010] In some embodiments, a system for manufacturing footwear includes an additive manufacturing system configured to form a sole structure having a lattice structure and at least one conduit extending through a region of the lattice structure. The system further includes an injection device connected to an end of the at least one conduit and configured to inject a reinforcing material into a channel defined by the at least one conduit. The system also includes a tool configured to remove at least a portion of the end of the at least one conduit.

[0011] In some embodiments, the reinforcing material comprises a resin material infused into the channel in a liquid state. In some embodiments, the injector introduces the resin material simultaneously with the continuous fiber bundle. In some embodiments, the injector introduces the continuous fiber bundle and the resin material sequentially. In some embodiments, the system further includes a curing module, where the curing module cures the reinforcing material to form a reinforcing material having a higher density than the material of the sole structure. In some embodiments, the region of the sole structure is anisotropic. In some embodiments, the region of the sole structure comprises at least one of a forefoot region, a midfoot region, or a heel region. In some embodiments, the lattice structure comprises a plurality of beams and a plurality of nodes forming at least one of a triangular pattern or a gyroid pattern. In some embodiments, the plurality of beams comprises at least one beam that curves between opposing ends. In some embodiments, the plurality of beams comprises at least one beam that extends linearly between opposing ends.

[0012] In some embodiments, a sole structure for footwear includes a midsole including a plurality of beams interconnected by a plurality of nodes to form a lattice structure, and a plurality of reinforcements. The plurality of reinforcements include channels, a reinforcing material disposed within the channels and including fiber bundles and a resin, and an inlet end fluidly connected to an outlet end by the channels. The sole structure further includes an outsole applied to a bottom surface of the midsole, and an upper attached to an upper surface of the sole structure.

[0013] In some embodiments, the channel of each of the plurality of reinforcements extends continuously from the inlet end to the outlet end. In some embodiments, the fiber bundle extends continuously from the inlet end to the outlet end through at least one of the plurality of reinforcements. In some embodiments, the channel of at least one of the plurality of reinforcements has a cross-sectional shape selected from the group consisting of circular, polygonal, and non-polygonal. In some embodiments, the channel of at least one of the plurality of reinforcements varies in diameter between the inlet end and the outlet end. In some embodiments, at least one of the inlet end and the outlet end includes a beveled or chamfered edge. In some embodiments, the plurality of reinforcements includes an outer reinforcement, a central reinforcement, and an inner reinforcement spaced apart from one another along the midsole. In some embodiments, the outer reinforcement protrudes from the outer sidewall of the sole structure, and the inner reinforcement protrudes from the inner sidewall of the sole structure.

[0014] In some embodiments, a method of manufacturing footwear includes providing a sole plate having a plurality of recesses and a plurality of cleat ports, forming a support structure and at least one conduit on the sole plate, and further including introducing a reinforcing material into the at least one conduit to form a reinforcing member, and molding a plurality of cleats in locations corresponding to the plurality of cleat ports to form a sole structure.

[0015] In some embodiments, the method further includes attaching an upper to the top of the sole structure. The upper is disposed above the support structure and the at least one conduit, and the plurality of cleats is disposed at the bottom of the sole structure. In some embodiments, the step of introducing reinforcing material into the at least one conduit to form a reinforcing member includes connecting an end of the at least one conduit to an injection device. In some embodiments, the support structure and the at least one conduit are molded into the sole structure by the molding material during the step of molding the plurality of cleats. In some embodiments, the support structure is disposed directly between at least one of the plurality of cleats and the upper surface of the sole structure. In some embodiments, the support structure includes a plurality of support regions. At least one of the plurality of support regions is disposed spaced apart from the other of the plurality of support regions.

[0016] In some embodiments, a method for manufacturing a sole structure includes providing a sole plate and additively forming a plurality of support regions and at least one conduit on the sole plate. The at least one conduit includes a channel defined therethrough. The at least one conduit extends through a portion of at least one of the plurality of support regions. The method further includes injecting a reinforcing material into the plurality of support regions and the at least one conduit to form a reinforcing member. The method also includes molding the sole plate having the plurality of support regions and the at least one conduit with a covering material.

[0017] In some embodiments, the covering material forms a plurality of cleats. In some embodiments, at least one of the plurality of support regions is disposed directly between at least one of the plurality of cleats and the upper surface of the sole structure. In some embodiments, At least one of the plurality of support regions is partially disposed within at least one of the plurality of cleats. In some embodiments, the sole plate includes a plurality of recesses. The plurality of support regions are disposed within the plurality of recesses.

[0018] In some embodiments, a sole structure for footwear includes a sole plate having a plurality of recesses and a plurality of support regions disposed within the sole structure and adjacent to the sole plate. Each of the plurality of support regions includes a plurality of beams interconnected by a plurality of nodes to form the support structure. The sole structure further includes at least one reinforcing member extending within the sole structure. All of the at least one reinforcing member is disposed within the plurality of support regions. Each of the plurality of reinforcing members defines a channel with a reinforcing material disposed within the channel. The reinforcing material within each channel includes fiber bundles and resin.

[0019] In some embodiments, the sole structure includes a plurality of cleats. In some embodiments, each of at least two of the plurality of support regions is disposed directly between at least one of the plurality of cleats and an upper surface of the sole structure. In some embodiments, at least one of the plurality of support regions is disposed partially within at least one of the plurality of cleats. In some embodiments, the plurality of support regions include a lateral metatarsal support and a medial metatarsal support disposed at a distance from one another. In some embodiments, the lateral metatarsal support and the medial metatarsal support are connected by a plurality of support links. In some embodiments, one of the plurality of reinforcing members extends within the lateral metatarsal support. In some embodiments, the plurality of support regions are covered within the sole structure by a covering material that is visible through the sole structure from outside the footwear.

[0020] Other aspects, including features and advantages of the footwear, will be readily apparent to those skilled in the art upon review of the drawings and detailed description herein, and all such aspects of the footwear are therefore intended to be included in the detailed description and this summary. [Brief explanation of the drawings]

[0021] [Figure 1] FIG. 1 is a schematic diagram of a system for manufacturing a component according to an embodiment of the present disclosure. [Figure 2]2 is a perspective view of an embodiment of a component formed in connection with the system of FIG. 1. [Figure 3] FIG. 10 is a perspective view of the top, outer surface, and toe tip of another embodiment of a component. [Figure 4] 4 is a perspective view of footwear including the components of FIG. 3, the components shown in a completed configuration. [Figure 5] FIG. 4 is a top view of the component of FIG. 3. [Figure 6] FIG. 4 is a bottom view of the component of FIG. 3. [Figure 7] FIG. 4 is a side view of the outer surface of the component of FIG. 3. [Figure 8] FIG. 4 is a side view of the inner surface of the component of FIG. 3. [Figure 9] 9 is a cross-sectional view of the component of FIG. 3 taken along line 9-9 of FIG. 6. [Figure 10] 10 is a cross-sectional view of the component of FIG. 3 taken along line 10-10 of FIG. 6. [Figure 11] 11 is a cross-sectional view of the component of FIG. 3 taken along line 11-11 of FIG. 6. [Figure 12] FIG. 2 is a perspective view of the bottom, lateral side, and toe cap of another embodiment of a component formed in connection with the system of FIG. 1, showing an outsole on the component. [Figure 13] FIG. 13 is a bottom view of the component of FIG. 12. [Figure 14] FIG. 13 is a top view of the component of FIG. 12. [Figure 15] FIG. 13 is a side view of the lateral surface of FIG. 12 with the outsole removed. [Figure 16] FIG. 13 is a side view of the medial side of FIG. 12 with the outsole removed. [Figure 17] FIG. 13 is a perspective view of footwear including the component of FIG. 12. [Figure 18] 2 is a perspective view of a top, exterior, and toe tip of another embodiment of a component formed in connection with the system of FIG. 1. FIG. [Figure 19] FIG. 19 is a bottom view of the component of FIG. 18. [Figure 20] FIG. 19 is a perspective view of the top, outer side, and toe tip of the component of FIG. 18, showing a footboard on the component. [Figure 21] 2 is a flowchart of an example method of forming an article of manufacture that includes components formed in connection with the system of FIG. 1 . [Figure 22] 2 is a schematic diagram of a cross-sectional view of another embodiment of a component formed in association with the system of FIG. 1. [Figure 23] 2 is a schematic diagram of a cross-sectional view of another embodiment of a component formed in association with the system of FIG. 1. [Figure 24] 2 is a schematic diagram of a cross-sectional view of another embodiment of a component formed in association with the system of FIG. 1. [Figure 25] 2 is a bottom view of one embodiment of a sole chassis of a pre-finished sole structure formed in connection with the system of FIG. 1. FIG. [Figure 26] FIG. 26 is a top view of the sole chassis of FIG. 25. [Figure 27] FIG. 26 is a top view of the sole chassis of FIG. 25 in a completed state. [Figure 28] FIG. 28 is a schematic diagram of a cross-sectional view of the component of FIG. 27. [Figure 29] 29 is a flowchart of an example of a method for forming the sole structure of FIGS. 25 to 28. [Figure 30] FIG. 2 is a top view of another embodiment of a sole chassis of a sole structure associated with the system of FIG. 1. [Figure 31A] FIG. 1 is a schematic diagram of a cross-sectional view of a bonded mold according to an embodiment of the present disclosure. [Figure 31B] FIG. 31B is a schematic diagram of another embodiment of a component manufactured using the bonded mold of FIG. 31A. [Figure 32] FIG. 10 is a schematic diagram of yet another embodiment of a sole structure according to an embodiment of the present disclosure. [Figure 33] FIG. 10 is a schematic diagram of yet another embodiment of a sole structure according to an embodiment of the present disclosure. [Figure 34] FIG. 33 is a side view of an embodiment of a sole structure formed in relation to the schematic view of FIG. 32 or FIG. 22. [Figure 35] FIG. 2 is a schematic diagram of a cross-sectional view of a mold according to an embodiment of the present disclosure. [Figure 36A] FIG. 1 is a schematic diagram of a mold according to an embodiment of the present disclosure. [Figure 36B] FIG. 36B is a perspective view of another embodiment of a sole structure manufactured using the mold of FIG. 36A. DETAILED DESCRIPTION OF THE INVENTION

[0022] The following description and accompanying drawings disclose various embodiments or configurations of shoes and sole structures. While shoe or sole structure embodiments are disclosed with reference to athletic shoes, such as running shoes, tennis shoes, and basketball shoes, the concepts associated with shoe or sole structure embodiments may be applied to a wide range of footwear and footwear styles, such as cross-training shoes, football shoes, golf shoes, hiking shoes, hiking boots, ski and snowboard boots, soccer shoes and cleats, walking shoes, and track cleats. The shoe or sole structure concepts may also be applied to footwear considered non-athletic, such as dress shoes, sandals, loafers, slippers, and heels. In addition to footwear, certain concepts described herein may also be applied to and incorporated into other types of apparel or other athletic equipment, such as helmets, padding or protective padding, shin guards, and gloves. Furthermore, certain concepts described herein may also be incorporated into cushions, backpack straps, golf clubs, and other consumer and industrial products. Accordingly, the concepts described herein may be utilized in a variety of products.

[0023] The present disclosure relates to systems and methods for manufacturing sole structures having conduits configured to be at least partially filled with a composite material that reinforces or strengthens the sole structure upon curing or solidification. Thus, the sole structure includes conduits extending into a region of the sole structure, such as a midsole. Each end of the conduits is connected to an injection device that can introduce composite material into the channel of each conduit. The composite material in the conduits is then cured or solidified to form a reinforcement. Thus, the reinforcement is comprised of the reinforcement material, i.e., the cured and / or processed composite material, and is disposed within an internal cavity, channel, or circuit within the sole structure. Using additive manufacturing systems and methods, sole structures including conduits of various configurations, quantities, sizes, and shapes can be printed, allowing for optimization or customization of the reinforcement within the sole structure. In particular, the configuration, quantity, size, and shape of the reinforcement are achieved by designing, arranging, and building the sole structure with the conduits using additive manufacturing techniques. To further enhance optimization and customization capabilities, additive manufacturing allows users to create sole structures with complex shaped lattice regions, such as gyroid structures, auxetic structures, triangular or polygonal lattice structures, etc. Using additive manufacturing systems and methods, the sole structure and the conduits therein can be formed from the same or different materials and printed layer-by-layer into a single component, saving time and reducing waste compared to traditional or subtractive manufacturing methods. Using the systems and methods described herein, the sole structure can be reinforced with composite materials including continuous fiber bundles, such as carbon fiber, aramid fiber, glass fiber, boron fiber, or natural or organic fibers. Thus, after curing and strengthening the composite material within the sole structure, a high-performance reinforcing material is obtained, which reduces the number of steps and components involved in manufacturing footwear and reduces structural defects and quality variations.

[0024] 1 shows a schematic diagram of a system 100 that includes a manufacturing module 104 for manufacturing a footwear component 108, an infusion module 112 for introducing a composite reinforcement material into the component 108, a curing module 116 for treating or curing the composite material in the component 108, a finishing module 120 for performing finishing operations such as trimming, cutting, grinding, polishing, etching, engraving, or other post-processing operations (e.g., foaming or coating operations), and an assembly module 124 for assembling the component 108 into footwear. In some embodiments, the manufacturing module 104 includes an additive manufacturing device or system, sometimes referred to herein as a 3D printer or 3-D printer. In some embodiments, the manufacturing module 104 includes an injection molding system, a co-molding system, a compression molding system, a foaming system, a loom, a winding system, or any suitable manufacturing device or system for manufacturing the footwear component 108.

[0025] Additive manufacturing is preferred for manufacturing components according to the present disclosure. The additive manufacturing process used by manufacturing module 104 can be performed using a 3D printer, such as a printer manufactured by Formlabs®, HP®, or MarkForged®, that can receive a design model and generate printing instructions for printing the component. The design model can be an electronic three-dimensional representation of the component intended to be incorporated into the footwear. In some embodiments, the design model can be in the form of a 3D CAD file, a 3D stereolithography file (.STL file), or any file compatible with a web- or cloud-based design program, such as Eiger® from MarkForged®. Various additive manufacturing methods can be used to manufacture footwear components according to the present disclosure. These methods include binder jetting, direct energy deposition (DED), selective laser sintering (SLS), multi-jet fusion (MJF), selective laser melting (SLM), fused deposition modeling (FDM), electron beam melting (EBM), laser driven bed fusion (LPBF), ultrasonic additive manufacturing, material extrusion, material jetting, Joule printing, electrochemical deposition, cold spray metal fabrication, DLP metal fabrication, ultrasonic solidification or ultrasonic additive manufacturing (UAM), LENS laser-based fabrication, bath photopolymerization, sheet lamination, or electron beam freeform fabrication (EBF3).

[0026] 1 , manufacturing module 104 may further include various processing machines or systems such as milling, grinding, polishing, trimming or cutting, stamping, drilling, compressing, tensioning, etc. In some cases, manufacturing module 104 includes an additive manufacturing system for forming conduit 128 of component 108 and also includes a processing system for preparing conduit 128 for use in injection module 112, such as by reducing surface roughness within channel 152.

[0027] The injection module 112 may include an insertion module configured to introduce a resin 136 and a fiber bundle 140 into at least one conduit 128 of the component 108 to provide the component 108 with a reinforcement material 132. The reinforcement material 132 includes the resin 136 and the fiber bundle 140. The conduit 128 is thus a hollow tubular structure having a first end 144 opposite a second end 148 and defining a channel 152 extending between the first end 144 and the second end 148. As shown in FIG. 1 , the injection module 112 may be operatively and removably connected to the first end 144 and the second end 148 of the conduit 128 of the component 108. Accordingly, one of the first end 144 or the second end 148 may be referred to herein as an inlet end, and the other may be referred to as an outlet end. The first end 144 and the second end 148 are configured to be fluidly connected to one another via the channel 152 of the conduit 128. In some embodiments, the injection module 112 is operatively and removably connected to only one of the first end 144 or the second end 148. In some embodiments, the injection module 112 is configured to introduce the fiber bundle 140 simultaneously with introducing the resin 136 in a liquid state or form into the channel 152 of the conduit 128. In some embodiments, the injection module 112 is configured to sequentially insert the fiber bundle 140 and the resin 136 at different times or stages, such as introducing the fiber bundle 140 before introducing the resin 136 or introducing the resin 136 before the fiber bundle 140.

