Method of using a three-dimensional printer and a compression mold to manufacture a plate for a footwear product

Abstract

A method of manufacturing a component for a sole structure of an article of footwear includes providing a printer having a platform, a first head receiving a first supply, and a second head receiving a second supply. The method further includes printing a base layer on the platform, the base layer including a substrate material and defining a longitudinal axis. The method further includes continuously printing a first fiber layer on the base layer, the first fiber layer defining a first fiber orientation disposed at a first angle relative to the longitudinal axis, and continuously printing a second fiber layer on the first fiber layer, the second fiber layer defining a second fiber orientation disposed at a second angle relative to the longitudinal axis. The first angle is different from the second angle.

Description

[Technical Field]

[0001] [CROSS-REFERENCE TO RELATED APPLICATIONS] This application claims the benefit of and priority to U.S. Application No. 17 / 578,752, filed January 19, 2022, which is incorporated herein by reference in its entirety.

[0002] [Federally Sponsored Research and Development Reference] Not applicable

[0003] [Sequence table] Not applicable

[0004] The present disclosure relates generally to footwear having plates, and more particularly to footwear having plates formed by additive manufacturing processes to have customized reinforcement and propulsion patterns. [Background technology]

[0005] Most conventional shoes and footwear generally include an upper and a sole attached to the lower end of the upper. Conventional shoes also include an internal space, or void or cavity, formed by the inner surface of the upper and the sole, which receives the user's foot before securing the shoe to the foot. The sole is attached to the bottom surface or boundary of the upper and is positioned between the upper and the ground. As a result, the sole typically provides the user with stability and cushioning while wearing the shoe. In some cases, the sole may include multiple components, such as an outsole, midsole, and upper. 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 and impact energy on the foot or leg when the user is running, walking, or engaging in another activity. The sole may also include additional components, such as an embedded plate, to increase the overall rigidity of the sole and reduce energy loss during use.

[0006] The upper generally extends upward from the sole and defines an interior cavity that completely or partially encases the foot. The upper often spans the instep and toe areas, as well as the medial and lateral sides of the foot. Many footwear pieces also include a tongue that extends across the instep to bridge the gap between the medial and lateral edges of the upper. The tongue may also be positioned below the lacing system, between the medial and lateral sides of the upper, to allow adjustment of the shoe's tightness. The tongue may also be user-operable to move the foot in and out of the interior space or cavity. Furthermore, the lacing system allows the user to adjust certain dimensions of the upper and sole, thereby allowing the upper to fit a wide variety of foot shapes and sizes.

[0007] The sole can include a wide variety of materials selected based on one or more intended uses of the shoe. The sole may also include sections of different materials tailored to specific areas of the upper. For example, the forefoot and adjacent heel sections of the sole may be more durable or rigid for increased stability. Other areas of the shoe may be softer to provide flexibility, cushioning, and conformability to the user's foot. Additionally, individuals suffering from flat feet or other foot conditions often incorporate insoles into their shoes for more targeted support. Given the wide variety of user preferences, customizable shoes are desirable to provide cushioning, support, and rigidity along various areas, directions, and zones of the shoe. Summary of the Invention [Problem to be solved by the invention]

[0008] However, while many currently available shoes have various features related to the above characteristics, many shoes have sole structures that suffer from a lack of customization because they include sole structures manufactured in standard sizes and shapes. Furthermore, many athletic shoes, particularly running shoes, are manufactured in a manner that produces a significant amount of waste.

[0009] Therefore, what is desired is an article of footwear that lends itself to customized characteristics and that is manufactured with minimal waste. These and other shortcomings of the prior art are outlined in the following disclosure. [Means for solving the problem]

[0010] Many advantages of the articles of footwear described herein will be apparent to those skilled in the art. The articles of footwear described herein can have a variety of configurations. The articles of footwear can have an upper and a sole structure coupled to the upper.

[0011] In some embodiments, a method for manufacturing a component for a sole structure of an article of footwear includes providing a printer having a platform, a first head receiving a first supply, and a second head receiving a second supply. The method further includes printing a base layer on the platform, the base layer being made of a substrate and defining a longitudinal axis. The method further includes sequentially printing a first fiber layer on the base layer, the first fiber layer defining a first fiber orientation disposed at a first angle relative to the longitudinal axis, and sequentially printing a second fiber layer on the first fiber layer, the second fiber layer defining a second fiber orientation disposed at a second angle relative to the longitudinal axis. The first angle is different from the second angle. The method also includes subjecting the printed model to a compression molding process. The printed model includes at least the base layer, the first fiber layer, and the second fiber layer.

[0012] In some embodiments, the first fiber layer comprises at least 60% substrate material. In other embodiments, the second fiber layer comprises at least 50% fiber material. Furthermore, the first fiber layer and the second fiber layer define different layer volumes. In some embodiments, the first fiber layer comprises at least one of carbon fiber, aramid fiber, boron fiber, or glass fiber. In some embodiments, the printed model comprises at least five fiber layers. The printed model includes an arch segment extending between the rear segment and the front segment. Further, a transparent resin is applied to the printed model within the compression mold. The printed model includes a third fiber layer defining a third fiber orientation oriented at a third angle relative to the longitudinal axis, the third angle being equal to the first angle, and the second fiber layer being separated from the first fiber layer by the second fiber layer.

[0013] In some embodiments, a plate is provided in a sole structure of an article of footwear including an upper with an insole. The plate includes an inner surface facing the outer surface, a heel end facing the toe end, a base layer including a substrate material, and multiple composite layers connected to the base layer. Each composite layer includes a first volume of the substrate and a second volume of a fiber material. The first volume of the substrate material and the second volume of the fiber material are different. Each composite layer defines a fiber orientation, and the fiber orientation differs between adjacent composite layers. The plate is printed layer by layer to define an upper surface and a bottom surface, and at least a portion of the upper surface is spaced apart from the insole of the upper.

[0014] In some embodiments, the composite layers are arranged as a stack between the top and bottom surfaces of the plate, the stack having quasi-isotropic properties. Each composite layer has anisotropic properties, and the anisotropy varies between adjacent composite layers. The anisotropy includes at least one of bending resistance, torsional resistance, or tensile stiffness. The first volume of the substrate is smaller than the second volume of the fibrous material. The second volume of the fibrous material includes at least one of carbon fiber, aramid fiber, boron fiber, or glass fiber.

[0015] In yet another aspect, a method for using a three-dimensional printer and compression mold to manufacture a plate for a footwear article includes providing a supply of substrate material to a first head of the printer, providing a supply of fiber material to a second head of the printer, providing a preformed model on a platform within the printer, and providing a design model to the printer. The first head and the second head are selectively activated and deactivated to print at least two composite layers on the preformed model. The at least two composite layers are separated from the preformed model and received in the compression mold.

[0016] In some embodiments, each of the at least two composite layers includes a continuous fiber strand provided by the second head. The plate includes a front segment having a first stiffness, an arch segment having a second stiffness, and a rear segment having a third stiffness. The first stiffness is greater than the second stiffness, and the third stiffness is greater than the first stiffness. The first stiffness, the second stiffness, and the third stiffness are equal.