[0028] Continuing to refer to FIG. 1 , the infusion module 112 is configured to exert a pushing force and / or a pulling force on the resin 136 and the fiber bundle 140 using a pressurized fluid, such as a gas, a liquid, a slurry, or a combination thereof. For example, the pressurized fluid may be the resin 136 in a liquid state, or the pressurized fluid may be a gas such as air or an inert gas such as nitrogen. Thus, the infusion module 112 may be connected to both the first end 144 and the second end 148 of the conduit 128 to apply a pressure differential across the conduit 128. In this case, a negative pressure or vacuum is applied to the outlet end and a positive pressure is applied to the inlet end. In some embodiments, the infusion module 112 applies only a positive pressure to the inlet end or only a negative pressure to the outlet end. In some embodiments, the injection module 112 uses mechanical forces, such as clamps, plungers, tethers, hooks, screw conveyors or augers, rollers, or pulley systems, or combinations thereof, to pull or push the reinforcement material 132 through the channel 152 of the conduit 128. To assist in this operation, the injection module 112 may be configured to receive feedback signals 156 to sense, measure, detect, and / or determine various parameters associated with the introduction of the reinforcement material 132 into the conduit 128. For example, the feedback signals 156 may relate to distance, pressure, temperature, mass, volume, conductivity, friction, etc.

[0029] As described above, the infusion module 112 is configured to introduce a fiber bundle 140 or multiple fiber bundles 140, which may include continuous fiber bundles or filaments including at least one of carbon fiber, aramid fiber, glass fiber, or metal or metal alloy filaments. The fiber bundles 140 of the reinforcing material 132 are configured to provide stiffness, stability, and strength, thereby reinforcing, stabilizing, or strengthening the component 108 in selected portions, regions, and directions. In some embodiments, the fiber bundles 140 include at least one optical fiber that enables light and / or signal transmission throughout the conduit 128 of the component 108. In some cases, the optical fiber can form part of a mechanical stress or deformation sensor or monitor other mechanical properties of the component 108. The fiber bundles 140 may include organic materials such as flex fiber, hemp fiber, or bamboo fiber. The fiber bundles 140 can be constructed of copper, steel, or other metallic materials to provide thermal or electrical conductivity to the component. The fiber bundle 140 can be composed of braided or unbraided, wound or unwound, entangled or parallel fibers. The fiber bundle 140 can be composed of fibers having a diameter of about 5 microns to about 25 microns, and the fiber bundle 140 can include 500 or more fibers. If the fiber bundle 140 is composed of continuous fibers or filaments, the fiber bundle 140 can extend continuously from the first end 144 to the second end 148 through the channel 152 of the conduit 128.

[0030] Continuing to refer to FIG. 1 , the injection module 112 can inject the resin 136, which can be a heat-resistant resin or a thermoplastic resin. For example, a thermoplastic resin is a material that is solid at room temperature and melts above a threshold temperature, such as polypropylene (PP), polyamide (PA), polyethylene (PE), styrene butadiene acrylonitrile (SBA), polylactic acid (PLA), etc. A heat-resistant resin is a resin that is liquid at room temperature and solidifies during a curing process, such as epoxy resin, polyester resin, vinyl ester resin, phenolic resin, etc. Compared to thermoplastic resins, heat-resistant resins decompose or burn above a certain temperature and have lower viscosities than thermoplastic resins, which improves fiber impregnation and makes it easier to introduce fibers combined with the resin into the conduit 128. In some embodiments, the resin 136 advantageously contributes to the introduction of the fiber bundles 140 into the channels 152 of the conduit 128. When cured and solidified, the resin 136 serves as a bonding interface between the fiber bundles 140 and the component 108. The fabrication module 104 can mold the components 108 and the conduits 128 from the same type of photosensitive resin used in the reinforcement material 132 so that they can be cured by exposure to various forms of light. In some cases, the resin 136 used in the reinforcement material 132 shares properties with the material used to form the components 108 or the conduits 128. In some embodiments, the resin 136 differs in curing characteristics from the material of the components 108 or the conduits 128. For example, the resin 136 is a temperature-curable material, and the components 108 or the conduits 128 are light-curable materials. Additionally, the material of the components 108 or the conduits 128 has a different appearance (e.g., color, texture, grain, etc.) than the material of the resin 136, thereby allowing them to be visually distinguished.

[0031] Continuing with reference to FIG. 1 , the injection module 112 is configured to selectively fill the channels 152 of the conduit 128 with the reinforcing material 132. In some embodiments, the channels 152 are only partially filled with the reinforcing material 132. This may be advantageous, for example, when the conduit 128 is configured to be at least partially trimmed or removed from the component 108. For example, portions of the first end 144 and / or second end 148 may include volumes without reinforcing material to facilitate removal of such portions via the finishing module 120. In some embodiments, the channels 152 are completely filled with the reinforcing material 132. By varying the proportions of resin 136 and fiber bundles 140 that comprise the reinforcing material 132, the functionality and properties of the reinforcing material 132 can be selectively adjusted or modified to achieve particular desired properties within the component 108. For example, increasing the proportion of fiber bundles 140 may increase stiffness or strength, while increasing the proportion of resin 136 may reduce mass and improve adhesion within the conduit 128.

[0032] The curing module 116 is configured to cure the composite reinforcement material 132, including the resin 136, introduced into the conduit 128 by the injection module 112. To that end, the curing module 116 can apply heat, light, electromagnetic waves, or a combination thereof. In some applications, the curing module 116 can include applying tension or compression, such that, after curing, the reinforcement material 132 and the component 108 can be pre-tensioned or pre-compressed to impart desired behavior or performance characteristics to the component 108. After the reinforcement material 132 has cured within the component 108, the conduit 128 and the cured reinforcement material 132 contained therein are referred to as a reinforcement or reinforcement member 160 (see, for example, FIG. 4 ). Embodiments of the conduits 128 disclosed herein are also applicable to the reinforcement members 160 arising from or associated with those conduits 128. For example, aspects described herein regarding the position, shape, size, relative dimensions, function, etc. of the conduits are also applicable to reinforcing members formed from those conduits using the systems and methods described herein.

[0033] As described above, finishing module 120 is configured to perform post-processing or finishing operations on component 108. Finishing module 120 may include tools configured to trim, cut, grind, polish, etch, drill, or engrave component 108. For example, finishing module 120 may be a trimming tool for removing a portion of conduit 128, such as trimming first end 144 or second end 148.

[0034] In some embodiments, one or more conduits 128 of the component 108 are selected to function as part of a cooling circuit through which a cooling fluid (not shown), such as water, glycol, refrigerant, ammonia, air, or any suitable medium, may be passed to transfer heat from the component 108. This transfer may occur in connection with the infusion module 112, the curing module 116, or the finishing module 120. Accordingly, such conduits 128 selected for use in the cooling circuit are configured to remain empty so that a composite mixture including resin and continuous fiber bundles is not introduced by the infusion module 112.

[0035] FIG. 2 illustrates one embodiment of a component 108 that may be part of a sole structure for footwear. In the illustrated embodiment, the component 108 comprises a support or lattice structure 170 formed of a plurality of beams 174 interconnected at a plurality of nodes 178 and defining a plurality of voids 182 between and / or between the plurality of beams 174 and the plurality of nodes 178. The plurality of beams 174 may be referred to herein as beams, segments, ribs, or struts. The plurality of nodes 178 may be referred to herein as nodes, intersections, or junctions. The plurality of voids 182 may be referred to herein as voids, openings, or open spaces. In the illustrated embodiment, the beams 174 vary in beam length, beam thickness, and beam shape. In some embodiments, the beams 174 extend linearly between the nodes 178. In some embodiments, the beams 174 extend curved, circuitous, or non-linearly between the nodes 178. In some embodiments, the beams 174 are solid structures. In some embodiments, the beams 174 are formed as hollow tubular structures. In some embodiments, regions or portions of the lattice structure 170 are warped, twisted, curved, stretched, distorted, or condensed, such that the density of the lattice structure 170 varies between portions or regions thereof.

[0036] The lattice structure 170 is divided into a number of unit cells 186 that form a repeating pattern, with the unit cells 186 repeating in different directions to define the lattice structure 170. The lattice structure 170 can have unit cells 186 of various shapes, such as triangular, cubic, pyramidal, elliptical, polygonal, irregular, etc. The unit cell 186 can be at least one of a simple cube, a body-centered cube, a face-centered cube, a prismatic, a diamond, a fluorite, an octet, a truncated cube, a truncated octahedron, a Kelvin cell, an isotonic, a reentrant, a Weissfeld, a triangular honeycomb, a rotated triangular honeycomb, a hexagonal honeycomb, a reentrant honeycomb, a rotated square honeycomb, a square honeycomb, a face-centered cubic form, a body-centered cubic form, a simple cubic form, a hexagonal prism diamond, a hexagonal prism vertex centroid, a hexagonal prism edge, a hexagonal prism Reeves phase, a hexagonal prism central axis edge, a square octet vertex centroid, an octet vertex centroid, or a dodecahedron. The lattice structure 170 can be formed by a differential geometric structure. For example, the lattice structure 170 can be formed by a gyroid pattern including a plurality of interconnected periodic minimal faces. The gyroid pattern can define a plurality of unit cells 186 that are repeated in a pattern across a desired volume. In general, the use of differential geometric structures (e.g., gyroid patterns) can reduce stress concentrations formed along the lattice structure 170 due to the reduction of sharp angles formed on the lattice structure. In some embodiments, the lattice structure 170 is formed without sharp angles, and each corner, interface, edge, and intersection has a radius of curvature. In some embodiments, the lattice structure 170 is composed of irregular beams, where the beams 174 do not form a repeating pattern in different directions but have unique shapes relative to one another. This allows the lattice structure 170 to have an organic, biological, or natural appearance. Furthermore, the lattice structure 170 can be classified or described based on its functionality or performance characteristics, such as, for example, auxetic, rubbery, isotropic, or anisotropic.

[0037] The lattice structure 170 may be referred to herein as a lattice array, structural array, gridwork, framework, skeleton, or scaffold. The lattice structure 170 occupies a support region or lattice area 190 having an entire lattice volume bounded by a surface defined by the outermost perimeter points 194 of the lattice structure 170, the entire lattice volume encompassing the voids 182 of the lattice structure 170. In other words, the lattice area 190 covers, occupies, or spans the entire lattice volume. The infill volume is occupied by the lattice body, including the beams 174 and nodes 178, but excluding the voids 182. The infill volume may be between about 5% and about 90% of the entire lattice body. In some embodiments, the infill volume may be between 20% and 80%, 30% and 70%, 40% and 60%, 5% and 20%, 5% and 30%, 5% and 40%, 5% and 50%, or 45% and 75% of the entire lattice body. In some embodiments, the lattice structure 170 defines an effective density, defined as the lattice mass divided by the total lattice volume, where the effective density varies throughout the lattice structure 170. In some embodiments, the lattice structure 170 is printed with the conduits 128 using a 3D printer, so that the conduits 128 are included as part of the lattice mass and, therefore, as part of the effective density. Effective density is measured in grams per cubic centimeter (g / cm 3 ) and 0g / cm 3 to 2.00 g / cm 3 In some embodiments, the effective density can range from 0.001 g / cm 3 ~1.99g / cm 3 , 0.05g / cm 3 ~1.95g / cm 3 , 0.10g / cm 3 ~1.90g / cm 3 , 0.50g / cm 3 ~1.50g / cm 3 , 0.75g / cm 3 ~1.25g / cm 3 , or 1.00 g / cm 3 ~1.15g / cm 3 may be.

[0038] Referring to FIG. 2 , the component 108 includes three conduits 128 spaced apart from one another and extending across the component 108 through a lattice structure 170. Thus, the lattice structure 170 can connect to the conduits 128 at various locations or junctions. In some embodiments, at least one of the beams 174, at least one of the nodes 178, or both, terminates or connects to the conduits 128 at the first end 144 and / or the second end 148, or at a location between the first end 144 and the second end 148. Each of the conduits 128 includes a channel 152 extending from the first end 144 to the second end 148. In the illustrated embodiment, the channel 152 is shown as having a circular or round cross-sectional shape, although other configurations are contemplated. In some embodiments, the cross-sectional shape of the channel 152 is selected from the group consisting of an elliptical, a polygonal, a circular, or a non-polygonal shape. For clarity, examples of polygons include squares, rectangles, pentagons, hexagons, octagons, and decagons. In the illustrated embodiment, first end 144 is shown as having a planar or flat edge 198. However, in other embodiments, edge 198 may be non-planar, such as, for example, angled, beveled, chamfered, rounded, notched, or castellated.

[0039] In some embodiments, the conduits 128 are integrally formed with the component 108 via the manufacturing module 104 by an additive manufacturing system or method, such that the lattice structure 170 and the conduits 128 are printed as a single unit. In some embodiments, the conduits 128 are inserted into a mold, and the component 108 is formed around each conduit 128 by a molding process, such as injection molding, compression molding, co-molding, or the like. In some embodiments, the conduits 128 are inserted into and / or through the lattice structure 170 during or after the formation of the lattice structure 170, e.g., along preformed channels or receptacles configured to receive the conduits 128. Thus, the conduits 128 may be considered separate or distinct structures from the lattice structure 170 of the component 108. In some embodiments, the conduits 128 and the component 108 may be formed of the same material as one another. In some embodiments, the conduits 128 and the component 108 are formed of different materials as one another. In some embodiments, the component 108 and the conduit 128 are made of materials that differ from one another in at least one material property, such as density, hardness, tensile strength, or melting point. The reinforcing material 132 has a higher stiffness, stiffness, density, or hardness, or a combination thereof, than the corresponding property of the material used to form the component 108 or the conduit 128. Preferably, the component is formed of a resilient or elastomeric material, and the reinforcing material 132 provides the stiffness, hardness, and / or density to the component 108. In some embodiments, the component 108 is formed of a polymeric material, such as thermoplastic polyamide elastomer (TPA) or thermoplastic polyurethane (TPU). Such materials can be supplied to the additive manufacturing system in powder form. Preferably, the reinforcing material 132 has a higher density than the density of the material used to form the component 108, including the conduit 128 and the lattice structure 170.

[0040] In some embodiments, the reinforcement density of the reinforcement material 132 is about 0.50 g / cm 3 ~About 3.00g / cm 3 , or about 0.75 g / cm3 ~Approx. 2.75g / cm 3 , or approximately 1.00 g / cm 3 ~Approx. 2.50g / cm 3 , or approximately 1.25 g / cm 3 ~Approx. 2.25g / cm 3 In some embodiments, the reinforcement density of the reinforcement material 132 is about 1.45 g / cm 3 In some embodiments, the reinforcement density of the reinforcement material 132 is 3.00 g / cm 3 In some embodiments, the component material density of the material of component 108 is greater than about 0.25 g / cm 3 ~Approx. 2.50g / cm 3 , about 0.50g / cm 3 ~Approx. 2.00g / cm 3 , about 0.75g / cm 3 ~Approx. 1.50g / cm 3 , or approximately 1.00 g / cm 3 ~Approx. 1.25g / cm 3 In some embodiments, the component material density is about 1.01 g / cm 3 In some embodiments, the component material density is about 1.10 g / cm 3 In some embodiments, the component material density is 0.25 g / cm 3 is less than.

[0041] Thus, to reinforce the component 108, the reinforcement density is selectively set to be greater than the component material density. In some embodiments, the ratio of the minimum component density to the maximum reinforcement density is about 12:1. In some embodiments, the ratio of the maximum component density to the minimum reinforcement density is about 1.2:1. It is understood that the ratio of the component material density to the reinforcement density can vary between the minimum and maximum values, such as from about 12:1 to about 1.2:1. In some embodiments, the ratio of the component material density to the reinforcement density is about 1.43:1, or in other words, the reinforcement density is about 43.56% greater than the component material density. In some embodiments, the ratio of the component material density to the reinforcement density is about 1.31:1, or in other words, the reinforcement density is about 31.81% greater than the component material density.

[0042] For clarity, this disclosure refers to directional coordinates X, Y, and Z. Specifically, the X direction corresponds to an outside-to-inside direction perpendicular to the longitudinal direction along which the longitudinal axis L extends, the Y direction corresponds to a longitudinal direction parallel to the longitudinal axis L, and the Z direction corresponds to a vertical direction perpendicular to the X and Y directions. The term "in-plane" is also used herein to refer to a two-dimensional plane extending in the X and Y directions and perpendicular to the Z direction. It is further understood that the longitudinal axis L also defines a longitudinal plane LP extending perpendicular to the Z direction.