[0017] Other aspects of the articles of footwear, including features and advantages of the articles of footwear, will become apparent to one of ordinary skill in the art upon review of the figures and detailed description herein, and therefore, all such aspects of the articles of footwear are intended to be included in the detailed description and this summary. [Brief explanation of the drawings]

[0018] [Figure 1] FIG. 1 is a perspective view of the bottom and medial side of an article of footwear configured as a right shoe including an upper and a sole structure according to one embodiment of the disclosure. [Figure 2] FIG. 2 is a top view of the article of footwear of FIG. [Figure 3] FIG. 3 is a top view of the article of footwear of FIG. 1 with the upper removed and the skeletal structure of a user's foot superimposed thereon. [Figure 4] 4 is an exploded perspective view of the article of footwear of FIG. 1 illustrating a plate according to an embodiment of the present disclosure. [Figure 5A] FIG. 5A is a cross-sectional view of the plate taken along line 5-5 of FIG. [Figure 5B] FIG. 5B is a cross-sectional view of the article of footwear taken along line 5-5 of FIG. [Figure 6] FIG. 6 is a graph showing the relationship between the elastic modulus and the volume fraction of the fibers. [Figure 7] FIG. 7 is a schematic diagram of a printer used for additive manufacturing of a plate according to one embodiment of the present disclosure. [Figure 8A] FIG. 8A is a flow diagram illustrating a process for printing a plate according to an embodiment of the present disclosure. [Figure 8B] FIG. 8B is a flow diagram illustrating a process for printing a plate according to an embodiment of the present disclosure. [Figure 9A] FIG. 9A is a schematic diagram of the components of a compression mold. [Figure 9B] FIG. 9B is a schematic diagram of the components of a compression mold. [Figure 10] FIG. 10 is a schematic diagram of the top surface of several layers of a plate for another embodiment of a footwear product that has undergone an exemplary manufacturing process. [Figure 11] FIG. 11 is a schematic diagram of the top surface of several layers of a plate for another embodiment of footwear through an exemplary manufacturing process. [Figure 12] FIG. 12 is a schematic diagram of the top surface of several layers of a plate for another embodiment of footwear through an exemplary manufacturing process. [Figure 13] FIG. 13 is a schematic diagram of the top surface of several layers of a plate for another embodiment of footwear that has undergone an exemplary manufacturing process. [Figure 14] FIG. 14 is a schematic diagram of the top surface of several layers of a plate for another embodiment of footwear that has undergone an exemplary manufacturing process. [Figure 15] FIG. 15 is a schematic diagram of the top surface of several layers of another embodiment of a footwear product plate that has undergone an exemplary manufacturing process. [Figure 16]FIG. 16 is a schematic diagram of the top surface of several layers of a plate for another embodiment of footwear that has undergone an exemplary manufacturing process. [Figure 17] FIG. 17 is a schematic diagram of the top surface of several layers of a plate for another embodiment of footwear that has undergone an exemplary manufacturing process. [Figure 18] FIG. 18 is an exploded view of another embodiment of a sole structure incorporating yet another embodiment of a plate. [Figure 19] FIG. 19 is a schematic side view of yet another embodiment of a plate, the plate configured as an outsole with traction elements. [Figure 20] FIG. 20 is a schematic cross-sectional view of the traction element taken along line 20-20 of FIG. [Figure 21] FIG. 21 is a schematic diagram of the top view of the opening in the plate of FIG. DETAILED DESCRIPTION OF THE INVENTION

[0019] The following description and accompanying figures 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 can be applied to a wide range of footwear and footwear forms, 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 and sole structure concepts can also be applied to non-athletic footwear, such as dress shoes, sandals, loafers, slippers, and heels. In addition to footwear, certain concepts described herein can also be applied to and incorporated into other types of apparel or other athletic equipment, including helmets, padding or protective padding, shin guards, and gloves. Furthermore, certain concepts described herein can be incorporated into cushions, backpack straps, golf clubs, or other consumer or industrial products. Accordingly, the concepts described herein can be utilized in a variety of products.

[0020] As used herein, the term "about" refers to variations in numerical quantities that may occur, for example, due to typical measuring and manufacturing procedures used in articles of footwear or other manufactured articles that may include embodiments disclosed herein, due to inadvertent errors in these procedures, due to differences in the manufacture, source, or purity of ingredients used to make a composition or mixture or to practice a method. Throughout this disclosure, the terms "about" and "approximately" refer to a range of values ​​of ±5% of the numerical value that the term precedes.

[0021] The present disclosure is directed to articles of footwear and / or specific components of articles of footwear, such as uppers and / or soles or sole structures. The uppers may be composed of knitted components, woven fabrics, and / or nonwoven fabrics. Knitted components can be produced by knitting yarns, woven fabrics can be produced by weaving yarns, and nonwoven fabrics can be produced by manufacturing a monolithic nonwoven. Knitted fabrics include fabrics formed by warp knitting, weft knitting, plain knitting, circular knitting, and / or other suitable knitting techniques. Knitted fabrics can have, for example, plain knit, mesh knit, and / or rib knit constructions. Woven fabrics include, but are not limited to, fabrics formed by any of a number of weave configurations, such as plain weave, twill weave, satin weave, dobbin weave, jacquard weave, double weave, and / or double cloth weave. Nonwoven fabrics include, for example, fabrics made by airlaid and / or spunlaid processes. The uppers may be composed of various materials, such as first yarns, second yarns, and / or third yarns, which may have different properties or visual characteristics.

[0022] 1-3 illustrate an exemplary embodiment of footwear 100 configured as a shoe including an upper 102 and a sole structure 104. Upper 102 is attached to sole structure 104, which together define an interior cavity 106 (see FIGS. 2 and 3) into which a foot can be inserted. For reference, footwear 100 defines a forefoot region 108, a midfoot region 110, and a heel region 112 (see FIGS. 2 and 3). Forefoot region 108 generally corresponds to the portion of footwear 100 that encases portions of the foot, including the toes, ball of the foot, and the joints connecting the metatarsals to the toes or phalanges. Midfoot region 110 is adjacent to and proximal to forefoot region 108 and generally corresponds to the portion of footwear 100 that encases the arch of the foot along with the arch of the foot. Heel region 112 is proximate and adjacent to central region 110 and generally corresponds to the portion of footwear 100 that wraps around the rear of the foot, including the heel or calcaneus, ankle, and / or Achilles tendon. Longitudinal axis V extends through central region 110 of footwear 100 and defines a vertical plane disposed between forefoot region 108 and heel region 112. Longitudinal axis L extends through sole 104 of footwear 100 and into forefoot region 108, central region 110, and heel region 112. Longitudinal axis L defines a vertical plane that is generally perpendicular to the vertical plane of longitudinal axis V, and vertical plane L may be disposed tangentially to or flush with a portion of sole 104.

[0023] While only one shoe 100, i.e., a shoe worn on a user's right foot, is depicted, it should be understood that the concepts disclosed herein are applicable to a pair of shoes (not shown), including a left shoe and a right shoe sized and shaped to accommodate a user's left and right feet, respectively. However, for ease of disclosure, while a single shoe is referenced to describe aspects of the present disclosure, the following disclosure with reference to footwear 100 is applicable to both the left and right shoes. However, in some embodiments, there may be differences between the left and right shoes other than the left / right configuration. Furthermore, in some embodiments, the left shoe may include one or more additional components that the right shoe does not, and vice versa.

[0024] Many conventional footwear uppers are formed from multiple components, such as textiles, polymer foams, polymer sheets, leather, and synthetic leather, which are joined by adhesive bonding or stitching at seams. In some embodiments, the upper 102 of footwear 100 is formed from a knit construction or knitted components. In various embodiments, the knitted components can incorporate different types of yarns that can impart different properties to the upper. For example, one region of the upper 102 may be formed from a first type of yarn that imparts a first set of properties, while another region of the upper 102 may be formed from a second type of yarn that imparts a second set of properties. With this configuration, the properties of the upper 102 can be varied throughout the upper 102 by selecting specific yarns for different regions of the upper 102.

[0025] With reference to the material(s) comprising the upper 102, the specific properties that a particular type of yarn imparts to a region of the knitted component may depend, at least in part, on the materials forming the various filaments and fibers of the yarn. For example, cotton may impart a soft effect, biodegradability, or a natural aesthetic to the knitted material. Elastane and stretch polyester may each provide the knitted component with desired stretch and recovery properties. Rayon may provide a high-shine, moisture-wicking material, wool may provide enhanced moisture-wicking material, nylon may provide a durable, abrasion-resistant material, and polyester may provide a durable, hydrophobic material.

[0026] Other aspects of the knitted component can also be varied to affect the properties of the knitted component and provide desired attributes. For example, the yarns forming the knitted component can include monofilament yarns or multifilament yarns, or the yarns can include filaments each formed of two or more different materials. Additionally, the knitted component can be formed using a particular knitting process to impart specific properties to regions of the knitted component. Thus, both the material forming the yarn and other aspects of the yarn can be selected to impart different properties to specific regions of the upper 102.

[0027] In some embodiments, the elasticity of the knit structure can be measured based on a comparison of the width or length of the knit structure in a first, unstretched state to the width or length of the knit structure in a second, stretched state after a lateral force is applied to the knit structure. In further embodiments, the upper 102 can also include additional structural elements. For example, in some embodiments, a heel plate or cover (not shown) can be provided in the heel region 112 to provide additional support to the user's heel. In some cases, other elements, such as plastic materials, logos, trademarks, etc., can be applied or secured to the exterior surface using adhesives or a thermoforming process. In some embodiments, properties associated with the upper 102, such as stitch type, thread type, or properties associated with different stitch types or thread types, such as stretch, aesthetics, thickness, breathability, waterproofness, or scuff resistance, can be varied. In some embodiments, the upper 102 is comprised of various layers that are heat-pressed together to bond the various layers of the upper 102. For example, the layers comprising the upper 102 can be heat-pressed at a single temperature at one time. The materials that make up the upper 102 may include an inner mesh layer, a thermoplastic polyurethane (TPU) film, and an outer mesh layer. In some embodiments, a TPU skin may be applied along the outer surface of the upper.

[0028] Referring again to FIG. 1 , sole structure 104 is connected to or secured to upper 102 and extends between a user's foot and the ground when footwear 100 is worn by a user. Sole structure 104 may include one or more components, which may include an outsole, a midsole, a heel, a toe cap, and / or an insole. For example, in some embodiments, the sole structure may include an outsole that provides traction for the user and structural integrity to the sole structure, a midsole that provides a cushioning system, and an insole that supports the user's arch. Furthermore, the insole may be a strobel board, a forefoot board, a lasting board, or the like, attached to the upper by strobel stitching, or a combination thereof; the insole may be provided between upper 102 and sole structure 104, or the insole may be provided as part of upper 102.

[0029] Additionally, an insole can be disposed within the interior cavity 106 of the upper 102 and can be in direct contact with the user's foot while the footwear 100 is being worn. Additionally, the upper 102 can also include a liner (not shown), which can enhance comfort, for example, by reducing friction between the user's foot and the upper 102, sole 104, insole, etc., and / or by providing moisture-wicking properties. The liner can cover the entire interior cavity 106 or only a portion of it. In some embodiments, a bond (not shown) can surround the opening of the interior cavity 106 to secure the liner to the upper 102 and / or to provide aesthetic elements to the footwear 100.

[0030] 2 and 3, footwear 100 also defines a lateral surface 116 and a medial surface 118. When a user is wearing the shoe, lateral surface 116 corresponds to the portion of footwear 100 that faces outward, while medial surface 118 corresponds to the portion of footwear 100 that faces inward. Thus, footwear 100 has opposing lateral and medial surfaces 116, 118. Medial surface 118 and lateral surface 116 are adjacent to one another along a longitudinal center plane or axis 120 of footwear 100, which is coplanar with longitudinal axis L in FIG. 1 . As discussed further herein, longitudinal center plane or axis 120 may define a center, mid-axis between medial surface 118 and lateral surface 116 of footwear 100. In other words, the longitudinal plane or axis 120 extends between the rear proximal end 122 of the footwear 100 and the front distal end 124 of the footwear 100 and can continuously define the middle of the insole 126, sole structure 104, and / or upper 102 of the footwear 100, i.e., the longitudinal plane or axis 120 is a linear axis extending through the rear proximal end 122 of the heel region 112 to the front distal end 124 of the toe region 108.

[0031] Unless otherwise specified, and without reference to Figures 2 and 3, footwear 100 may be defined by a forefoot region 108, a midfoot region 110, and a heel region 112. Forefoot region 108 may generally correspond to the portion of footwear 100 that encases a portion of foot 128, including toes or phalanges 130, ball of foot 132, and one or more of the joints 134 connecting metatarsals 136 of foot 128 with toes or phalanges 130. Midfoot region 110 is proximate to and adjacent to forefoot region 108. Midfoot region 110 generally corresponds to the portion of footwear 100 that encases the arch of foot 128 along with the bridge of foot 128. Heel region 112 is proximate to and adjacent to midfoot region 110. Heel region 112 generally corresponds to the portion of footwear 100 that wraps around the rear of foot 128, including the heel or calcaneus 138, the ankle (not shown), and / or the Achilles tendon (not shown).

[0032] 2 and 3 , forefoot region 108, central region 110, heel region 112, medial surface 118, and lateral surface 116 are intended to define boundaries or regions of footwear 100. To that end, forefoot region 108, central region 110, heel region 112, medial surface 118, and lateral surface 116 generally characterize sections of footwear 100. Certain aspects of the present disclosure may refer to portions or elements coextensive with one or more of forefoot region 108, central region 110, heel region 112, medial surface 118, and / or lateral surface 116. Furthermore, both upper 102 and sole structure 104 may be characterized as having portions along forefoot region 108, central region 110, heel region 112, and / or medial surface 118 and / or lateral surface 116. Thus, the upper 102 and sole structure 104, and / or individual portions of the upper 102 and sole structure 104, can include portions located along the forefoot region 108, the midregion 110, the heel region 112, and / or the medial surface 118 and / or the lateral surface 116.