[0043] As shown in FIG. 2 , the conduits 128 extend in multiple directions within the component 108, e.g., curving downward in the −Z direction and extending axially in the +X direction. Each conduit 128 defines a central axis 202 extending from a first end 144 to a second end 148, with the central axis 202 being representatively shown in only one of the conduits 128. The conduits 128 define a length LL1 measured along the central axis 202 from the first end 144 to the second end 148. As shown in FIG. 2 , the component 108 includes multiple conduits 128, and the conduits 128 may have different lengths LL1. In the illustrated embodiment, the conduits 128 have conduit walls 206 that define an outer radius OR and an inner radius IR relative to the central axis 202. The outer radius OR and / or the inner radius IR may vary along the conduit 128 between the first end 144 and the second end 148. In some embodiments, the inner radius IR and the outer radius OR are constant along the conduit 128 between the first end 144 and the second end 148. As shown in FIG. 2 , the component 108 includes multiple conduits 128, and the conduits 128 may have different outer radii OR or inner radii IR relative to one another. The outer radius OR and the inner radius IR are mathematically related to the outer diameter OD and the inner diameter ID, respectively, by known equations, and therefore it is understood within the scope of this disclosure for the conduits 128 to have corresponding outer diameters OD and inner diameters ID.

[0044] As referenced herein, the thickness of each conduit 128 may be defined relative to an outer diameter (OD) or its equivalent. In some embodiments, the conduit 128 defines a central axis 202 and may have a non-circular cross-sectional shape. In this case, the conduit 128 has an equivalent diameter, referred to as the thickness of the conduit 128. Similarly, the thickness of the channel 152 of each conduit 128 corresponds to an inner diameter (ID) or its equivalent. The thickness of the channel 152, the thickness of the conduit 128, or both may be constant or variable over the length (LL1) of each conduit 128. For example, the channel 152 of a conduit 128 may taper or narrow from the first end 144 to the second end 148. Also, the thickness of the channel 152, the thickness of the conduit 128, or both may vary between conduits 128, one being larger or smaller than the other. It is understood that the wall thickness of the conduit wall 206 is expressed as the difference between OR and IR. Thus, the wall thickness of the conduit wall 206 may vary along the conduit 128 between the first end 144 and the second end 148. As shown in Figure 2, the component 108 includes multiple conduits 128 having approximately uniform or constant wall thicknesses relative to one another. In some embodiments, the wall thicknesses of the conduits 128 may vary from one another.

[0045] In some embodiments, the wall thickness of the conduit wall 206 may be thicker than the maximum or minimum beam thickness of the beams 174 of the lattice structure 170. In some embodiments, the wall thickness of the conduit 128 may be thinner than the maximum or minimum beam thickness 210 of the beams 174. In some embodiments, the wall thickness of the conduit wall 206 may be proportional to the maximum or minimum beam thickness of the beams 174 of the lattice structure 170. For example, the ratio of the wall thickness of the conduit wall 206 to the maximum or minimum beam thickness of the beams 174 may be about 1:1, about 2:1, about 1:2, about 3:1, about 1:3, or about 5:1 or about 1:5. In the illustrated embodiment, the OR of the conduit 128 is greater than the maximum beam thickness 210 defined by the beams 174 of the lattice structure 170. In some embodiments, the OR of the conduit 128 is approximately equal to the maximum beam thickness 210 of the beams 174. In some embodiments, the OR of the conduit 128 is less than the maximum beam thickness of the beams 174.

[0046] As described above, the component 108 is designed with reinforcements arranged to impart strength characteristics, such as stiffness or resistance, in specific regions or in specific directions. Accordingly, the conduit 128 can define a central axis 202 that curves in one or more directions along the conduit 128 between the first end 144 and the second end 148. In some embodiments, the conduit 128 is straight and uncurved between the first end 144 and the second end 148, and thus the central axis 202 is also straight and uncurved. In some cases, the conduit 128 can form a corner (not shown) that defines an angle, such as a right angle, an acute angle, or an obtuse angle, and the central axis 202 has a corresponding angle. Thus, the central axis 202 is coincident with and defined by an extension of the conduit 128. The central axis 202 is centered within the channel 152 of the conduit 128 and intersects the first end 144 and the second end 148. In some embodiments, the channel 152 of the conduit 128 is uninterrupted and empty, and the central axis 202 does not intersect any portion of the conduit 128 or the component 108, including the lattice structure 170. In some embodiments, the channel 152 of the conduit 128 is interrupted by a portion of the component 108, such as the lattice structure 170 or the conduit wall 206, and the central axis 202 may intersect that portion of the component 108. In some embodiments, a portion of the component 108, such as the lattice structure 170 or the conduit wall 206, intersects or penetrates into the channel 152 without intersecting the central axis 202. For example, the conduit 128 may have ridges, protrusions, nodes, undulations, threads, valves, or other features (not shown) located within a portion of the channel 152 along the conduit wall 206, which may or may not intersect the central axis 202.

[0047] As used herein, the term "rigidity" refers to a component's ability to resist deformation when subjected to an applied load. Specifically, "rigidity" is described herein as elastic deformation, i.e., temporary deformation that is considered nondestructive. Therefore, "rigidity" may be used in conjunction with the terms "resistance" and "strength." Furthermore, "rigidity" may be described in terms of various directions, types of deformation, material properties, etc. For example, a component's "rigidity" may be classified as bending stiffness, tensile stiffness, or shear stiffness. Furthermore, a component's "rigidity" is correlated with the elastic modulus (E) of the material used, which can be quantified by the Young's modulus equation: E = σ / ε, where σ is the uniaxial stress, i.e., force per unit area, and ε is the strain, i.e., the rate of deformation. For clarity, "rigidity" may be more specifically defined herein to refer to specific types of resistance, such as bending resistance (BR) or torsional resistance (TR). In some cases, a component's "rigidity" may be quantified or calculated in terms of its dimensions, mass, or volume. For example, the "stiffness" of a component may be measured in Newtons per millimeter (N / mm) or gigapascals (GPa), although other units may be used. Furthermore, "stiffness" may be described in qualitative terms as high or low, or may be understood in relation to various aspects of the footwear, such as comfort, support, stability, rigidity, and durability.

[0048] In general, components constructed from composite fiber materials, such as continuous fiber bundles and resin, offer improved strength-to-weight ratios compared to sole structures made entirely of polymeric materials, metals, or no fibers. Composite fiber materials are often strongest in tension, but only in a specific direction—the axial direction in which the composite fiber material is under tension. Thus, a composite material with fiber material aligned in a single uniaxial direction will be strongest in that direction but exhibit different, e.g., weaker, properties in other directions. Thus, composite materials are considered to be anisotropic, i.e., exhibit a set of strength properties that differ in different directions. Anisotropy includes at least one of bending resistance, torsional resistance, tensile stiffness, and compressive stiffness. Anisotropy may vary from reinforcement to reinforcement. The component 108 can be variably reinforced to have anisotropy with lateral and medial reinforcement, vertical and horizontal reinforcement, curved and linear reinforcement, or a combination of these. In some embodiments, the region of the component containing reinforcement 160 exhibits quasi-isotropy. In addition to the stiffeners 160, the lattice structure 170 of the component 108 may also be configured to impart anisotropic, quasi-isotropic, or isotropic properties to the component 108.

[0049] The stiffness of the component 108 and / or its stiffeners 160 can be understood in terms of bending resistance BR and torsional resistance TR. Bending resistance BR is the mathematical relationship between lateral force and deflection, and is sometimes referred to herein as spring constant or stiffness. Similarly, torsional resistance TR is the mathematical relationship between torsional force and deflection, and is sometimes referred to as rotational stiffness. It is well known that bending resistance BR and torsional resistance TR are proportional to the elastic modulus of a material or material composition. Shape and dimensions are also proportional to bending resistance BR and torsional resistance TR, depending on the direction and location of the applied load. For example, dimensions defined in a direction parallel to the direction of the applied load have a significant impact on the specific resistance, such as when a bending load is applied in the Z direction and thickness is defined in the Z direction.

[0050] 3-11 illustrate one embodiment of a component 108 in the form of a sole structure 300 configured for use in the systems and methods disclosed herein. As shown in FIG. 3 , sole structure 300 has a toe tip 304 opposite a heel tip 308, a lateral side 312 opposite a medial side 316, and an upper portion 320 opposite a bottom portion 324. Sole structure 300 includes a forefoot region 328 adjacent to and including toe tip 304, a heel region 332 adjacent to and including heel tip 308, and a midfoot region 336 disposed between forefoot region 328 and heel region 332. Sole structure 300 further includes an upper rim 340 extending along a periphery 344 of upper portion 320 of sole structure 300 and at least partially surrounding an upper surface 348 of sole structure 300. Sole structure 300 also has a bottom surface 352 disposed on bottom 324 opposite top surface 348. In the illustrated embodiment, upper rim 340 is configured to extend continuously from forefoot region 328 along lateral surface 312 and medial surface 316, through midfoot region 336, and to heel region 332, enveloping heel tip 308, such that upper rim 340 at least partially surrounds top surface 348. Referring to FIGS. 3 and 4 , top surface 348 of sole structure 300 is configured to face upper 376 when assembled to sole structure 300.

[0051] The sole structure 300 also includes a midsole 356 extending between the upper portion 320 and the bottom portion 324. The midsole 356 may be constructed of a thermoplastic material, such as polyurethane (PU), and / or ethylene vinyl acetate (EVA), copolymers thereof, or similar materials. In other embodiments, the midsole 356 may be an EVA solid sponge ("ESS") material, EVA foam (e.g., PUMA® ProFoam Lite™, IGNITE Foam), polyurethane, polyether, olefin block copolymer, organic sheet, thermoplastic material (e.g., thermoplastic polyurethane, thermoplastic elastomer, thermoplastic polyolefin, etc.), or supercritical foam. The midsole 356 may be a single polymer material or a blend of materials, such as EVA copolymer, thermoplastic polyurethane, polyether block amide (PEBA) copolymer, and / or olefin block copolymer. One example of a PEBA material is PEBAX®. In some embodiments, the midsole 356 is manufactured by a process including injection molding, compression molding, foam molding, layer-by-layer printing, i.e., additive manufacturing systems or methods, and the like.

[0052] In the embodiment shown in FIGS. 3-11 , the midsole includes a support or lattice region 360 having a support or lattice structure 364 and conduits 128 extending therethrough. The lattice structure 364 is similar to the lattice structure 170 shown in FIG. 2 in that it includes a plurality of beams 174 interconnected by a plurality of nodes 178 and defining a plurality of voids 182. While the lattice structure 364 in FIGS. 3-11 is shown as a gyroid pattern, other configurations are contemplated. As discussed above in connection with FIG. 1 , the lattice structure 364 may have a varying effective density throughout the lattice region 360, including the midsole 356 of the sole structure 300, as shown in FIG. 2 . In the illustrated embodiment, the effective density of the lattice structure 364 may increase at, along, or near the conduits 128, the toe tip 304, the heel tip 308, the base 324, and the upper rim 340. This increase in effective density may result from the interfaces or contacts between the beams 174 and peripheral portions of the sole structure 300, including the conduits 128, the toe end 304, the heel end 308, the bottom 324, and the upper rim 340. Thus, the lattice structure 364 is configured to support such regions and portions of the midsole 356 and the sole structure 300. Furthermore, the lattice structure 364 may decrease the effective density away from or in areas spaced from such portions of the sole structure 300, thereby reducing the overall mass of the sole structure 300 and improving flexibility.

[0053] Sole structure 300 defines an outer sidewall 368 extending along outer surface 312 from toe tip 304 to heel tip 308, and an inner sidewall 372 extending along inner surface 316 from toe tip 304 to heel tip 308. Lattice region 360 of midsole 356 is continuous with and coextensive with inner sidewall 372 along inner surface 316 and outer sidewall 368 along the outer surface. Thus, lattice structure 364 of midsole 356 at least partially defines inner sidewall 372 and outer sidewall 368, and as such is exposed and visible along outer surface 312 and inner surface 316 from the exterior of sole structure 300.

[0054] In comparison, Figure 3 illustrates sole structure 300 in a pre-processed state, while Figure 4 illustrates sole structure 300 in a finished state after it has been combined with upper 376 to form footwear 380. The pre-processed state in Figure 3 refers to the state of sole structure 300 before it has been processed by or engaged with injection module 112, and conduits 128 are hollow. Accordingly, Figure 3 illustrates a state in which first end 144 and second end 148 of conduits 128 extend or protrude outward from sole structure 300. Specifically, first end 144 of each conduit 128 extends outward from heel end 308 of sole structure 300, and second end 148 of each conduit 128 extends outward from upper surface 348 of sole structure 300 adjacent to toe end 304. Thus, the conduit 128 extends through the heel region 332 , the midfoot region 336 , and the forefoot region 328 .

[0055] 3-11 , conduits 128 are comprised of a set of three conduits, including lateral conduit 384, central conduit 388, and medial conduit 392. Central conduit 388 is disposed between medial conduit 392 and lateral conduit 384. Lateral conduit 384 extends continuously from first end 144 to second end 148 and defines an lateral intermediate segment 396 that projects laterally from lateral sidewall 368 of sole structure 300 within midfoot region 336. Similarly, medial conduit 392 extends continuously from first end 144 to second end 148 and defines an medial intermediate segment 400 that projects laterally from medial sidewall 372 of sole structure 300. Medial intermediate segment 400 and lateral intermediate segment 396 are curved, arched, or bowed relative to medial sidewall 372 and lateral sidewall 368, respectively. 6 , the medial intermediate segment 400 and the lateral intermediate segment 396 are curved, arched, or bowed relative to a longitudinal axis L that defines a longitudinal plane LP (i.e., extending in the up-down or Z-direction) that bisects the toe end 304 and the heel end 308 of the sole structure 300. The lateral intermediate segment 396 and the medial intermediate segment 400 can be understood to define a concave or convex curvature relative to the longitudinal plane LP. For example, the inwardly facing surface of the lateral intermediate segment 396 has a concave curvature relative to the longitudinal plane LP, while the outwardly facing surface of the lateral intermediate segment 396 has a convex curvature relative to the longitudinal plane LP. Similarly, the inwardly facing surface of the medial intermediate segment 400 has a concave curvature relative to the longitudinal plane LP, while the outwardly facing surface of the medial intermediate segment 400 has a convex curvature relative to the longitudinal plane LP.

[0056] Conduit 128 penetrates lattice region 360 of sole structure 300 such that conduit 128 penetrates midsole 356 of sole structure 300 from heel end 308 toward toe end 304. Conduit 128 is disposed between upper portion 320 and bottom portion 324 of sole structure 300 in heel region 332, midfoot region 336, and forefoot region 328, with second end 148 of conduit 128 curving upward through upper portion 320 and projecting from top surface 348 adjacent to toe end 304. As a result, conduit 128 is disposed perpendicular to longitudinal plane LP (see FIG. 6 ) and a distance D1 from bottom surface BP, which extends tangentially. The lateral conduit 384, the central conduit 388, and the medial conduit 392 each extend from the first end 144 toward the second end 148 to the bottom 324 of the sole structure 300, with the distance D1 varying from the first end 144 toward the second end 148 for each of the lateral conduit 384, the central conduit 388, and the medial conduit 392. Referring to the lateral side view of FIG. 7 , the first end 144 of the lateral conduit 384 is positioned closer to the bottom surface BP than the second end 148, and the distance D1 at the first end 144 is shorter or less than the distance D1 at the second end 148. The distance D1 also varies along the lateral intermediate segment 396, and in particular, the distance D1 along the lateral intermediate segment 396 decreases toward the toe side (i.e., toward the tip of the toe).