[0033] 2 and 3, the toe region 108, the central region 110, the heel region 112, the medial surface 118, and the lateral surface 116 are shown in detail. The toe region 108 extends from a toe end 140 to a widest portion 142 of the footwear 100. The widest portion 142 is defined or measured along a first line 144 that is perpendicular to the longitudinal axis 120 and extends from the distal end of the toe end 140 to the distal end of the heel end 146 opposite the toe end 140. The central region 110 extends from the widest portion 142 to a narrowest portion 148 of the footwear 100. The narrowest portion 148 of the footwear 100 is defined as the thinnest portion of the footwear 100 measured across a second line 150 that is perpendicular to the longitudinal axis 120. The heel region 112 extends from the narrowest portion 148 to the heel end 146 of the footwear 100 .

[0034] It should be understood that numerous variations will be apparent to those skilled in the art from the foregoing description, and that individual components thereof may be incorporated into numerous articles of footwear. Accordingly, it should be understood that aspects of footwear 100 and its components, while the boundaries of forefoot region 108, midregion 110, heel region 112, medial surface 118, and / or lateral surface 116, as described herein, may be described with reference to general areas or portions of footwear 100, may vary among articles of footwear. However, aspects of footwear 100 and its individual components may also be described with reference to precise areas or portions of footwear 100, and the appended claims herein may incorporate limitations related to these boundaries of forefoot region 108, midregion 110, heel region 112, medial surface 118, and / or lateral surface 116 as described herein.

[0035] 2 and 3 , medial surface 118 begins at distal toe end 140 and curves outward along the medial side of footwear 100, along forefoot region 108, and toward central region 110. Medial surface 118 reaches a first line 144, where it curves inward toward central longitudinal axis 120. Medial surface 118 extends from first line 144, i.e., widest portion 142, to a second line 150, i.e., narrowest portion 148, where it crosses first line 144 and extends into central region 110. Upon reaching second line 150, medial surface 118 curves outward, away from central longitudinal axis 120, where it crosses second line 150 and extends into heel region 112. The medial surface 118 then curves outward and then inward toward the heel end 146 , terminating at a point where the medial surface 118 meets the central longitudinal axis 120 .

[0036] The lateral surface 116 also curves outward along the lateral side of the footwear 100, beginning at the distal toe end 140 and extending along the forefoot region 108 toward the central region 110. The lateral surface 116 curves inward toward the central longitudinal axis 120 when it reaches a first line 144. The lateral surface 116 extends from the first line 144, or widest portion 142, toward a second line 150, or narrowest portion 148, at which point, i.e., crosses the first line 144, into the central region 110. Upon reaching the second line 150, the lateral surface 116 curves outward away from the central longitudinal axis 120, where it extends into the heel region 112, i.e., crosses the second line 150. The lateral surface 116 then curves outward and then inward toward the heel end 146 , terminating at a point where the lateral surface 116 meets the central longitudinal axis 120 .

[0037] 2 and 3 , upper 102 extends along lateral and medial sides 116 and 118 across forefoot region 108, midfoot region 110, and heel region 112 to accommodate and encase a user's foot. When fully assembled, upper 102 also includes an inner surface 162 and an outer surface 164. Inner surface 162 faces inward and generally defines interior cavity 106, while outer surface 164 of upper 102 faces outward and generally defines the periphery or boundary of upper 102. Upper 102 also includes an opening 166 disposed at least partially in heel region 112 of footwear 100, which provides access to interior cavity 106 for foot entry and egress. In some embodiments, upper 102 can also include an instep region 168 extending from opening 166 in heel region 112 across an area corresponding to the instep to an area near forefoot region 108. The upper region 168 can define a region similar to the region where the tongue 170 of this embodiment is located. In some embodiments, the upper 102 does not include the tongue 170, i.e., the upper 102 is tongue-less.

[0038] Referring to FIG. 1 , sole structure 104 includes a midsole 172 and an outsole 174. In some embodiments, the outsole can be defined as the portion of sole 104 that at least partially contacts the outer surface, e.g., the ground, when footwear 100 is worn. Outsole 174 can define a bottom edge or bottom surface 176 of sole structure 104 across heel region 112, mid region 110, and forefoot region 108. Additionally, outsole 174 can include a ground-engaging portion or surface of sole structure 104 and oppose its insole. As shown in FIG. 1 , bottom surface 176 of outsole 174 can include a tread pattern 178, which can include a variety of shapes and configurations. Outsole 174 can be formed from one or more materials to impart durability, abrasion resistance, wear resistance, or traction to sole structure 104. In some embodiments, outsole 174 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 174 may define a Shore A hardness of up to 95. Additionally, outsole 174 may be manufactured by processes including injection molding, vulcanization, layer-by-layer printing, or additive manufacturing systems or methods, etc.

[0039] Continuing to refer to FIG. 1 , midsole 172 may be defined as at least a portion of sole 104, extending from outsole 174 toward upper 102 or extending and connecting between outsole 174 and upper 102. Midsole 172 may be individually constructed from a thermoplastic material, such as polyurethane (PU), and / or ethylene vinyl acetate (EVA), its copolymers, or similar types of materials. In other embodiments, midsole 172 may be constructed from an EVA-Solid-Sponge ("ESS") material, EVA foam (e.g., PUMA® ProFoam Lite TMThe midsole 172 may be made of 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. An example of a PEBA material is PEBAX®. In some embodiments, the midsole 172 is manufactured by a process including injection molding, vulcanization, layer-by-layer printing, i.e., additive manufacturing systems or methods, or the like.

[0040] In embodiments in which midsole 172 is formed from a supercritical foam process, the supercritical foam may be comprised of microporous or particulate foam, such as TPU, EVA, PEBAX®, or a mixture thereof, produced using a process carried out in an autoclave, injection molding apparatus, or a sufficiently heated / pressurized vessel capable of processing the mixing of a supercritical fluid (e.g., CO, N, or a mixture thereof) with a material (e.g., TPU, EVA, PEBAX®, or a mixture thereof) that is preferably molten. In an exemplary process, a solution of supercritical fluid and molten material is pumped into a pressurized vessel, after which the pressure in the vessel is released, causing the molecules of the supercritical fluid to rapidly convert to a gas, forming small pockets within the material, which then expands into a foam. In further embodiments, midsole 172 can be formed using alternative methods known in the art, including the use of an expansion press, an injection molding machine, a pellet expansion process, a cold foam process, compression molding techniques, die cutting, or any combination thereof. For example, midsole 172 may be formed using a process that includes an initial foaming process that uses a supercritical gas to foam a material, followed by compression molding or die cutting to a specific shape.

[0041] Returning to FIG. 2 , footwear 100 also includes a fastening system 180 including laces 184 and a plurality of eyelets 188. In this embodiment, laces 184 extend through the plurality of eyelets 188. In some embodiments, fastening system 180 may include an elastic band. Fastening system 180 allows a user to change the size of upper 102, for example, tightening or loosening a portion of upper 102 and / or sole 104 around the foot as desired by the wearer. Fastening system 180 may also include a band (not shown) along the center of upper 102 that includes one or more loops through which laces 184 can be guided. In other embodiments, fastening system 180 may be a hook-and-loop fastening system such as Velcro®. For example, in some embodiments, fastening system 180 may include one or more hook-and-loop straps. In yet other embodiments, fastening system 180 may be any other laceless fastening system known in the art. In still other embodiments, tightening system 180 may include another manual lacing system, a rotary closure device, or an automatic lacing system, such as the lacing systems described in U.S. patent application Ser. No. 15 / 780,368, filed May 31, 2018, and U.S. patent application Ser. No. 16 / 392,470, filed April 23, 2019, both of which are incorporated by reference in their entireties herein.

[0042] This disclosure provides plates manufactured using an additive manufacturing process (e.g., printed layer by layer). The additive manufacturing process incorporates user metrics collected from various sources (e.g., pressure heat map information, laser scanners, force plates, user preferences, etc.) and continuous fiber fabrication (CFF) manufacturing techniques to optimize the plate for specific user performance preferences, such as propulsion, stability, and comfort. Additive manufacturing allows plates to be manufactured with minimal waste compared to traditional subtractive manufacturing processes (e.g., injection molding, milling, grinding, etc.). Furthermore, additive manufacturing avoids the excessive labor typically required for customized, unique designs tailored to specific user preferences, allowing plates to be manufactured with fewer processes and repetitive operations. Furthermore, CFF manufacturing techniques allow plates to be manufactured efficiently and inexpensively while still using expensive, high-performance materials such as carbon fiber, fiberglass, and Kevlar®. Additive manufacturing minimizes material and time waste by adding material in an iterative process to build the plate as designed. This is especially important when considering the costs associated with expensive materials like carbon fiber and Kevlar®, as well as the supply and / or shipping availability of such materials as needed. Eliminating waste allows users to source materials in more precise and predictable quantities, while also reducing transportation costs and the emissions and pollution associated with shipping expensive materials long distances, such as globally.

[0043] Additive manufacturing using CFF is preferred for the production of plates according to the present disclosure. The additive manufacturing process can be carried out using a 3D printer, such as a printer manufactured by MarkForged®, that can receive a design model and generate print instructions for 3D printing the plate. The design model can be an electronic three-dimensional representation of the plate intended to be formed for the footwear molding. In some embodiments, the design model can be a 3D CAD file, a 3D stereolithography file (.STL file), or an Eiger file provided by MarkForged®. TM It may be in the form of any file compatible with web-based or cloud-based design programs such as .

[0044] Alternatively or additionally, the design model may be generated by the controller in response to input data. For example, physical characteristics collected, input into the software, and used to design and generate the design model may include the end user's weight, the end user's gait, and / or the end user's foot pressure maps measured during standing, walking, cutting, and / or running. Additionally, various measurements of the foot may be recorded to determine appropriate plate dimensions and other aspects of the footwear, and data related to the foot's gait may be obtained to determine whether the foot orientation indicates toe-strike, heel-strike, or other scenarios. The foot measurements and data may be used to determine the optimal shape and performance characteristics of the plate, as well as the optimal location of the plate within the footwear. Furthermore, the collected measurements and data may be used to select materials from which the plate will be constructed. Furthermore, the additive manufacturing process described herein may allow the stiffness of the plate to be tailored for a particular wearer based on the collected measurements and data. In another example, plates may be manufactured in increments of stiffness, providing semi-custom footwear that allows individual wearers to select the appropriate stiffness.

[0045] Various alternative additive manufacturing methods that can be used to manufacture the plates of the articles of footwear according to the present disclosure include binder jetting, direct energy deposition, selective laser melting (SLM), fused deposition modeling (FDM), electron beam melting, laser powered bed fusion (LPBF), ultrasonic additive manufacturing, material extrusion, material jetting, joule printing, electrochemical deposition, cold spray metal printing, DLP metal printing, ultrasonic consolidation or ultrasonic additive manufacturing (UAM), LENS laser-based printing, liquid vat photopolymerization, sheet lamination, or electron beam freeform fabrication (EBF3).

[0046] As used herein, the term "stiffness" refers to the way a component resists deformation when a load is applied. Specifically, "stiffness" is described herein with respect to elastic deformation, i.e., temporary deformation that is considered non-destructive. Therefore, "stiffness" can be used in conjunction with the terms "resistance" and "strength." Furthermore, "stiffness" can be described herein with respect to various directions, types of deformation, material properties, and the like. For example, the "stiffness" of a component can be decomposed into bending stiffness, tensile stiffness, or shear stiffness. Furthermore, the "stiffness" of a component is correlated to the modulus of elasticity (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 surface, and ε is the strain, i.e., proportional deformation. For clarity, "stiffness" may be further specified herein to refer to specific types of resistance, such as bending resistance (BR) or torsional resistance (TR). For clarity, "stiffness" may be further defined herein to refer to specific types of resistance, such as bending resistance (BR) or torsional resistance (TR). In some cases, the "stiffness" of a component may be quantified or calculated in terms of dimension, mass, or volume. For example, the "stiffness" of a component may be measured in units of Newtons per millimeter (N / mm) or gigapascals (GPa), although other units may be used. Furthermore, "stiffness" may also be referred to qualitatively as high or low, while being understood in relation to various aspects of footwear, such as comfort, support, stability, rigidity, and durability.

[0047] 4 illustrates an exploded view of footwear 100 including plate 200 according to one embodiment of the present disclosure. Plate 200 includes a top surface 204 opposite a bottom surface 208, a rear segment 212, an arch segment 216, and a front segment 220. Rear segment 212 may extend through at least the heel region 112 of footwear 100 when installed therein and may correspond to a portion of plate 200 located near a rear portion of the foot, as previously described herein. Arch segment 216 of plate 200 is proximate and adjacent to rear segment 212 and corresponds to a portion of plate 200 located near the central region 110 of footwear 100 that, together with the foot bridge, encases the arch of the foot. The forefoot segment 220 of the plate 200 is closely adjacent to the arch segment 216 and corresponds to the portion of the plate 200 disposed near the forefoot region 108 of the footwear 100 that encases the toes, the ball of the foot, and the joints connecting the metatarsals with the toes or phalanges. The plate 200 defines a longitudinal reference axis 224 that intersects the plate 200 at the heel end 146 and the toe end 140. The plate 200 also defines a centerline axis 228 that bisects the heel end 146 and the toe end 140, such that the reference axis 224 extends obliquely relative to the centerline axis 228.

[0048] In the illustrated embodiment, plate 200 is embedded within midsole 172, as indicated by the dashed exploded lines, showing its approximate location within midsole 172. However, in some embodiments, plate 200 may be fitted between midsole 172 and upper 102, or between midsole 172 and outsole 174, or plate 200 may be configured as outsole 174 attached to upper 102, or plate 200 may be included as part of upper 102.