[0057] 8, the first end 144 of the medial conduit 392 is located closer to the bottom surface BP than the second end 148, and therefore the distance D1 at the first end 144 is shorter, i.e., smaller, than the distance D1 at the second end 148. Furthermore, the distance D1 varies along the medial intermediate segment 400, and in particular, the distance D1 along the medial intermediate segment 400 decreases toward the toe side (i.e., toward the toe tip). Therefore, the lateral conduit 384, the central conduit 388, and the medial conduit 392 extend the entire length of the sole structure 300 and generally follow the contours of the user's foot. Therefore, the length LL1 of each of the conduits 384, 388, and 392 may be approximately 70% to approximately 130% of the entire length of the sole structure 300 between the heel tip 308 and the toe tip 304. In the illustrated embodiment, the lateral conduit 384 and the medial conduit 392 curve downward from the midfoot region 336 toward the sole 324, toward an area corresponding to the metatarsophalangeal (MTP) region of the user's foot, and then curve upward toward the toe cap 304. Thus, the reinforcing member 160 formed from the lateral conduit 384, the medial conduit 388, and the medial conduit 392 can support the user's foot in a manner that provides stability, energy return, propulsion, damping or cushioning, and comfort. This is due, in part, to the bending resistance (BR) provided by all three of the lateral conduit 384, the medial conduit 392, and the central conduit 388 to loads applied in the Z direction, for example, as the user performs a walking or running gait cycle or a jumping motion. Additionally, torsional resistance (TR) is provided by disposing the lateral conduit 384, the medial conduit 392, and the central conduit 388 within the sole structure 300 and interconnecting them via the lattice structure 364. The outer conduit 384, inner conduit 392, and central conduit 388 are spaced apart from one another in a medial-posterior direction, i.e., along the X-axis, to stiffen the sole structure 300 against torsional or rotational loads applied in the Z-direction at positions offset laterally or medially from the longitudinal plane LP, for example, as a user walks or runs through a gait cycle or performs cutting maneuvers in different directions.

[0058] Referring to the bottom view of FIG. 6 , the outer conduit 384 is disposed outside (i.e., toward the outside) of the longitudinal plane LP, and the inner conduit 392 is disposed inside (i.e., toward the inside of the longitudinal plane LP). Thus, the outer conduit 384 and the inner conduit 392 are disposed on opposite sides of the longitudinal plane LP. The outer conduit 384 is disposed entirely on the outer surface 312 of the longitudinal plane LP. The inner conduit 392 is disposed entirely on the inner surface 316 of the longitudinal plane LP. Illustratively, the outer conduit 384 is disposed a distance D2L from the longitudinal plane LP, and the inner conduit 392 is disposed a distance D2M from the longitudinal plane LP. The distance D2L varies between the first end 144 and the second end 148 of the outer conduit 384 to provide the desired torsional resistance TR. Specifically, distance D2L increases as one progresses longitudinally (i.e., in a heel-to-toe or toe-off direction) from first end 144 toward lateral intermediate segment 396 of midfoot region 336, and then decreases as one progresses from lateral intermediate segment 396 of forefoot region 328 toward second end 148. In the illustrated embodiment, D2L has a maximum value at a point located at lateral intermediate segment 396 of midfoot region 336 and a minimum value at a point located at second end 148 of forefoot region 328, although other configurations are contemplated.

[0059] Similarly, the distance D2M varies between the first end 144 and the second end 148 of the medial conduit 392 to provide the desired torsional resistance TR. Specifically, the distance D2M increases as one progresses longitudinally (i.e., in a heel-to-toe or toe-off direction) from the first end 144 toward the medial intermediate segment 400 of the midfoot region 336, and then decreases as one progresses from the medial intermediate segment 400 of the forefoot region 328 toward the second end 148. In the illustrated embodiment, D2M has a maximum value at a point located on the medial intermediate segment 400 of the midfoot region 336 and a minimum value at a point located on the second end 148 of the forefoot region 328, although other configurations are contemplated. Thus, the lateral conduit 384 and the medial conduit 392 are positioned offset from the longitudinal plane LP. In the illustrated embodiment, only the central conduit 388 intersects the longitudinal plane LP. In some embodiments, the outer conduit 384, the inner conduit 392, or both are positioned to intersect the longitudinal plane LP. Additionally, the outer conduit 384, the inner conduit 392, and the central conduit 388 are positioned at different distances from one another. For example, the outer conduit 384 can be positioned closer to the central conduit 388 than the inner conduit 388. In some embodiments, the outer conduit 384 is at least partially positioned to be equidistant from the inner conduit 392 and the central conduit 388. By positioning the outer conduit 384 and the inner conduit 388 in a similar but mirror-image relationship with respect to the longitudinal plane LP or the central axis 202 of the central conduit 388, the torsional resistance TR can be uniform or symmetrical about the longitudinal axis L or the central axis 202 of the central conduit 388. In some embodiments, the outer conduit 384, the inner conduit 392, and the central conduit 388 provide an asymmetric torsional resistance TR about the longitudinal axis L or the central axis 202.

[0060] 5, 6, and 9-11, the lateral conduit 384 and the medial conduit 392 are arranged to extend across the midsole 356 of the sole structure 300 in a non-parallel configuration. In other words, the lateral conduit 384 and the medial conduit 392 move toward and away from each other within the sole structure 300. For example, moving toward the toe, the lateral conduit 384 and the medial conduit 392 converge with each other in the heel region 332 between the first end 144 and the respective intermediate segments 396, 400. In the midfoot region 336, the lateral conduit 384 diverges from the medial conduit 392 between the rear intersection 404 and the peak 408 of the lateral intermediate segment 396, and the lateral conduit 384 converges toward the medial conduit 392 from the peak 408 to the forward intersection 412. Additionally, the lateral conduits 384 and the medial conduits 392 are arranged to converge with one another between their respective intermediate segments 396, 400 and the second end 148. Thus, the lateral conduits 384 and the medial conduits 392 are arranged non-parallel to one another within each of the forefoot region 328, the midfoot region 336, and the heel region 332 of the sole structure 300. In some embodiments, the lateral conduits 384 and the medial conduits 392 are arranged parallel to one another along at least a portion of the sole structure 300. In some embodiments, the lateral conduits 384 and the medial conduits 392 are arranged parallel to one another along the entire sole structure 300.

[0061] As shown in FIGS. 6 and 9-11 , the central conduit 388 is disposed between the lateral conduit 384 and the medial conduit 392 and at least partially intersects the longitudinal plane LP. In the illustrated embodiment, the longitudinal plane LP intersects the first end 144 of the central conduit 388 adjacent the heel end 308, then curves toward the lateral surface 312 to define a central intermediate segment 416 disposed outside the longitudinal plane LP in the midfoot region 336, and then curves toward the longitudinal plane LP in the forefoot region 328, where the second end 148 of the central conduit 388 intersects the longitudinal plane LP. The bottom surface 352, i.e., the ground contact surface, of the bottom portion 324 of the sole structure 300 is provided with a plurality of recesses 420 for accommodating portions of an outsole (not shown). Additionally, the bottom portion 324 of the sole structure 300 has openings 424 formed therein at least along the midfoot region 336. The central intermediate segment 416 of the central conduit 388 is at least partially visible through the opening 424, although other configurations are possible.

[0062] For clarity, FIG. 5 illustrates the length LL1 of the lateral conduit 384, but it is understood that the medial conduit 392 and the central conduit 388 similarly define respective lengths. In some embodiments, the lengths LL1 of the lateral conduit 384, the medial conduit 392, and the central conduit 388 are equal or identical. In some embodiments, the lengths LL1 of the lateral conduit 384, the medial conduit 392, and the central conduit 388 are different from one another. In some embodiments, the lengths LL1 of the conduits 384, 388, and 392 are reduced by less than 1%. In some embodiments, the lengths LL1 of the conduits 384, 388, and 392 are reduced by 25% or more. Referring to FIG. 7 , the lateral sidewall 368 is disposed between the top 320 and bottom 324 of the sole structure 300 and includes an lateral ridge 428 that extends in a curved path from the toe tip 304 to the heel tip 308. The lateral ridge 428 is positioned near the bottom 324 in at least a portion of the forefoot region 328 and the midfoot region 336. The lateral ridge 428 is positioned near the top surface 320 in at least a portion of the heel region 332 and the midfoot region 336. The lateral ridge 428 intersects the lateral conduit 384 and extends along the lateral intermediate segment 396 and a portion of the first end 144.

[0063] 8 , medial sidewall 372 is disposed between upper portion 320 and bottom portion 324 of sole structure 300 and includes a medial ridge 432 that extends in a curved path from toe tip 304 to heel tip 308. Medial ridge 432 is disposed near bottom portion 324 in at least a portion of forefoot region 328 and midfoot region 336. Medial ridge 432 is disposed near upper portion 320 in at least a portion of heel region 332 and midfoot region 336. Medial ridge 432 intersects medial conduit 392 and extends along medial intermediate segment 400 and a portion of first end 144.

[0064] 7 and 8, the second end 148 of each conduit 128 protrudes from an upper surface 348 of the upper portion 320 of the sole structure 300 a sufficient distance to allow a user or device to operably attach the injection module 112 and / or the curing module 116. Similarly, as shown in FIG. 6, the first end 144 of each conduit 128 protrudes from the heel end 308 of the sole structure 300 a sufficient distance to allow a user or device to operably attach the injection module 112 and / or the curing module 116. In this manner, the first end 144 and the second end 148 of each conduit 128 are configured to provide an engagement interface for operably engaging with the injection module 112 or the curing module 116.

[0065] As described above in connection with FIG. 1 , the first end 144 and the second end 148 of the conduit 128 are configured to be at least partially removed by cutting or trimming via the operation of the finishing module 120. Such trimming or cutting occurs after the curing module 116 cures the reinforcement material 132 introduced by the injection module 112, and the finishing module 120 removes a portion of the conduit 128, the reinforcement material 132, or both. Thus, the first end 148 and the second end 148 of the conduit 128 have a sacrificial or removable portion 436. The sacrificial portion 436 of the conduit 128 may be separated from adjacent portions of the conduit 128 by markings 440, such as solid or dashed lines, symbols, or the like. In other words, the markings 440 may be visual indicators including at least one of a color contrast, a texture contrast, perforations, or indicia. In some cases, the markings 440 are integrally formed with the conduit 128 or printed with the conduit 128. In some cases, the markings 440 are applied by the finishing module 120. In some cases, the markings 440 are applied by the fabrication module 104. In some cases, the markings 440 are applied to the conduit 128 by adhesives, fasteners, inks, machining, clamping, slicing, or heating. In some cases, the markings 440 are temporary and are formed using a laser beam or light source. In some cases, the markings 440 form a weakened area or feature, such as a perforation or thinned section, that facilitates removal of a sacrificial portion 436 of the conduit 128. The sacrificial portion 436 may be located on the conduit 128 at a position spaced from the first end 144 or the second end 148. For example, the sacrificial portion 436 may be located on the outer intermediate segment 396 or between the inner intermediate segment 396 and the first end 144. Additionally, the length LL1 of the conduits 384, 388, 392 is configured to be shortened when the sacrificial portions 436 of the first end 144 and the second end 148 are removed by operation of the finishing module 120. Thus, the length LL1 of the conduits 384, 388, 392 may be shortened by about 1% to about 25%.

[0066] In some cases, the first end 144 and second end 148 of the conduit 128 are configured to be trimmed flush with or aligned with the outer surface 444 of the sole structure 300, including the top surface 348, bottom surface 352, lateral sidewall 368, medial sidewall 372, and heel end 308. For example, FIG. 4 shows the heel end 308 of footwear 380 after the first end 144 of the outer conduit 384 has been trimmed or removed to be flush with the outer surface 444 of the sole structure 300. In the illustrated embodiment, the outer intermediate segment 396 of the outer conduit 384 remains exposed outside the lateral sidewall 368 of the sole structure 300. In other embodiments, the outer intermediate segment 396 may be removed to be flush with the outer surface 444 of the lateral sidewall 368 of the sole structure 300. Additionally, second end 148 of conduit 128 is configured to be removed to facilitate attachment of upper 376 to top portion 320 of sole structure 300. In some embodiments, first end 144 and second end 148 of conduit 128 may be removed such that they are recessed from outer surface 444 of sole structure 300. In some embodiments, first end 144 and second end 148 of conduit may be partially removed such that a portion extends or protrudes from the outer surface of sole structure 300. In some embodiments, first end 144 and second end 148 are not removed.

[0067] 12 and 13 illustrate another embodiment of a component 108 in the form of a sole structure 500 configured for use in the systems and methods disclosed herein. The same reference numerals and terminology are used for aspects of the sole structure 500 that are structurally or functionally equivalent to the sole structure 300 of FIGS. 3-11 . In FIGS. 12 and 13 , an outsole 504 is provided on the bottom 324 of the sole structure 500. In the illustrated embodiment, the outsole 504 includes a forward outsole portion 508, a rearward lateral outsole portion 512, and a rearward medial outsole portion 516. Additionally, openings 424 are formed in the bottom 324 of the sole structure 500 at least along the midfoot region 336. The outsole 504 may be formed from one or more materials to provide durability, abrasion resistance, wear resistance, or traction to the sole structure 300. In some embodiments, outsole 504 may be formed from any type of elastomeric material, such as rubber, including thermoset or thermoplastic elastomers, or a thermoplastic material, such as thermoplastic polyurethane (TPU). In some embodiments, outsole 504 may define a Shore A hardness of up to 95. Additionally, outsole 504 may be manufactured by processes including injection molding, vulcanization, layer-by-layer printing, i.e., additive manufacturing systems or methods, and the like.

[0068] 14-16 illustrate the sole structure 500 of FIGS. 12 and 13 with the outsole 504 hidden or removed. The sole structure 500 includes conduits 128, consisting of an lateral conduit 520, a central conduit 524, and a medial conduit 528, which extend through the midsole 356 from the heel end 308 toward the toe end 304. The central conduit 524 has a central intermediate segment 532 that is at least partially visible through the opening 424, although other configurations are possible. Unlike the embodiment of FIGS. 14-16, the outsole 504 is comprised of an lateral conduit 520, a central conduit 524, and a medial conduit 528. As shown in FIGS. 3-11, the lateral conduit 520 and the medial conduit 528 do not extend outside the sole structure 500 in the midfoot region 336. In contrast, the outer conduit 520 and the inner conduit 528 have smaller values ​​of maximum D2L and maximum D2M (see FIG. 6), respectively, and are therefore positioned to increase the flexibility of the torsional resistance TR of the sole structure 500. As a result, the reinforcing members 160 make the sole structure 500 less resistant to twisting or torsional loads than the sole structure 300 of FIGS. 3-11. The sole structure 500 includes a midsole 356 having a lattice region 360, where the lattice structure 364 is composed of beams 174 extending linearly between nodes 178, forming unit cells 186 that define a repeating pattern throughout the lattice region 360 (see FIGS. 12 and 13). The lattice structure 364 of the sole structure 500 can be described as triangular, polygonal, or regular in shape. FIG. 17 illustrates footwear 580 including an upper 376 applied to the sole structure 500 of FIGS. 14-16.

[0069] 18 and 19 illustrate another embodiment of a component 108 in the form of a sole structure 600 configured for use in the systems and methods disclosed herein. The same reference numbers and terminology are used to describe aspects of the sole structure 600 that are structurally or functionally equivalent to the sole structure 300 of FIGS. 3-11. In the illustrated embodiment of FIG. 18, the sole structure 600 is structurally or functionally equivalent to the sole structure 300 of FIGS. 3-11. As shown in FIG. 18, the sole structure 600 includes conduits 128, including an outer conduit 604, a central conduit 608, and an inner conduit 612, which penetrate the lattice structure 364 of the midsole 356 and extend across the sole structure 600 from the heel region 332 to the forefoot region 328. In the illustrated embodiment, the second ends 148 of the lateral conduit 604, medial conduit 612, and central conduit 608 protrude from the bottom 324 of the sole structure 600 adjacent the toe tip 304. Specifically, the second ends 148 curve downwardly away from the bottom 324. The lateral conduit 604 and medial conduit 612 extend away from the bottom 324 while converging at the second ends 148. The longitudinal axis L is shown as intersecting both the second end 148 and the first end 144 of the central conduit 608. Thus, the first end 144 and second end 148 of the central conduit 608 are coplanar with each other along the longitudinal plane LP. Unlike the embodiment of FIGS. 3-11 , the lateral conduit 604 and medial conduit 612 do not extend outward from the sole structure 600 in the midfoot region 336.

[0070] FIG. 20 illustrates the sole structure 600 of FIGS. 18 and 19 in a completed state after engaging the injection module 112, the curing module 116, and the finishing module 120, with the sacrificial portion 436 (see FIG. 3) removed and the conduits 128 converted into reinforcements 160, prior to assembly with the upper. Additionally, a footboard 616 is attached to the upper surface 348 and surrounded by the upper rim 340. The footboard 616 may be part of an insole configured to be positioned within the upper for added comfort and insulation. In some embodiments, the footboard 616 is a plate that provides additional stability or energy return to the user. The footboard 616 is applied to the upper surface 348 to cover the conduits 128 positioned within the midsole 356 of the sole structure 600 and may contact the second end 148 of each conduit 128.

[0071] FIG. 21 illustrates an exemplary method 700 for manufacturing footwear including a component with reinforcements using the system 100 of FIG. 1. The method 700 includes step 704 of creating a design model of a component, such as a sole structure, including the placement of conduits that provide reinforcements or other benefits. For example, the component 108 may be designed, simulated, modified, and optimized in a CAD program, such as a program using finite element analysis (FEA), meshless methods, boundary element methods (BEM), topology optimization algorithms, regression modeling, implicit bodies, or other simulation or analysis techniques, to identify regions, areas, or points within the component 108 that could benefit from the reinforcements, thereby tailoring the reinforcements 160 and the component 108 to have desired performance characteristics. Such benefits may include comfort, stability, energy recovery or propulsion, tensile or compressive strength, bending or torsional strength, etc. Other benefits may not be associated with other properties, such as the ability to sense or measure various properties or conditions in the component 108, such as electrical or thermal conductivity, stress, strain, velocity, direction, altitude, temperature, position, or combinations thereof. The CAD program can be iteratively manipulated until an optimized or modified design of component 108 has the desired enhancement or advantage. In some embodiments, the CAD program uses optimization software such as nTopology®, an engineering design and manufacturing software that integrates 3D modeling, simulation, and manufacturing processes into a single computing environment managed through a visual programming interface. In some cases, component 108 is designed based on measurements or data obtained during experimentation, such as data obtained from testing a physical item (e.g., a prototype or reference) equipped with sensors, user input, data collected from various users and tests, or a combination thereof. In some embodiments, any portion of the components, reinforcement members, support members / regions, chassis / sole plates, and / or sole structures described herein can be designed, customized, and / or optimized based on user data or input.In some embodiments, any portion of the components, reinforcement members, support members / regions, chassis / sole plates, and / or sole structures described herein can be designed, customized, and / or optimized on a computer system or computer media. Thus, the sole structures described herein can be specifically designed for a particular user.

[0072] The method 700 includes step 708 of forming a component, such as the sole structure 300, 500, or 600, including one or more conduits for receiving a reinforcement material using an additive manufacturing system based on the design model. For example, the manufacturing module 104 may include a 3D printer that receives the optimized or modified design model and forms the sole structure 300 with the conduits 128, including the outer conduit 384, the central conduit 388, and the inner conduit 392. Each conduit 128 has a first end 144 or inlet end, a second end 148 or outlet end, and a channel 152 disposed between the first end 144 and the second end 148. The method 700 further includes step 712 of connecting one end of each conduit to an injection module. As described above, the injection module 112 may be operably and removably connected to the first end 144, the second end 148, or both, of each of the conduits 384, 388, or 392. The method 700 further includes a step 716 of introducing a reinforcing material into one or more conduits. For example, the injection module 112 may introduce the reinforcing material 132, including the resin 136 and the fiber bundles 140, into the channels 152 of the conduits 128. In some cases, the injection module 112 introduces the reinforcing material 132 into each of the outer conduits 384, the central conduit 388, and the inner conduit 392. In some examples, the injection module 112 introduces the reinforcing material 132 into fewer than all of the conduits 128, such as only the outer conduit 384 and the inner conduit 392.

[0073] 21 , the method 700 further includes a step 720 of curing the reinforcing material 132 within the component 108. Specifically, the curing module 116 is used to cure the reinforcing material 132 inserted and retained within the component 108. As described above, the curing module 116 may apply heat, light, electricity, or a combination thereof. In some applications, the curing module 116 may include the application of a tension or compression force such that, after curing, the reinforcing material 160 and the component 108 are pre-tensioned or pre-loaded to impart desired behavior or performance characteristics to the component 108. Parameters associated with the curing module 116 may be varied based on the material, volume, mass, and / or placement of the reinforcing material 132 within the component 108. As a result of the curing process, the reinforcing material 132 is transformed or converted into a reinforcing member 160. The reinforcing member 160 may include the reinforcing material 132, the conduit 128, or both. In some embodiments, the conduits 128 are configured to be removed, such that the reinforcing member 160 is formed primarily from the reinforcing material. The method may further include a step 720 of removing a portion of the end of each conduit. For example, the finishing module 120 may be used to remove or trim the first end 144 of each conduit 128. In some embodiments, the second end 148 of each conduit 128 may be removed or trimmed. In some embodiments, step 724 is not performed, and the ends of the conduits 128 are not trimmed. The method 700 further includes a step 728 of finishing the component. As described above in connection with FIG. 1 , the component 108 may be processed by various finishing methods or techniques using the finishing module 120. Finally, the method 700 includes a step 732 of assembling the component into an article of manufacture. In some embodiments, the component 108 is a sole structure 300 that is combined with an upper 376 (see FIG. 4 ) to form footwear 380. In some embodiments, component 108 is a sole structure 500 that combines with an outsole 504 (see FIG. 8) and upper 376 to form footwear 580.In some embodiments, the component 108 is a sole structure 600 combined with a footboard 616 (see FIG. 20).

[0074] It is understood that the method 700 of FIG. 21 can be used to form the reinforcing member 160 using a variety of components, including any of the sole structures 300, 500, 600 disclosed herein. Additionally, the method 700 is not limited to the particular order of steps described above. The method 700 can be used to design and manufacture sole structures that are customized or unique to a particular user, sport, occupation, function, or benefit. Additionally, the method 700 can be used to design and manufacture a variety of components, such as apparel, sports equipment, jewelry, tools, and other devices.

[0075] FIG. 22 is a representative illustration of a cross-sectional view of a sole structure 800 formed in accordance with the methods and systems described herein and having a first plate 804 and a second plate 808. Each of the first plate 804 and the second plate 808 extends through the sole structure 800 and includes at least one reinforcing member. In the illustrated embodiment, the first plate 804 has a plurality of first reinforcing members 812 disposed thereon, including a first outer reinforcing member 816, a first central reinforcing member 820, and a first inner reinforcing member 824. Each of the first reinforcing members 812 is comprised of a cured reinforcing material 132 and has a rectangular cross-sectional shape disposed within and at least partially surrounded by a conduit 128. The first plate 804 defines a vertical plate thickness T1 parallel to the longitudinal plane LP, the plate thickness T1 being measured between a first upper surface 828 and a first lower surface 832. The first upper surface 828 of the first plate 804 is configured to face the upper surface 348 of the sole structure 800. The reinforcement thickness T2 defines a plate thickness T2 in a vertical direction parallel to the longitudinal plane LP. For clarity, the reinforcement thickness T2 is shown only for the first outer reinforcement 816. In the illustrated embodiment, the reinforcement thickness T2 is less than the plate thickness T1. The reinforcement thickness T2 is uniform or constant among the first plurality of reinforcements 812. Thus, the first plurality of reinforcements 812 are embedded within the first plate 804 between the first upper surface 828 and the first lower surface 832. The longitudinal plane LP intersects the first plate 804 between the first outer surface 828 and the first inner surface 840. Furthermore, the longitudinal plane LP intersects the first central reinforcement 820. The first plate 804 protrudes or extends outward from the outer surface 444 of the sole structure 800. Specifically, first inner surface 840 of first plate 804 protrudes from outer surface 444 of inner surface 316 of sole structure 800. In comparison, first outer surface 836 is disposed inside or medial to outer surface 444 of outer surface 312. First plurality of reinforcing members 812 are disposed entirely within first plate 804 and entirely within outer surface 444 of sole structure 800.

[0076] 22 , the second plate 808 is positioned near the bottom 324 of the sole structure 800, and the first plate 804 is positioned near the top surface of the sole structure 800. In other words, the first plate 804 is positioned axially above the second plate 808 along a direction perpendicular to the longitudinal plane LP. The second plate 808 has a second top surface 860 configured to face the first bottom surface 832. The second plate 808 has a second bottom surface 864 configured to face the bottom 324 of the sole structure 800. The second plate 808 intersects the longitudinal plane LP between a second outer side surface 868 and a second inner side surface 872. The second outer side surface 868 is configured to extend or protrude outward from the outer surface 444 of the lateral surface 312 of the sole structure 800. Thus, the second outer surface 868 is disposed outboard of the first outer surface 836 of the first plate 804 relative to the longitudinal plane LP. The second inner surface 872 is disposed medial or inboard of the outer surface 444 of the medial side 316 of the sole structure 800. Thus, the second inner surface 872 is disposed medial to the first inner surface 840 of the first plate 804 relative to the longitudinal plane LP.

[0077] In the second plate 808, the second plurality of reinforcing members 876 includes a second outer reinforcing member 880, a second inner reinforcing member 884, a second central reinforcing member 888, and a second middle reinforcing member 892. Thus, the second plurality of reinforcing members 876 includes four reinforcing members. The number of reinforcing members can be any number, such as 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15 or more, 20 or more, 25 or more, 35 or more, 50 or more, or 100 or more. The second plurality of reinforcing members 876 differ from one another in cross-sectional shape. For example, the second outer reinforcing member 880 has a square or trapezoidal shape, which differs from the oval shape of the second inner reinforcing member 888. The second middle reinforcing member 892 has a hexagonal cross-sectional shape, which differs from the square or rectangular shape of the second central reinforcing member 888. Additionally, the second plurality of reinforcements differ from one another in reinforcement thickness T2. The second inner reinforcement 884 has a greater wall thickness WT compared to the second outer reinforcement 880. The second outer reinforcement 880 is disposed at least partially on the outer side of the outer surface 444 of the lateral surface 312 of the sole structure 800. Thus, at least one reinforcement of the second plurality of reinforcement members 876 is disposed on the outer side of the midsole 356 of the sole structure 800.

[0078] Additionally, the second intermediate stiffener 892 is positioned below or outside at least a portion of the second bottom surface 864 of the second plate 808. Thus, at least one stiffener of the second plurality of stiffeners 876 is positioned outside at least a portion of the second plate 808. Each stiffener of the second plurality of stiffeners 876 is offset from the longitudinal plane LP such that the longitudinal plane LP does not intersect any of the second plurality of stiffeners 876. Additionally, the second plurality of stiffeners 876 are spaced apart from one another in the outward-inward direction. Specifically, the distances between adjacent stiffeners of the second plurality of stiffeners 876 vary relative to one another. For example, the second central stiffener 884 is positioned farther from the second inner stiffener 888 than the second intermediate stiffener 892.

[0079] Additionally, three stiffeners of the second plurality of stiffeners 876 are disposed outboard of the longitudinal plane LP. The second outer stiffener 880, the second intermediate stiffener 892, and the second central stiffener 884 are disposed entirely outboard of the longitudinal plane LP, and only the second inner stiffener 888 is disposed entirely inboard of the longitudinal plane LP. Thus, the second plurality of stiffeners 876 are disposed in an unequal and asymmetrical configuration relative to the longitudinal plane LP.

[0080] 23 is a representative illustration of a cross-section of a sole structure 900 formed in accordance with the methods and systems described herein. The sole structure 900 has a plurality of reinforcements 904, including a heel reinforcement 908 disposed in the heel region 332, a midfoot reinforcement 912 disposed in the midfoot region 336, and a forefoot reinforcement 916 disposed in the forefoot region 328. The plurality of reinforcements 904 extend continuously from the top surface 348 to the bottom surface 352 of the sole structure 900. Additionally, a plurality of cap components 920 are provided in connection with the plurality of reinforcements 904. Specifically, the heel reinforcement 908 is coupled to the heel cap 924 by a connecting rod 928. In some embodiments, the heel cap 924 is coupled to the reinforcement material 132 within the heel reinforcement 908 via the connecting rod 928 by screwing, clamping, welding, or adhesive. Heel cap 924 can function as a ground-engaging member, such as a cleat, spike, tread, or outsole portion, in heel region 332. Midfoot reinforcement 912 is coupled to midfoot cap 932 by screwing, fastening, welding, or adhesive without the use of connecting rod 928. Midfoot cap 932 can function as a ground-engaging member, such as a cleat, spike, tread, or outsole portion, in midfoot region 336. Additionally, forefoot reinforcement 916 is integrally formed with forefoot cap 936, and both forefoot reinforcement 916 and forefoot cap 936 are made from reinforcement material 132. In some embodiments, forefoot cap 936 can function as a ground-engaging member, such as a cleat, spike, or outsole portion. Forefoot reinforcement 916 varies in thickness T3 of the tread or outsole portion in forefoot region 328. Heel reinforcement 908 varies in thickness T3 measured in a heel-to-toe direction parallel to longitudinal axis L. In the illustrated embodiment, the thickness T3 of the heel reinforcement 908 decreases from the top surface 348 to the bottom surface 352 of the sole structure 900. The forefoot reinforcement 916 has a thickness T3 that decreases from the bottom surface 352 to the top surface 348 of the sole structure 900. Thus, the heel reinforcement 908 and the forefoot reinforcement 916 taper or narrow between the top surface 348 and the bottom surface 352 of the sole structure 900.

[0081] 24 is a representative diagram showing a cross section of a sole structure 1000 formed in accordance with the methods and systems described herein, the sole structure 1000 having a linear reinforcing member 1004 that extends continuously from the heel end 308 to the forefoot region 328 of the sole structure 1000. A heel cap 1008 is attached to the first end 144 of the linear reinforcing member 1004. The heel cap 1008 is attached to the linear reinforcing member 1004 outside the outer surface 444 of the heel end 308 of the sole structure 1000. Thus, a gap 1012 is formed between the heel cap 1008 and the outer surface 444 of the sole structure 1000. The method 700 of FIG. 21 can be used to form the sole structures 300, 500, 600, 800, 900, and 1000 disclosed herein.

[0082] 25-28 , another embodiment of a sole structure 1500 includes multiple support regions 1504 disposed at various locations between the lateral surface 312 and the medial surface 316 and between the toe end 304 and the heel end 308. The same reference numbers and terminology are used to describe aspects of the sole structure 1500 that are structurally or functionally equivalent to the sole structure 300 of FIGS. 3-11 . In FIGS. 25-28 , the multiple support regions 1504 can be formed from individual lattice structures or support structures 1510 spaced apart from one another. As described herein, the support structures 1510 can include interconnected ribs, struts, beams, and / or members. In some embodiments, the support structures 1510 can be a network or web of ribs, struts, beams, and / or members. Thus, it is contemplated that the support structure 1510 can be any support network or web. The support structures 1510 form the multiple support regions 1504.

[0083] In some cases, the support structures 1510 are positioned in areas of the sole structure 1500 that are expected to experience high stresses or pressures. For example, finite element analysis (FEA) or other engineering analysis programs can be used to identify and predict areas of the sole structure 1500 that are expected to experience relatively high pressures, stresses, or strains under expected loads due to the shape and material properties of the sole structure 1500. The support structures 1510 can be positioned in these areas to reduce the amplitude of the stresses or pressures experienced in these areas by distributing the stresses or pressures over a predetermined surface area. For example, in a sole structure having cleats or studs formed or attached along the ground contact or bottom surface, the support structures 1510 may be positioned in or near the connection areas 1514 of the studs or cleats 1520 (see FIGS. 27 and 28). The support structures 1510 can be positioned and configured to reduce stresses in various directions or due to various loads. For example, the support structure 1510 can be configured to reduce stress in the axial direction 1524 defined by the cleat 1520, thereby increasing the surface area over which the axial stress is distributed (see FIG. 28 ). In some examples, the support structure 1510 can be configured to reduce stress resulting from bending loads acting on the cleat 1520, thereby increasing the support structure 1510's resistance to bending in one or more directions. A similar function can be provided by a support structure 1510 configured to improve resistance to twisting or rotation about the axial direction 1524. In this manner, the support structure 1510 reduces stress concentrations in the sole structure 1500, thereby improving comfort and strength. In some embodiments, the multiple support regions 1504 can provide a spring effect during use by a user.