[0049] For clarity, this disclosure refers to directional coordinates X, Y, and Z. In particular, the X direction corresponds to a lateral-to-medial direction perpendicular to the longitudinal direction along which longitudinal reference axis 224 extends, the Y direction corresponds to a longitudinal direction parallel to longitudinal reference axis 224, and the Z direction corresponds to a vertical direction perpendicular to the X and Y directions. Additionally, the term "in-plane" is used herein to refer to a two-dimensional plane extending in the X and Y directions, with the Z direction being orthogonal. It will be appreciated that longitudinal reference axis 224 also defines a longitudinal reference plane extending perpendicular to the Z direction. With reference to FIGS. 1 and 4 , it will be appreciated that the longitudinal plane defined by longitudinal axis L may be coplanar with an in-plane direction or portion of footwear 100. Furthermore, the longitudinal plane defined by longitudinal axis V may extend in the Z direction and be generally perpendicular to the in-plane direction and the longitudinal plane.

[0050] Plate 200 defines a periphery 232 that curves outward relative to centerline axis 228 from heel end 146 toward lateral surface 116 in heel region 112, at least partially defining posterior segment 212. Periphery 232 further extends along lateral surface 116 toward central region 110 and curves inward relative to centerline axis 228 to at least partially define arch segment 216. Periphery 232 further extends into forefoot region 108 and curves outward before curving inward toward toe end 140, at least partially defining forefoot segment 220. Similarly, periphery 232 curves outward from heel end 146 toward medial surface 118 in heel region 112, at least partially defining posterior segment 212. Periphery 232 further extends along medial side toward central region 110 and curves inward to at least partially define arch segment 216. Additionally, perimeter 232 extends into forefoot region 108, curves outward, and then curves inward toward toe tip 140 to at least partially define front segment 220. Thus, perimeter 232 extends continuously across plate 200 from rear segment 212 to front segment 220 and vice versa, and from lateral surface 116 to medial surface 118 and vice versa. In some embodiments, multiple perimeter elements 236 (see FIG. 5A ) may be disposed along a portion of perimeter 232 or along the entire perimeter 232. In other embodiments, plate 200 does not include any perimeter elements 236 along perimeter 232.

[0051] However, in certain embodiments, plate 200 may be formed from an additive manufacturing process in which various layers of plate 200 are printed in a printing process, such as any of the additive manufacturing processes described above. Referring to FIG. 5A , plate 200 includes multiple composite layers 240a-g arranged sequentially in a vertical stack between top surface 204 and bottom surface 208. Throughout this disclosure, multiple composite layers 240a-g may be referred to collectively or individually as composite layers 240 and further as reinforcing layers. Each of composite layers 240 extends continuously from inner surface 118 to outer surface 116 and from rear segment 212 to front segment 220. However, in other embodiments, some composite layers 240 may be discontinuous between inner surface 118 and outer surface 116, between rear segment 212 and front segment 220, or a combination thereof.

[0052] In FIG. 5A , plate 200 is depicted as including seven composite layers 240a-g. However, plate 200 may include more or fewer composite layers than shown. In some embodiments, plate 200 includes only three composite layers, while in other embodiments, plate 200 includes 100 composite layers, 1000 composite layers, or more. Furthermore, in some embodiments, plate 200 is comprised of thousands of composite layers in certain portions or regions, while other portions or regions of plate 200 include fewer composite layers. In the illustrated embodiment, vertical plane V is centered between outer surface 116 and inner surface 118 of plate 200, and horizontal plane H is perpendicular to vertical plane V and is tangential to or coplanar with a portion of bottom surface 208 of plate 200. In this particular example, plate 200 has a shape in which top surface 204 of plate 200 is curved relative to a horizontal plane H between inner surface 118 and outer surface 116, and composite plies 240 each have a different curvature between inner surface 118 and outer surface 116, which curvatures may differ from each other and from the curvature of top surface 204. Additionally, bottom surface 208 defines a curvature that varies relative to horizontal plane H between outer surface 116 and inner surface 118. Additionally, periphery 232 of plate 200 is curved along outer surface 116 and inner surface 118.

[0053] Referring to FIG. 5A, plate 200 includes at least a substrate or substrate material 244 and fibers or fiber material 248. It will be understood that substrate material 244 may be referred to herein as a filler substrate, or matrix. It will further be understood that fibers 248 may be referred to herein as fiber strands, filaments, or yarns. Plate 200 includes composite layers 240a-g having properties and / or compositions that differ from each other or from at least adjacent composite layers 240a-g. To that end, each composite layer 240a-g of plate 200 has various measurable properties, including a layer volume VL, a substrate fraction SPL of VL, a fiber fraction FPL of VL, a fiber orientation or steering direction FOL of the layer, an axial effective modulus EAL of the layer, a transverse effective modulus ETL of the layer, and a layer thickness TL. Additionally, the plate 200 has various measurable properties including total volume VT, total substrate fraction SPT, total fiber fraction FPT, total effective fiber orientation or steering direction FOT, total effective axial modulus EAT, total effective transverse modulus ETT, and total thickness TT.

[0054] In some embodiments, plate 200 may be formed from a composite or one or more layers of fibers, such as carbon fiber, aramid fiber, e.g., Kevlar®, boron fiber, glass fiber, natural fibers, and polymer fibers, or combinations thereof. In these embodiments, the fibers may be affixed or glued to a substrate of, for example, nylon, epoxy, or a plastic material such as ultra-high molecular weight polyethylene (UHMWPE), or a fibrous or composite material, among other suitable materials. In some embodiments, fibrous material 248 is fused to substrate 244 by heat and pressure during an additive manufacturing process. In other embodiments, fibrous material 248 is sewn, embroidered, glued, cemented, woven, fastened, or otherwise attached to substrate material 244 and / or fibrous material 248. In some embodiments, plate 200 may be formed from unidirectional tapes including carbon fiber, aramid fiber such as Kevlar®, boron fiber, glass fiber, polymer fiber, or any other material with high strength-to-weight properties.

[0055] In the illustrated embodiment, each of the composite layers 240a-g differs in at least one measurable property from an adjacent composite layer 240a-g, as indicated by the different hatching used to represent each composite layer 240a-g. In some embodiments, one or more composite layers 240a-g are identical but are separated by one or more intervening composite layers 240a-g having different measurable properties. As shown in FIG. 5A, the bottom surface 208 may be defined entirely by one composite layer 240g, but in other embodiments, the bottom surface 208 may be defined by portions of two or more composite layers 240g. Similarly, the top surface 204 may be defined entirely by one composite layer 240a or may be defined by portions of two or more composite layers 240g. Additionally, while each composite layer 240a-g may be exposed at the exterior surface 116 and the interior surface 118, in some embodiments, one or more of the composite layers 240a-g may be hidden or recessed relative to the interior surface 118 and / or the exterior surface 116. Additionally, the composite layers 240a-g may be interrupted by voids (not shown) that intersect or separate one or more of the composite layers 240a-g. The plate 200 may be fabricated as a complementary arrangement or structure with voids (not shown) and composite layers 240, allowing complementary behavior, i.e., increasing lateral dimensions when stretched longitudinally, or vice versa. Additionally, the plate 200 may be fabricated with channels (not shown) that allow airflow through portions of the plate 200.