[0084] Referring to FIG. 25 , a bottom view of the sole chassis or sole plate 1530 of the sole structure 1500 is shown. FIG. 26 shows a top view of the sole plate 1530 of the sole structure 1500. The sole plate 1530 of FIGS. 25 and 26 does not have cleats 1520 attached thereto, and the sole plate 1530 is provided with a plurality of cleat ports or openings 1534. As described above and as shown in FIG. 26 , the sole plate 1530 is positioned higher than the sole chassis or sole plate 1530 to which the cleats 1520 are attached. As shown in FIG. 26 , the sole structure 1500 includes a plurality of support regions 1504 with support structures 1510 at various strategic locations on the sole plate 1530. In some embodiments, the sole plate 1530 may not include any cleat ports 1534 at all. Thus, in some embodiments, the sole structure 1500 may not include cleats 1520 at all, and the features described below may be utilized in footwear without cleats 1520, i.e., cleatless shoes.

[0085] 26 , sole structure 1500 is formed from separate segments or components interconnected to one another by reinforcing material 132 and / or multiple support links 1540. Specifically, sole structure 1500 includes a lateral midfoot support portion 1544, a lateral heel support portion 1548, a medial forefoot support portion 1552, a medial midfoot support portion 1556, and a medial heel support portion 1560. As described herein, lateral midfoot support portion 1544, lateral heel support portion 1548, medial forefoot support portion 1552, medial midfoot support portion 1556, and medial heel support portion 1560 define multiple support regions 1504. lateral midfoot support portion 1544 has a curved shape and extends along the lateral surface 312 of the midfoot region. The lateral midfoot support 1544 extends along the forefoot region 336 of the sole structure 1500 from an area adjacent the forefoot region 328 of the sole structure 1500 to an area adjacent the heel region 332 of the sole structure 1500. In some embodiments, the lateral midfoot support 1544 can extend into the forefoot region 328 and / or the heel region 332. As shown in FIG. 26 , the lateral midfoot support 1544 curves toward the longitudinal axis L at the center of the lateral midfoot support 1544. An lateral conduit 1564 extends along the lateral midfoot support 1544. The lateral conduit 1564 may be formed with and / or ultimately contain a reinforcing material 132 similar to the conduit 128 described above using methods disclosed herein. In some embodiments, the lateral conduit 1564 can extend the entire lateral midfoot support 1544. As explained herein and described above, the lateral conduits 1564 can extend in any direction or pattern along the lateral midfoot support 1544. In some embodiments, the lateral conduits 1564 can extend along areas that are expected to experience relatively high pressures, stresses, or strains under expected loads due to the shape and material properties of the sole structure 1500.

[0086] Referring to FIG. 26 , the lateral heel support portion 1548 is located on the heel side of the lateral midfoot support portion 1544 and is disposed on the lateral surface 312 of the sole structure 1500. The lateral heel support portion 1548 may be disposed on a portion of the sole plate 1530 that includes one of the cleats 1520. The lateral heel support portion 1548 may include a generally spherical shape that surrounds one of the multiple cleat ports 1534 of the sole plate 1530. As shown in FIG. 26 , the lateral heel support portion 1548 is connected to the lateral midfoot support portion 1544. However, in other embodiments, the lateral heel support portion 1548 may not be connected to the lateral midfoot support portion 1544, i.e., may be separate and distinct from the lateral midfoot support portion 1544. As further shown in FIG. 26 , the lateral conduit 1564 extends partially within the lateral heel support portion 1548. In some embodiments, the lateral conduit 1564 may extend completely through the lateral heel support 1548. In other embodiments, the lateral conduit 1564 may not extend into the lateral heel support 1548.

[0087] Referring to FIG. 26 , the medial forefoot support portion 1552 is disposed on the medial surface 316 of the forefoot region 328 of the sole structure 1500, with the medial forefoot support portion 1552 being disposed above a portion of the sole plate 1530 that will become one of the cleats 1520 (see FIG. 28 ). As such, the medial forefoot support portion 1552 is disposed above one of the cleat ports 1534 of the sole plate 1530. Like the lateral heel support portion 1548, the medial forefoot support portion 1552 comprises a generally cylindrical shape. The medial forefoot support portion 1552 is connected to the medial midfoot support portion 1556 by a plurality of support links 1540. As described herein, the plurality of support links 1540 connect one or more of the plurality of support regions 1504 to one another. In some embodiments, the support link 1540 may have the same materials and properties as the support structure 1510. Also, in some embodiments, the support link 1540 may have the same material and properties as the reinforcing material 132 (e.g., the outer conduit 1564). Still further, in other embodiments, the support link 1540 may have a different material or different material properties than the support structure 1510 and / or the reinforcing material 132. As shown in FIG. 26 , the support link 1540 is formed from the same support structure 1510 as the support structures 1510 in the multiple support regions 1504, but at a lower density, i.e., fewer beams 174 and / or nodes 178 per similar volume or unit cell 186. Thus, the support link 1540 includes fewer beams 174 extending in multiple directions from one or more of the multiple support regions 1504. In some embodiments, the support link 1540 may include thicker (or thinner) beams 174 than the support structures 1510 in the multiple support regions 1504. Also, in some embodiments, one or more beams 174 in the support link 1540 may include different thicknesses. For example, support link 1540A connecting lateral midfoot support 1544 and medial midfoot support 1556 may be thicker than support link 1540B connecting medial forefoot support 1552 and medial midfoot support 1556.

[0088] Further, with reference to FIG. 26 , medial midfoot support portion 1556 is connected to medial forefoot support portion 1552 via a plurality of support links 1540B. Medial midfoot support portion 1556 has a curved shape and extends along the medial surface 316 of midfoot region 336 of sole structure 1500 from an area adjacent to forefoot region 328 to an area adjacent to heel region 332. In some embodiments, medial midfoot support portion 1556 may extend into forefoot region 328 and / or heel region 332. As shown in FIG. 26 , medial midfoot support portion 1556 curves at its center toward longitudinal axis L. Thus, medial midfoot support portion 1556 and lateral midfoot support portion 1544 curve toward each other and then away from each other as they extend from an area adjacent to forefoot region 328 toward the heel. The medial conduit 1580 extends along the medial metatarsal support 1556. The medial conduit 1580 can be formed with and / or ultimately contain a reinforcing material 132 similar to the conduit 128 described above, using the methods and systems disclosed herein. In some embodiments, the medial conduit 1580 can extend throughout the medial metatarsal support 1556. As described herein and above, the medial conduit 1580 can extend in any direction or pattern along the medial metatarsal support 1556. In some embodiments, the medial conduit 1580 can extend along a portion of the sole structure 1500 that is expected to experience relatively high pressures, stresses, or strains under expected loads, depending on the shape and material properties of the sole structure 1500.

[0089] 26, the medial heel support portion 1560 is located on the heel side of the medial midfoot support portion 1556 and is disposed on the medial surface 316 of the sole structure 1500. The medial heel support portion 1560 may be disposed on a portion of the sole plate 1530 that will become one of the cleats 1520 (see FIG. 28). The medial heel support portion 1560 may have a generally cylindrical shape and be disposed in one of the cleat ports 1534 of the sole plate 1530. As shown in FIG. 26, the medial heel support portion 1560 is located on the heel side of the medial midfoot support portion 1556 and is disposed on the medial surface 316 of the sole structure 1500. As shown in FIG. 26, the medial heel support portion 1560 is not connected to the medial midfoot support portion 1556. However, in alternative embodiments, the medial heel support 1560 may be connected to the medial midfoot support 1556, similar to the lateral midfoot support 1544 and the lateral heel support 1548. In some embodiments, the support link 1540 may connect the medial heel support 1560 and the medial midfoot support 1556. As further shown in FIG. 26 , the medial conduit 1580 does not extend into the medial heel support 1560. In alternative embodiments, the medial conduit 1580 may extend partially or completely into the medial heel support 1560. As described herein, the medial heel support 1560 is generally aligned with the lateral heel support 1548.

[0090] 26 , the plurality of support links 1540 includes a plurality of support links 1540A connecting the medial midfoot support 1556 and the lateral midfoot support 1544, and a plurality of support links 1540B connecting the medial midfoot support 1556 and the medial forefoot support 1552. As discussed above, the plurality of support links 1540A are thicker than the plurality of support links 1540B. However, in some embodiments, the support links 1540A may have the same support structure type, i.e., the same thickness, as the support links 1540B. As discussed herein, the support links 1540 may extend along portions of the sole structure 1500 that are expected to experience relatively greater pressure, stress, or strain under expected loads due to the shape and material properties of the sole structure 1500. Thus, the support links 1540 may connect one or more of the multiple support regions 1504 and / or provide support and / or distribute stress or pressure over a predetermined surface area, thereby reducing the amplitude of stress or pressure experienced in those regions of the sole structure 1500. As further described herein, any of the multiple support regions 1504 may be connected by multiple support links 1540.

[0091] 26 , the sole plate 1530 is provided with a plurality of recesses 1586. Specifically, the lateral midfoot support 1544 is disposed within an lateral pocket 1588 within the sole plate 1530. Similarly, the medial midfoot support 1556 is disposed within an medial pocket 1590 within the sole plate 1530. The lateral pocket 1588 has a similar shape to the lateral midfoot support 1544, and the medial pocket 1590 has a similar shape to the medial midfoot support 1556. As described herein, the lateral pocket 1588 and the medial pocket 1590 are part of the plurality of recesses 1586 within the sole plate 1530. In some embodiments, the plurality of support regions 1504 can be disposed within the plurality of recesses 1586 within the sole plate 1530.

[0092] 26 , all of the support regions 1504, except for the medial heel support 1560, are a single, unitary component. That is, they are all connected to one another by the support structure 1510 or the support links 1540. In some embodiments, all of the support regions 1504 may be formed as a single, unitary component. Also, in some embodiments, one or more of the support regions 1504 may be separate or separate from the other regions 1504. For example, each of the support regions 1504 may be its own independent component or structure and not connected to the other support regions 1504 by the support structures 1510 and support links 1540.

[0093] As described herein, the multiple support regions 1504 shown in FIG. 26 are merely one example. Thus, the sole structure 1500 may include more or fewer support regions 1504 than those shown, and each support region 1504 may have a different shape, configuration, or formation than that shown. As discussed above, the multiple support regions 1504 may be strategically positioned around the periphery of the sole structure 1500 to provide support and distribute stress or pressure over a predetermined surface area, thereby reducing the amplitude of stress or pressure exerted on those regions of the sole structure 1500. For example, in some embodiments, the sole structure 1500 may include a support region that covers each of the cleat ports 1534. Additionally, in other embodiments, the sole structure 1500 may include a single support region that extends across the entire sole plate 1530. In some embodiments, one or more of the multiple support regions 1504 may be added to the sole structure 1500 solely for aesthetic purposes. It is also contemplated that the sole structure 1500 may include more or fewer conduits 1564, 1564 than those shown. For example, in some embodiments, each of the multiple support regions 1504 may include one or more conduits 1564, 1580 therein. Further, as described above, a single conduit 1564, 1580 may extend to one or more of the multiple support regions 1504. The conduits 1564, 1580 may also have any shape and may follow any path along the sole structure 1500. Furthermore, in some embodiments, one or more conduits 1564, 1580 may extend through the support link 1540 and / or through portions outside the multiple support regions 1504 within the sole structure 1500. Furthermore, in some embodiments, one or more conduits 1564, 1580 may extend outside the sole structure 1500, similar to the conduit 128 described above. Thus, as described herein, the conduits 1564, 1580 here may be the same as (and have the same characteristics and configuration as) the conduits 128 described above. Additionally, in alternative embodiments, the sole structure 1500 may not include conduits 1564, 1580 at all.In some embodiments, the sole structure 1500 can include a support structure 1510 and / or conduits 1564, 1580 that connect and / or join to the upper 376.

[0094] Referring to FIG. 27 , a sole structure 1500 is shown including a plurality of support regions 1504 along with a plurality of cleats 1520 integrally molded to a sole plate 1530. As described in further detail herein, after the plurality of support regions 1504 are added to the sole plate 1530, the sole plate 1530 with the support regions 1504 may be placed in a mold and coated with a covering material 1596. The covering material 1596 may have various levels of flexibility and / or stiffness depending on the application of the sole structure 1500. In some embodiments, the plurality of cleats 1520 may be formed from the covering material 1596. However, in other embodiments, the plurality of cleats 1520 may be formed from a different material than the covering material 1596. For example, in some embodiments, the plurality of cleats 1520 may be added after the covering material 1596 has been applied to the sole structure 1500. In such embodiments, the plurality of cleats 1520 may be metal cleats that are secured to cleat ports 1534 after the sole plate 1530 is molded. As described herein, the covering material 1596 may be any type of material that covers the sole plate 1530 and the plurality of support regions 1504. In some embodiments, the covering material 1596 may be a thermoplastic resin, such as TPU and / or TPE. In some embodiments, the covering material 1596 may be comprised of a polymer including an aliphatic component, an aromatic component, and / or a combination thereof. In some embodiments, the covering material 1596 may be comprised of a polymer including polyamide (PA), PEBA(X), and / or polypropylene (PP). In some embodiments, the covering material 1596 may include a foam, such as EVA, TPU, and / or PU. Furthermore, in some embodiments, the covering material 1596 may be rubber, PEBAX, and / or TPE-E. As shown in FIG. 27 , the covering material 1596 is a transparent material. Thus, the plurality of support regions 1504 are visible through the covering material 1596 of the sole structure 1500 and from the exterior of the sole structure 1500. In some embodiments, the covering material 1596 may be translucent and / or opaque.Thus, in alternative embodiments, the plurality of support regions 1504 may not be visible through the covering material 1596 .

[0095] 27 , the inner conduit 1580 and the outer conduit 1564 are converted into a reinforcing member 1610. Before the sole plate 1530 is covered with the covering material 1596, the conduits 1564, 1580 can receive the reinforcing material 132 in a manner similar to that described above with respect to the conduit 128. Thus, the inner conduit 1580 and the outer conduit 1564 can be formed into the reinforcing member 1610 via the reinforcing material 132. As described herein, the reinforcing material 132 can be added to the conduits 1564, 1580 in a manner and process similar to that described above with respect to the conduit 128. Thus, in some embodiments, the conduits 1564, 1580 can extend outwardly from the support structure 1510 in a manner similar to that described above with respect to the conduit 128 so that the reinforcing material 132 can be added to the conduits 1564, 1580. As such, after the conduits 1564, 1580 are filled with the reinforcing material 132, the conduits 1564, 1580 can be trimmed / cut as described above. Thus, in some embodiments, FIG. 26 may show the conduits 1564, 1580, i.e., reinforcing members 1610, after filling with the reinforcing material 132 and trimming / cutting. As described herein, the conduits 1564, 1580 are transformed into the reinforcing members 1610 upon receiving the reinforcing material 132. Thus, the conduits 1564, 1580 and the reinforcing members 1610 are identical except for the reinforcing material 132 within the reinforcing members 1610. For ease of description, the terms conduits 1564, 1580 and reinforcing members 1610 may be used or referred to interchangeably herein when describing features.

[0096] Referring to FIG. 28 , a cross-sectional view of a sole structure 1500 is shown. As shown in FIG. 28 , a plurality of recesses 1586 are illustrated within a sole plate 1530. As described herein, the plurality of recesses 1586 can have different depths throughout. In other words, the depth distance of the recesses 1586 in a direction perpendicular to the longitudinal axis L can vary along each of the plurality of recesses 1586. In some embodiments, all of the plurality of recesses 1586 can have the same depth throughout the sole structure 1500. In other embodiments, one or more individual recesses of the plurality of recesses 1586 can have the same depth throughout the individual recess. That is, there is no depth variation within a single recess. Alternatively, each of the plurality of recesses 1586 can have a different depth within the individual recess (see FIG. 28 ). It is contemplated that the depth and size of each recess of the plurality of recesses 1586 can be adjusted depending on the support structures 1510 of the plurality of support regions 1504.

[0097] 28 , the support structures 1510 of the plurality of support regions 1504 extend partially into the cleat 1520. In some embodiments, the support structures 1510 may extend further into the cleat 1520 and / or completely through the cleat 1520. If completely through, the support structures 1510 and / or reinforcing members 1610 form protrusions that protrude from the cleat 1520 and are used to improve traction with the ground. Also, in some embodiments, the support structures 1510 may not extend into the cleat 1520. As shown in FIG. 28 , the support structures 1510 of the plurality of support regions 1504 extend above the top surface 1630 of the sole plate 1530. In some embodiments, the support structures 1510 may not extend above the top surface 1630 of the sole plate 1530. Also, as shown in FIG. 28 , the reinforcing members 1610 are shown extending partially through the support structures 1510.

[0098] As described herein, the plurality of support regions 1504 and / or reinforcing members 1610 can extend along portions of the sole structure 1500 that, due to the shape and material properties of the sole structure 1500, are expected to experience relatively high pressure, stress, or strain under expected loads. The plurality of support regions 1504 and / or reinforcing members 1610 can function as springs to propel the user forward during use. The plurality of support regions 1504 and / or reinforcing members 1610 can dampen some of the forces applied by the user to the footwear. Thus, the plurality of support regions 1504 and / or reinforcing members 1610 can provide functional benefits similar to a plate in the sole structure 1500.

[0099] Figure 29 illustrates an exemplary method 1700 for manufacturing the sole structure 1500 of Figures 25-28. This exemplary method is described with reference to the flowchart shown in Figure 29, although many other methods for forming the sole structure 1500 may alternatively be used.

[0100] Referring to FIG. 29 , method 1700 includes step 1704 of providing a plate (e.g., sole plate 1530) having a plurality of recesses (e.g., recess 1586) and a plurality of cleat ports (e.g., cleat port 1534). The sole plate 1530 can be manufactured using any manufacturing technique. In some embodiments, the sole plate 1530 can be 3D printed. Also, in some embodiments, the sole plate 1530 can be formed from a polymeric material or a metallic material. After the sole plate 1530 is provided, in step 1708, method 1700 includes forming a support structure, e.g., support structure 1510, and conduits, e.g., conduits 1564, 1580, along the plate, e.g., sole plate 1530. As described herein, in step 1708, a plurality of support regions 1504, an inner conduit 1580, an outer conduit 1564, and / or a plurality of support links 1540 can be added to the sole plate 1530. The support structure 1510, support link 1540, and conduits 1564, 1580 can be added using 3D printing or different additive manufacturing processes. In some embodiments, the support structure 1510, support link 1540, and / or conduits 1564, 1580 may be added by injection molding.

[0101] 29 , method 1700 further includes step 1712 of introducing a reinforcing material, e.g., reinforcing material 132, into a conduit, e.g., conduits 1564, 1580, to form a reinforcing member, e.g., reinforcing member 1610. As described herein, introducing reinforcing material 132 into conduits 1564, 1580 may be similar to that described above with respect to conduit 128. In some embodiments, after step 1712, conduits 1564, 1580 (here, reinforcing member 1610) may be trimmed and / or cut in a manner similar to that described above.

[0102] 29 , method 1700 further includes step 1716 of molding a plurality of cleats (e.g., a plurality of cleats 1520) corresponding to a plurality of cleat ports (e.g., a plurality of cleat ports 1534). In step 1716, sole plate 1530 may be co-molded or injection molded to add a plurality of cleats 1520 and / or covering material 1596. In some embodiments, sole plate 1530 with support structure 1510 may be added to a plurality of molds to add covering material 1596 and a plurality of cleats 1520 thereon. Once step 1716 is complete, sole structure 1500 is fully formed and may be added to another sole structure and / or an upper to form footwear.

[0103] Referring to FIG. 30, another embodiment of a sole structure 1900 is shown. The same reference numbers and terminology are used to describe aspects of the sole structure 1900 that are structurally and functionally equivalent to the sole structure 300 of FIGS. 3-11 and the sole structure 1500 of FIGS. 25-29. As described herein, the sole structure 1900 is similar to the sole structure 1500 described in FIGS. 25-29, except for the features described below. As shown in FIG. 30, the sole structure 1900 includes a medial forefoot support portion 1910 that is larger than the medial forefoot support portion 1552 of FIGS. 25-29. The medial forefoot support portion 1910 is connected to the medial midfoot support portion 1556 by a plurality of support links 1540. The medial forefoot support portion 1910 extends along a majority of the forefoot region 328 and across a plurality of cleat ports 1534. The sole plate 1530 also includes a forefoot recess 1920 that includes a medial forefoot support portion 1910. As discussed herein, Figure 30 shows the sole structure 1900 before the cleats 1520 and covering material 1596 are added.

[0104] 30 , the medial conduit 1930 extends from the toe side of the medial midfoot support 1556 to the medial forefoot support 1910. The medial conduit 1930 extends through the support links 1540 to the medial forefoot support 1910. Within the medial forefoot support 1910, the medial conduit 1930 branches into a first branch 1940 and a second branch 1944 of the medial conduit 1930. The first branch 1940 of the medial conduit 1930 extends toward the lateral surface 312 of the sole structure 1900, and the second branch 1944 extends toward the medial surface 316 of the sole structure 1900. The structure 1900 extends toward the toe tip 304 of the sole structure 1900. The first branch 1940 and the second branch 1944 extend over some of the cleat ports 1534. However, in some embodiments, the first branch 1940 and the second branch 1944 may not extend over the cleat ports 1534. Also, in some embodiments, the inner conduit 1930 may include more branches than those shown. Furthermore, in some embodiments, the outer conduit 1564 may include multiple branches and extend in multiple directions across various portions of the sole structure 1900. The first and second branches 1940, 1944 of the inner conduit 1930 may extend along portions of the sole structure 1900 that are expected to experience relatively high pressure, stress, or strain under expected loads due to the shape and material properties of the sole structure 1900. Thus, in this embodiment, the first and second branches 1940, 1944 extend across the balls of the foot and can provide support and / or act as springs to propel the user forward. In some embodiments, the inner conduit 1930 and the outer conduit 1564 can be connected at one or more locations.

[0105] Referring to Figures 31A and 31B, another embodiment of a sole structure 2100 is shown. Aspects of the sole structure 2100 that are structurally or functionally equivalent to the sole structure 300 of Figures 3-11 and the sole structures 1500, 1900 of Figures 25-29 are described using the same reference numerals and terminology. In some embodiments, the sole structure 2100 may be constructed from individual segments or components interconnected to one another by reinforcing material 132. As shown in Figure 31B, the sole structure 2100 includes a front portion 2104, a rear portion 2108, and a conduit 2120. The rear portion 2108 includes a heel region 332 and a rear portion 2130 of the conduit 2120 that extends from the heel tip 308 to a mating surface 2134 of the rear portion 2108. The front portion 2104 includes a forefoot section 328 and a front portion 2140 of the conduit 2120 that extends from the toe tip 304 to a mating surface 2144 of the front portion 2104. In some embodiments, the front portion 2104 and the rear portion 2108 are integrally molded as a single seamless component such that the mating surfaces 2134, 2144 are seamlessly embedded within the final portion of the sole structure 2100 (see FIG. 31B). In some embodiments, a bonding mold 2150 can be used to fabricate the sole structure 2100 (see FIG. 31A).

[0106] 31A , a mating mold 2150 can include a posterior mold section 2154 having a posterior core 2158 and a front mold section 2162 having a front core 2166. The posterior core 2158 extends from a rear recessed wall 2170 of the posterior mold section 2154, and the front core 2166 extends from a front recessed wall 2174 of the front mold section 2162. When the posterior mold section 2154 and the front mold section 2162 are connected together, an end 2178 of the posterior core 2158 contacts an end 2182 of the front core 2166, forming a mold cavity 2184.

[0107] As material is injected into the front mold section 2162 and the rear mold section 2154, the material surrounds the front core 2166 and the rear core 2158 and conforms to the shape of each mold cavity to form the sole structure 2100. When the sole structure 2100 is removed from the combined mold 2150, a continuous hollow conduit, or conduit 2120, extends from the rear portion 2108 to the front portion 2104 (see FIG. 31B ). Thus, the rear core 2158 and the front core 2166 of the combined mold 2150 form the conduit 2120. As described herein, the conduit 2120 can be similar to and function similarly to the conduit 128 described above. The combined mold 2150 may include one or more channels (not shown) for injecting material.

[0108] 31A and 31B, the rear recessed wall 2170 forms a rear cavity 2186, and the front recessed wall 2174 forms a front cavity 2190. The rear cavity 2186 and the front cavity 2190 allow the conduit 2120 to protrude outwardly from the sole structure 2100 (see FIG. 31B). As mentioned above, the protruding portion of the conduit 2120 can be removed before or after adding the reinforcing material 132 to the conduit 2120. In some embodiments, the rear mold section 2154 and the front mold section 2162 can include multiple rear cores 2166 and front cores 2158 therein. For example, the rear mold section 2154 and the front mold section 2162 can include two, three, four, five, six, or more rear cores 2166 and front cores 2158. Thus, the sole structure 2100 can include multiple conduits 2120 therein. Additionally, while the rear core 2158 and the front core 2166 are shown as straight, they can have different shapes and configurations. For example, the rear core 2158 and the front core 2166 can be curved or angled in the rear mold section 2154 and the front mold section 2162. In some embodiments, the rear core 2158 and the front core 2166 can have a splined or curved shape. In this manner, the conduits 2120, similar to the conduits 128 described above, can penetrate the sole structure 2100 in any direction or along any pattern. In an alternative embodiment, the rear core 2158 and the front core 2166 can penetrate in a lateral-medial direction instead of a heel-to-toe direction.

[0109] In some embodiments, the rear mold section 2154 and the front mold section 2162 may not include the rear concave wall 2170 and the front concave wall 2174. Thus, in such embodiments, the sole structure 2100 may not have the conduits 2120 extending to the outside of the sole structure 2100. In some embodiments, the bonding mold 2150 may include heating and / or cooling ducts for heating and / or cooling the material within the bonding mold 2150. Also, in some embodiments, the sole structure 2100 may be formed with sacrificial structures. The sacrificial structures may be removed after the molding process by heat, light, contact, etc. Furthermore, in some embodiments, one or more elements may be added to the bonding mold 2150 to form cavities and openings within the sole structure 2100.

[0110] In some embodiments, instead of the rear mold section 2154 and the front mold section 2162, the combined mold 2150 may include an upper mold section and a lower mold section. Thus, the upper mold section forms the upper portion of the sole structure 2100, and the lower mold section forms the lower portion of the sole structure 2100. The upper mold section has an upper core at the bottom of the upper mold section, and the lower mold section has a lower core at the top of the lower mold section. The upper and lower cores each have a semicircular shape and mate with each other to form a cylindrical or circular cross section when the lower mold section is secured to the upper mold section. Then, when molded, the two semicircular cores form the conduit 2120. In some embodiments, the upper and lower mold sections can be filled with different materials, such that the sole structure 2100 formed from the mold can have different hardnesses across the vertical dimension of the sole structure 2100 (the direction perpendicular to the ground when the sole structure 2100 is placed on the ground).

[0111] Referring to FIG. 32 , another embodiment of a sole structure 2200 is shown in schematic form. Aspects of the sole structure 2200 that are structurally or functionally equivalent to the sole structure 300 of FIGS. 3-11 are described using the same reference numerals and terminology. As shown in FIG. 32 , the sole structure 2200 is structurally or functionally equivalent to the sole structure 300 of FIGS. 3-11 . As shown in FIG. 32 , the sole structure 2200 is divided into two parts, including a first sole component 2202 and a second sole component 2204 spaced apart from the first sole component 2202. The first sole component 2202 is connected to the second sole component 2204 by a plurality of conduits 2210. In some embodiments, the first sole component 2202 is completely separate and independent from the second sole component 2204, except for the connection provided by the plurality of conduits 2210, and no portion of the first sole component 2202 is in direct contact with the second sole component 2204. In other words, the first sole component 2202 and the second sole component 2204 are separate components that are only indirectly coupled to one another by the plurality of conduits 2210. In some embodiments, the plurality of conduits 2210 shown in FIG. 32 are identical to the conduits 128 shown in FIGS. 3-11 and described above. Thus, the plurality of conduits 2210 are configured to receive the reinforcing material 132 to form the reinforcing member 160 and support the sole structure 2200.

[0112] 32 , the plurality of conduits 2210 provide a bridge across a gap 2220 between the first sole component 2202 and the second sole component 2204. At least one of the conduits 2210 defines a bridge distance 2222 along which a portion of the conduit is exposed and not embedded in either the first sole component 2202 or the second sole component 2204 as it extends between the first sole component 2202 and the second sole component 2204. The bridge distance 2222 of at least one conduit 2210 is approximately equal to the gap distance 2224 measured between the first sole component 2202 and the second sole component 2204. In some embodiments, the bridge distance 2222 differs from the gap distance 2224. In some embodiments, the gap distance 2224 varies in one or more directions, such as, for example, vertically (upper-sole) or laterally (medial-lateral). In some embodiments, the maximum value of bridge distance 2222 is greater than the minimum value of gap distance 2224. In some embodiments, the maximum value of gap distance 2224 is greater than the maximum value of bridge distance 2222. Thus, first sole component 2202 is separated from second sole component 2204, exposing multiple conduits 2210 (see FIG. 34 ). In some embodiments, first sole component 2202 may be a midsole component, an outsole component, and / or an insole component in or near the heel region of sole structure 2200. Also, in some embodiments, second sole component 2204 may be a midsole component, an outsole component, or an insole component in or near the forefoot region of sole structure 2200.

[0113] 32 , the plurality of conduits 2210 includes a first conduit 2210a and a second conduit 2210b. In some embodiments, the plurality of conduits 2210 can include 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more conduits 2210. However, for ease of illustration, only two conduits 2210 are shown in FIG. 32 . Each of the plurality of conduits 2210 extends through the first sole component 2202 and the second sole component 2204. In some embodiments, the plurality of conduits 2210 may extend only partially within the first sole component 2202 and / or the second sole component 2204. In some embodiments, the plurality of conduits 2210 may extend through one of the sole components 2202, 2204 and partially within the other sole component 2202, 2204. Also, in some embodiments, the first conduit 2210a, unlike the second conduit 2210b, may extend into or through the first sole component 2202 and the second sole component 2204. In this manner, the sole structure 2200 provides great flexibility in designing the conduits 2210 to extend partially into and / or through the first sole component 2202 and / or the second sole component 2204. Furthermore, in FIG. 32 , the conduits 2210 are shown parallel and linear to one another. However, in some embodiments, the conduits 2210 may include various curves, contours, and spline shapes, similar to the conduits 128 and support links 1540 described above.

[0114] 32 , each of the plurality of conduits 2210 includes an inlet 2240 and an exhaust or outlet 2242. As described herein, in some embodiments, the inlet 2240 can be the outlet 2242, or vice versa. As shown in FIG. 32 , the inlets 2240 and outlets 2242 of the plurality of conduits 2210 extend outwardly from the first and second sole components 2202, 2204. In some embodiments, the injection module 112 is connected to the inlets 2240 and / or outlets 2242 and adds the reinforcement material 132 to the plurality of conduits 2210 in a manner similar to that described above with respect to the conduit 128. In some embodiments, after the plurality of conduits 2210 receives the reinforcement material 132, the inlets 2240 and outlets 2242 are trimmed and / or cut in a manner similar to that described above. After the plurality of conduits 2210 is filled with the reinforcing material 132 and the inlets 2240 and outlets 2242 are removed, the sole structure 2200 is molded, post-processed (e.g., foamed, coated, treated, painted), or finished to form footwear 2280 (see FIG. 34 ). In some embodiments, the sole components 2202, 2204, and / or the plurality of conduits 2210 can be treated or coated with a particular material or finish. As described herein, the dashed lines in FIG. 32 indicate portions of the plurality of conduits 2210 disposed within the first sole component 2202 or the second sole component 2204, or portions of the plurality of conduits 2210 that have been removed during a post-processing step.

[0115] In some embodiments, the schematic diagram in FIG. 32 can represent a recessed space that is added to a mold to form sole structure 2200. In other words, the general shape and contours of sole structure 2200, such as the features of FIG. 32, are added to a mold, and material is molded around that shape to form a portion of sole structure 2200. Reinforcement material 132 can then be added to multiple conduits 2210, and first and second sole components 2202, 2204 can be injected into this recessed space to form sole structure 2200. In some embodiments, first sole component 2202 and second sole component 2204 need only be added to this recessed space, not injected therein. Also, in some embodiments, first sole component 2202 may be formed separately from second sole component 2204 and connected to each other by multiple conduits 2210 through a separate molding process.