[0056] In the illustrated embodiment of FIG. 5B , plate 200 is embedded within sole 104 of footwear 100, and more specifically, plate 200 is embedded within midsole 172 of sole 104. Additionally, upper 102 includes insole 126 in a Straubel configuration such that insole 126 is spaced from plate 200 and does not directly contact plate 200. In some embodiments, plate 200 can be embedded within midsole 172 in a manner that allows a portion of plate 200 to contact insole 126 or upper 102. Additionally, in some embodiments, a portion of plate 200 can contact outsole 174. In other embodiments, plate 200 can be provided as part of upper 102. For example, plate 200 can be included as part of insole 126 or can be inserted into cavity 106 of footwear 100 similar to a conventional orthotic insert. In some embodiments, plate 200 may comprise the entire sole structure 104 of footwear 100 , or footwear 100 may include only upper 102 and plate 200 .

[0057] 5A and 5B, plate 200 is generally curved between medial surface 118 and lateral surface 116 and is also curved relative to the surrounding components of footwear 100. For example, plate 200 curves downward toward horizontal plane H between lateral surface 116 and vertical plane V, and curves upward away from horizontal plane H between vertical plane V and medial surface 118, such that plate 200 is convexly curved relative to horizontal plane H. In FIG. 5B, horizontal plane H is tangent to outsole 174, and therefore plate 200 is also convexly curved relative to outsole 174. However, plate 200 is concavely curved relative to upper 102, with plate 200 curved farthest from upper 102 near vertical plane V and closest to upper 102 at medial surface 118 and lateral surface 116. Furthermore, while insole 126 and plate 200 are depicted as having generally similar curvatures in footwear 100 in FIG. 5B, other configurations are possible. Additionally, the midsole 172 at least partially surrounds the plate 200 and, as shown, defines a curvature that varies above and below the plate 200, different from the curvature of the plate 200. In the illustrated embodiment, the insole 126, the midsole 172, the plate 200, and the outsole 174 are all mated to match each other's curvatures, such that no voids or gaps are disposed therebetween. However, it will be understood that a void or gap may be formed between one of the insole 126, the midsole 172, the plate 200, and the outsole 174 such that the curvature of the insole 126 does not match the curvature of the midsole 172.

[0058] Additionally, plate 200 may be preloaded or deformed when assembled into footwear 100. To that end, the curvature of plate 200 may be altered or reduced during assembly within sole 104 of footwear 100 to match the curvature of midsole 172, outsole 174, or insole 126. Comparing FIGS. 5A and 5B , for example, assembly with sole 104 of footwear 100 in FIG. 5B alters the curvature of bottom surface 208 of plate 200, reversing the curvature from concave to convex, for example. As a result, plate 200 deforms upon interaction with sole 104, generating stresses that may change or affect its properties, such as stiffness and propulsion, in one or more directions during use. These stresses generated by assembly with footwear 100, combined with the tailored stiffness and shape of plate 200, can provide responsive benefits that enhance the customizability of plate 200 within footwear 100. As used herein, the term "responsiveness" may refer to the sensitivity of the plate 200 to applied loads, i.e., external forces applied during use, whether the applied loads are due to the user's weight or activities such as running, walking, jumping, turning, lifting, etc., and may also refer to the sensitivity of the plate 200 to deformation in one or more directions. In certain embodiments, the responsiveness of the plate 200 may be varied along the anterior segment 220, the arch segment 216, and the posterior segment 212, and the responsiveness may be varied between the lateral surface 116 and the medial surface 118. In certain implementations, the arch segment 216 of the plate 200 may be preloaded to increase responsiveness, making the plate 200 more sensitive to walking activities where less deformation is experienced, while providing the user with the benefit of increased propulsion and support. In some embodiments, the anterior segment 220 may have increased responsiveness to provide maximum propulsion when the user steps off during a jumping activity.

[0059] In some embodiments, plate 200 is positioned diagonally between upper 102 and outsole 174 such that front segment 220 is farther from upper 102 than rear segment 212. In this manner, rear segment 212 is positioned higher vertically, i.e., higher in the Z direction, relative to front segment 220 and / or arch segment 216. In this manner, plate 200 can be positioned to promote propulsion or spring-back during use. Additionally, plate 200 can be formed with different shapes and curvatures along reference axis 224 and / or between medial surface 118 and lateral surface 116 to promote cushioning, propulsion, and support during use.

[0060] In some embodiments, the fibrous material 248 of the plate 200 may have a tensile stiffness defined at least in part by a tensile modulus measured according to a test method defined by test standard ASTM D4018 or an equivalent standard. For example, in certain embodiments, the fibrous material 248 of the plate 200 may have a tensile modulus of at least 70 GPa, or at least about 85 GPa, or at least about 200 GPa, or at least about 300 GPa. In further embodiments, the fibrous material 248 has a tensile modulus between about 300 GPa and about 400 GPa. Thus, the fibrous material 248 may have a tensile strength, i.e., a stress defined by a load per unit area, of about 500 megapascals (MPa) to about 800 MPa, measured according to a test method defined by test standard ASTM 3039 or an equivalent standard. Furthermore, the fibrous material 248 of the plate 200 may have a flexural stiffness defined at least in part by a flexural modulus measured according to a test method defined by test standard ASTM D790 or C651 or an equivalent standard. For example, the fibrous material 248 can have a flexural modulus of at least about 22 GPa, or at least about 50 GPa, or at least about 100 GPa, or at least about 200 GPa. In further embodiments, the fibrous material 248 has a flexural modulus between about 50 GPa and about 200 GPa. Thus, the fibrous material 248 can have a flexural strength, i.e., stress defined by the amount of load per unit area, of between about 200 MPa and about 600 MPa, measured according to the test method defined by test standard ASTM D790 or an equivalent standard. Additionally, the fibrous material 248 of the plate 200 can have a flexural strength of about 1.2 g / cm. 3 and approximately 2.0 g / cm 3 The density can be between 0.01 and 0.1.

[0061] Additionally, the substrate material 244 of the plate 200 may have a tensile stiffness defined at least in part by a tensile modulus measured according to a test method defined by test standard ASTM D638 or an equivalent. For example, in certain embodiments, the substrate material 244 may have a tensile modulus of at least about 1 GPa, or at least about 2 GPa, or at least about 4 GPa. Additionally, the substrate material 244 may have a flexural stiffness defined by a flexural modulus measured according to a test method defined by test standard ASTM D790 or an equivalent. For example, the substrate material 244 may have a flexural modulus of at least about 1 GPa, or at least about 2 GPa, or at least about 3 GPa. In further embodiments, the substrate material 244 has a flexural modulus between about 1.4 GPa and about 3.7 GPa. Thus, the substrate material 244 may have a flexural strength, i.e., a stress defined by a load per unit area, of about 50 MPa to about 90 MPa, measured according to a test method defined by test standard ASTM D790 or an equivalent. In another embodiment, the substrate material 244 of the plate 200 may have a heat deflection temperature measured according to the method defined in test standard ASTM D648 Method B or an equivalent standard. For example, the substrate material 244 may have a heat deflection temperature between about 41° C. and about 150° C. The substrate material 244 used to form the plate 200 may also have a thermal conductivity of about 1 g / cm 3 and approximately 1.5 g / cm 3 The density may be between .times. ...