[0116] Referring to Figure 33, another embodiment of a sole structure 2300 is shown in schematic form. The same reference numbers and terminology are used to describe aspects of the sole structure 2300 that are structurally or functionally equivalent to the sole structure 300 of Figures 3-11 and the sole structure 2200 of Figure 32. As described herein, the sole structure 2300 is identical to the sole structure 2200 of Figure 32, except for the conduit configuration, as described below. Specifically, instead of having multiple conduits 2210 as in Figure 32, the sole structure 2300 of Figure 33 includes a single conduit 2302 that extends continuously from the first sole component 2202 to the second sole component 2204 and back to the first sole component 2202. Conduit 2302 includes an inlet 2310, a first internal sole component portion 2312, a first exposed portion 2314, a second internal sole component portion 2316, a second exposed portion 2318, and a third internal sole component portion 2320. Second internal sole component portion 2316 forms a curve or bend to create a continuous U-shape connecting first and second exposed portions 2314, 2318 of conduit 2302. Thus, during use, reinforcement material 132 is added to conduit 2302 via inlet 2310 and travels through conduit 2302 to third internal sole component portion 2320. As discussed herein, the features described above with respect to FIG. 32 can also be applied to sole structure 2200 of FIG. 33.

[0117] 33 , sole structure 2300 reduces the amount of material and features that need to be trimmed after reinforcing material 132 is attached to sole structure 2300. Therefore, once conduit 2302 becomes reinforcing member 160, only inlet 2310 needs to be removed. As described herein, conduit 2302 can have any type of configuration through first sole component 2202 and second sole component 2204. For example, conduit 2302 may include another U-shaped internal portion within first sole component 2202 that directs conduit 2302 toward or into second sole component 2204. In such an embodiment, conduit 2302 would include three exposed portions instead of two. Also, in some embodiments, conduit 2302 can snake through first sole component 2202 and second sole component 2204 in any configuration to provide appropriate support and reinforcement to different portions of sole structure 2300. As described herein, the dashed lines in FIG. 33 indicate portions of the conduit 2302 that are disposed within the first sole component 2202 or the second sole component 2204, or portions of the conduit 2302 that are removed during post-processing steps.

[0118] Because sole structure 2300 does not have an outlet portion, sole structure 2300 requires an injection process to force reinforcing material 132 through conduit 2302. Therefore, the injection process requires increased injection force to overcome the back pressure caused by this closed-end configuration. Also, in some embodiments, sole structure 2300 may include a pressure relief or air displacement system to help replace the air in conduit 2302 with reinforcing material 132. For example, in some embodiments, the pressure relief or air displacement system may comprise a small opening or vent connecting third internal sole component portion 2320 to the exterior of sole structure 2300. In some embodiments, sole structure 2300 may be formed from a support or lattice structure similar to component 108 (e.g., support structure or lattice structure 170) that allows air to escape from conduit 2302 during the injection process. Also, in some embodiments, the sole structure 2300 may include different curing conditions (e.g., time or temperature) to ensure that the reinforcing material 132 at the closed end of the conduit 2302 is sufficiently cured.

[0119] Referring to FIG. 34, footwear 2280 is shown. Footwear 2280 represents a final product that combines sole structure 2200, as shown generally in FIG. 32, and sole structure 2300, as shown generally in FIG. 33. Footwear 2280 is designated herein with reference numbers corresponding to sole structure 2200 of FIG. 32. However, footwear 2280 may also correspond to sole structure 2300 of FIG. 33. As shown in FIG. 34, footwear 2280 includes a first sole component 2202 and a second sole component 2204 connected by a plurality of conduits 2210. As described above, the plurality of conduits 2210 are exposed to the external environment between first sole component 2202 and second sole component 2204. As described herein, first sole component 2202 is a heel midsole component, and second sole component 2204 is a forefoot midsole component. However, it is envisioned that the first and second sole components 2202, 2204 may be an insole, a removable insert, an outsole, a plate or propulsion member, a cleat, a heel counter, a heel cup, a tongue, a vamp, a lacing system component, an entire sole, and / or combinations thereof. As discussed above, the plurality of conduits 2210 formed in the reinforcing member 160 by the reinforcing material 132 provides support and spring-like properties to various advantageous portions of the sole structure 2200.

[0120] Referring to FIG. 35 , a schematic cross-sectional view of a mold 2500 is shown. The mold 2500 is a bonded mold including a first mold part 2502 and a second mold part 2504. The first mold part 2502 and the second mold part 2504 form a plurality of mold cavities 2506 therebetween. As shown in FIG. 35 , the mold 2500 can form one or more reinforcing members 2520 within the plurality of mold cavities 2506. In some embodiments, the reinforcing members 2520 are similar to or identical to the reinforcing members 160 described above. As further shown in FIG. 35 , the mold 2500 includes three mold cavities 2506. However, it is envisioned that the mold 2500 can include any number of mold cavities 2506.

[0121] 35 , the process for forming the reinforcing member 2520 will be described below. First, first and second mold sections 2502, 2504 are fastened together to form a plurality of mold cavities 2506. Next, the reinforcing material 132 is injected into the plurality of mold cavities 2506 to form the reinforcing member 2520. Once the reinforcing member 2520 has solidified, the first and second mold sections 2502, 2504 are separated from each other, and the reinforcing member 2520 is removed. The reinforcing member 2520 can then be integrally molded with another material to form a sole structure. In this manner, the reinforcing member 2520 is formed by the mold 2500, and then the reinforcing member 2520 is inserted into another mold to form the sole structure. In some embodiments, the reinforcing member 2520 is formed from any material with a high strength-to-weight ratio, such as a thermoplastic material, a thermoset material, an organic material, or a composite material including, for example, carbon fiber, aramid fiber, glass fiber, boron fiber, natural fibers, or organic fibers.

[0122] In some embodiments, mold 2500 can be rotated and multiple materials can be injected into mold 2500. For example, in some embodiments, a first material can be injected into mold 2500. The mold can then be rotated to a different position, and a second material, different from the first material, can fill the remaining space within multiple mold cavities 2506. In such embodiments, the first material does not fill the entire mold cavity 2506. In some embodiments, mold 2500 can include only a first mold section 2502 or a second mold section 2504. Thus, a flat surface is placed on first mold section 2502 or second mold section 2504, and mold 2500 generates a semicircular reinforcing member. Two semicircular reinforcing members are molded and then molded together to form reinforcing member 2520. The two semicircular reinforcing members can be made of different materials and / or have different properties. For example, in some embodiments, a first semicircular reinforcing member may have a first hardness and a second semicircular reinforcing member may have a second hardness that is different from the first hardness. Thus, the reinforcing member 2520 may be formed to have different material properties or materials throughout the reinforcing member 2520.

[0123] 36A , a schematic diagram of a mold 2600 configured to manufacture a sole component 2602 is shown. The mold 2600 includes an upper plate 2610 and a lower plate 2612. The upper plate 2610 has a first wall 2614 and at least one second wall 2616. The lower plate 2612 of the mold 2600 has a body 2630, a plurality of outer walls 2632, a top wall 2634, a plurality of insert walls 2636, and at least one cavity 2638, each cavity 2638 being provided with at least one corresponding cavity wall 2640. At least one injection passage 2642 originates from one of the plurality of outer walls 2632, extends therefrom through the body 2630, and is fluidly connected to the corresponding at least one cavity wall 2640. The first wall 2614 and the top wall 2634 are configured to be selectively secured to form part of a seal for at least one cavity 2638, and a liquid plastic material can be filled into the cavity 2638. The at least one cavity 2638 can be injected, poured, or sprayed to form the sole component 2602. A plurality of mandrel passages 2644 extend through the plurality of outer walls 2632, the body 2630, and the plurality of insert walls 2636.

[0124] Referring to FIG. 36A , the mold 2600 is used with a plurality of optical construction volume elements, or mandrels 2650. The plurality of mandrels 2650 are made of a substantially rigid material, such as steel or aluminum. In some embodiments, the mandrels 2650 each have a collar 2652. During use, each mandrel 2650 is configured to pass through one of the plurality of mandrel passages 2644 and extend into at least one cavity 2638 of the mold 2600. In this manner, the plurality of mandrels 2650 form conduits or channels 2660 within the sole component 2602 (see FIGS. 36A and 36B ). The conduits 2660 are then filled with the reinforcing material 132 in a manner similar to that described above with respect to the conduits 128. In some embodiments, the sole component 2602 can include 2, 3, 4, 5, 6, 7, 8, or more conduits 2660.

[0125] 36A , the process for forming the sole component 2602 is described below. First, the upper plate 2610 is placed on the lower plate 2612, and multiple mandrels 2650 are inserted into at least one cavity 2638 through multiple mandrel passages 2644. A first distal end 2670 of a first mandrel 2650 a contacts a second distal end 2672 of a second mandrel 2650 b, thereby forming a continuous recessed space within the at least one cavity 2638. Once the mandrels 2650 are inserted into the mold 2600, materials are injected through the at least one injection passage 2642 to fill the at least one cavity 2638. In some embodiments, multiple materials are injected through the at least one injection passage 2642 to fill the at least one cavity 2638. Once at least one cavity 2638 is filled and the material has solidified or cooled, the multiple mandrels 2650 are removed from the mold 2600. The upper plate 2610 is then removed, and the sole component 2602 is removed from the mold 2600 and moved to another area, where the conduits 2660 are filled with reinforcing material 132 in a similar process as described above. In some embodiments, once the multiple mandrels 2650 are removed from the mold 2600, the reinforcing material 132 may be injected into the sole component 2602 while the sole component 2602 is still in the mold 2600. Thus, in such embodiments, the reinforcing material 132 may be injected through the multiple mandrel passages 2644 and into the conduits 2660. Also, in some embodiments, a tube (not shown) may be inserted through the multiple mandrel passages 2644 and connected to the conduits 2660, and the reinforcing material 132 may be inserted therein.

[0126] As described herein, the mold 2600 may include multiple sensors for measuring activity within at least one cavity 2638. Additionally, in some embodiments, the mold 2600 may include various heating and cooling elements within the upper plate 2610 or the lower plate 2612. For example, in some embodiments, the mold 2600 may include mold conduits within the lower plate 2612 that can move liquids, such as refrigerant and / or water, through the body 2630 of the lower plate 2612. The mold conduits can route cold or hot liquids through the lower plate 2612 to further heat or cool material injected into the mold 2600. Additionally, in some embodiments, the upper plate 2610 may include a handle for removing the upper plate 2610 from the lower plate 2612. Additionally, in some embodiments, the upper plate 2610 can be removed from the lower plate 2612 using, for example, a hydraulic lift, a hoist, a crane, and / or a winch. As described herein, any of the features described with respect to mold 2600 can be used with mold 2500 illustrated in FIG.

[0127] Referring to FIG. 36B, the sole component 2602 is shown removed from the mold 2600. As described herein, the sole component 2602 may be a heel component, a midfoot component, and / or a forefoot component. The sole component 2602 may also be an insole, a midsole, and / or an outsole. Furthermore, depending on the number of mandrels 2650 used in the molding process, the sole component 2602 may include any number of conduits 2660. In some embodiments, the mandrels 2650 may be curved to form curved conduits. As described above, the sole component 2602 has reinforcing material 132 injected into the conduits 2660. The conduits 2660 are positioned in strategic locations on the sole component 2602 to provide additional support to a wearer of the sole component 2602.

[0128] As discussed above, sole structures according to the present disclosure can be formed using a combination of manufacturing techniques, such as injection molding, additive manufacturing, fiber injection, etc. As described herein, the disclosures described with respect to any sole structure can also be applied or implemented with respect to other sole structures. Accordingly, it is contemplated that any feature described in this disclosure can be used in combination with any other feature.

[0129] Other configurations are possible in other embodiments. For example, specific features and combinations of features presented in the above description with respect to particular embodiments can also be used in other embodiments and in other combinations, as appropriate. Also, any of the embodiments described herein can be modified to include any of the structures or methods disclosed in connection with other embodiments. Furthermore, the disclosure is not limited to the types of footwear specifically shown. Furthermore, aspects of the footwear of the embodiments disclosed herein can be modified for use with any type of footwear, apparel, or other athletic equipment.

[0130] As noted above, the present invention has been described in connection with specific embodiments and examples, but those skilled in the art will understand that the present invention is not necessarily limited thereto, and that various other embodiments, examples, applications, modifications, and derivations from the embodiments, examples, and applications are encompassed within the scope of the claims appended hereto. The entire disclosure of each patent and publication cited herein is incorporated by reference as if each patent or publication were individually incorporated by reference. Various features and advantages of the present invention are set forth in the following claims.

[0131] As used herein, the term "about" refers to variations in numerical values ​​that may result from, for example, common measuring and manufacturing procedures used in footwear or other products that may include embodiments disclosed herein, inadvertent errors in these procedures, differences in the manufacture, source, or purity of ingredients used in making a composition or mixture or practicing a method, etc. Throughout this disclosure, the terms "about" and "approximately" refer to a range of ±5% of the numerical value that precedes them. As described herein, all ranges disclosed herein include the outer boundaries of the range. [Industrial Applicability]

[0132] It will be apparent to those skilled in the art in light of the above description that numerous modifications of the present invention are possible. Accordingly, this description is for illustrative purposes only and is presented to enable 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.

[0133] [CROSS-REFERENCE TO RELATED APPLICATIONS] This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63 / 655,639, filed June 4, 2024, and U.S. Provisional Patent Application No. 63 / 696,065, filed September 18, 2024, each of which is incorporated herein by reference in its entirety.

[0134] [Federally Sponsored Research and Development Reference] Not applicable.

[0135] [Sequence table] Not applicable.

Claims

1. forming a sole structure using an additive manufacturing system, the sole structure including a conduit extending within a region of the sole structure, the conduit including an end projecting outwardly from a surface of the sole structure and a channel defined through the conduit; connecting the end of the conduit to an injection device; injecting a reinforcing material into the channel of the conduit to form a reinforcement; removing a portion of the end of the conduit.

2. The method of claim 1 , wherein the sole structure includes a lattice region having a lattice structure including a plurality of beams interconnected by a plurality of nodes and defining a plurality of voids.

3. 2. The method of claim 1, wherein the sole structure includes a midfoot region located between a forefoot region and a heel region, an upper surface opposite a bottom surface, and an outer surface opposite a medial surface, the conduit being disposed within each of the forefoot region, the midfoot region, and the heel region, and the end of the conduit being adjacent to at least one of the upper surface or the bottom surface.

4. The method of claim 1 , further comprising creating a design model of the sole structure including an arrangement of the conduits, and the additive manufacturing system configured to receive the design model and form the sole structure.

5. The method of claim 1 , further comprising curing the reinforcing material within the sole structure, the curing comprising applying at least one of heat, light, or electricity to harden the material.

6. The method of claim 1 , wherein the sole structure is composed of a material different from the reinforcing material injected into the conduit to form the reinforcement.

7. The method of claim 1 , wherein the reinforcing material comprises continuous fiber bundles and a resin material.

8. The method of claim 1 , wherein the channel is at least partially filled with the reinforcing material.

9. The method of claim 1 , wherein the channel is completely filled with the reinforcing material.

10. an additive manufacturing system configured to form a sole structure having a lattice structure and at least one conduit extending through a region of the lattice structure; an injection device connected to an end of the at least one conduit and configured to inject a reinforcing material into a channel defined by the at least one conduit; a tool configured to remove at least a portion of the end of the at least one conduit.

11. The system of claim 10 , wherein the reinforcing material comprises a resin material that is infused into the channels in a liquid state.

12. The system of claim 11 , wherein the injector introduces the resin material simultaneously with the continuous fiber bundle.

13. The system of claim 11 , wherein the injector sequentially introduces the resin material and the continuous fiber bundle.

14. The system of claim 10 , further comprising a curing module, wherein the reinforcing material is cured to form a reinforcement having a greater density than the material of the sole structure.

15. The system of claim 10 , wherein the region of the sole structure is anisotropic.

16. Provides a sole plate, additionally forming a plurality of support regions and at least one conduit on the sole plate, the at least one conduit including a channel defined therethrough, the at least one conduit extending through a portion of at least one of the plurality of support regions; injecting a reinforcing material into the channel of the at least one conduit to form a reinforcement; A method of manufacturing a sole structure, comprising molding the sole plate having the plurality of support regions and the at least one conduit with a covering material.

17. The method of claim 16 , wherein the covering material forms a plurality of cleats.

18. The method of claim 17 , wherein at least one of the plurality of support regions is disposed between at least one of the plurality of cleats and an upper surface of the sole structure.

19. The method of claim 17 , wherein at least one of the plurality of support regions is located partially within at least one of the plurality of cleats.

20. the sole plate includes a plurality of recesses; The method of claim 16 , wherein the plurality of regions are disposed within the plurality of recesses.

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