[0062] For reference, the tensile modulus of a steel or steel alloy, e.g., ASTM A36 steel, measured according to the test method defined by test standard ASTM E8 or an equivalent standard, is about 200 GPa, and the modulus of elasticity of such steel is about 7.85 g / cm 3In some embodiments, the tensile modulus of the plates of the present disclosure is about 200 GPa, measured according to the test method defined by test standard ASTM E8 or equivalent. Thus, plate 200 has a tensile modulus similar to that of steel, but is configured to have a density that is less than 25% of that of steel. Thus, the plates of the present disclosure have a strength-to-weight ratio that is substantially higher than that of steel with respect to at least one directional strength property.

[0063] The composition of plate 200 is substantially composed of substrate material 244 and fiber material 248, such that the sum of substrate percentage SPT and fiber percentage FPT is approximately 100% of the total volume TV of plate 200. Thus, if substrate percentage SPT is approximately 50%, the corresponding fiber percentage FPT is approximately 50%. Furthermore, because fiber material 248 generally has greater stiffness, including bending stiffness and tensile stiffness, than substrate material 244, the stiffness of plate 200 can be manipulated by controlling or selecting the composition of plate 200. Therefore, by fabricating plate 200 using additive manufacturing methods, the volume and placement of materials can be precisely and efficiently selected, and the composition of plate 200 can be selected depending on the desired stiffness. In some embodiments, plate 200 can have a substrate percentage SPT of approximately 75%, which corresponds to a fiber percentage FPT of approximately 25%, resulting in plate 200 having generally more flexible and elastic properties. This may be desirable when user comfort is a priority. In other embodiments, plate 200 can have a fiber fraction of about 75%, which corresponds to a substrate fraction of about 25%, resulting in plate 200 generally having greater stiffness and strength characteristics. This may be desirable when propulsion and support are a priority. In some embodiments, plate 200's substrate fraction SPT may range from about 25% to about 99%, and plate 200's fiber fraction FPT may range from about 25% to about 99%.

[0064] In some embodiments, plate 200 and its stiffness may be selected and designed for a particular user. For example, the stiffness of plate 200 may be selected based on the user's particular muscle strength, tendon flexibility, or joint flexibility. In further embodiments, the stiffness of plate 200 may vary, such that portions of plate 200 are stiffer than other portions of plate 200. In some embodiments, plate 200 is included within sole 104 of footwear 100. For example, plate 200 may be embedded within midsole 172, outsole 174, or insole 126. In other embodiments, plate 200 may be positioned between insole 126 and midsole 172, or plate 200 may be positioned between midsole 172 and outsole 174.

[0065] Generally, plates constructed of composite fiber materials, such as Kevlar®, carbon fiber, and fiberglass, have improved strength-to-weight ratios compared to plates made entirely without added metal, matrix, or fiber. However, composite fiber materials are strongest in tension, and this is limited to a specific direction, i.e., the axial direction in which the composite fiber material is stretched. Thus, a composite layer having fiber material oriented in a single uniaxial direction will be strongest in that direction but will exhibit different, e.g., weaker, properties in other directions. In this way, the composite layer is considered to be anisotropic, i.e., exhibit different strength properties in different directions.

[0066] Composite laminates or structures manufactured using continuous fiber fabrication (CFF) techniques can exhibit quasi-isotropic (QI) properties, e.g., substantially similar properties in most directions, due to the construction of multiple layers or plies with fiber arrays oriented at specific angles relative to a reference plane. In some examples, one or more layers may be formed with fiber arrays oriented at 0 degrees relative to the reference plane, other layers with fiber arrays oriented at ±45 degrees relative to the reference plane, and still other layers with fiber arrays oriented at 90 degrees relative to the reference plane. Furthermore, anisotropically biased layers may be formed with fiber arrays oriented at 0 degrees, ±30 degrees, and 90 degrees. Composite laminates with QI properties, i.e., QI laminates, may have substantially isotropic properties in-plane, e.g., increased tensile strength or stiffness, similar to isotropic materials. Substantially, QI laminates may include randomly oriented fibers or fiber arrays that provide substantially equal strength in all directions in a single plane. Typically, QI stacks include unidirectional, e.g., 3D-printed, layers oriented at 0, 90, 45, and -45 degrees, with at least 12.5 percent of the layers oriented in each of these directions. QI properties can also be achieved with layers oriented at 0, 60, and 120 degrees.

[0067] It will be appreciated that the stiffness of the plate 200 and / or its composite layer 240 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 bending resistance BR is sometimes referred to herein as spring constant or stiffness. Similarly, torsional resistance TR is the mathematical relationship between torsional force and deflection, and torsional resistance TR 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 configuration. Furthermore, geometry and dimensions are also proportional to bending resistance BR and torsional resistance TR depending on the orientation and location of the applied load. For example, dimensions defined parallel to the direction of the applied load have a greater impact on the specific resistance, e.g., if a bending load is applied in the Z-direction and thickness is defined in the Z-direction.

[0068] Additionally, the bending resistance (BR) and torsional resistance (TR) properties of each composite ply 240 are related to its effective modulus, depending in part on the direction of the applied load. For loads applied axially in-plane, i.e., in the X and Y directions, the ply axial effective modulus (EAL) is of primary importance. For loads applied transversely, i.e., in the Z direction, which includes bending deformation, the ply transverse effective modulus (ETL) is of primary consideration. EAL is approximated using the formula EAL=EF×FPL+ES*SPL, where EF is the modulus of elasticity of the fiber material 248, FPL is the volume fraction of the fiber material 248, EM is the modulus of elasticity of the substrate material 244, and SPL is the volume fraction of the substrate material 244.

[0069] Also, the formula TIFF0007793063000001.tif1794 is used to approximate the ETL. Thus, as the fiber volume fraction FPL approaches a value of 1.0, i.e., as the fiber material 248 occupies a greater percentage of the volume VL of the composite ply 240, the ETL approaches the value of the elastic modulus EF of the fiber material 248, as shown in the graph provided in FIG. 6. Additionally, the total effective elastic modulus in the axial EAT and the total effective elastic modulus in the transverse ETT can be approximated for the entire plate 200. To do this, average values ​​of the EAL and ETL for each composite ply 240 are calculated, with each value weighted according to its relationship to the total volume TV of the plate 200 and the offset of the fiber orientation FOL from the associated reference plane. Thus, composite plies 240 that comprise a greater percentage of the total volume TV of the plate 200 have a greater impact on the EAT and ETT of the plate 200. Additionally, composite plies 240 that are offset from the reference plane have a smaller impact on the EAT and ETT. This allows the bending resistance BR and torsional resistance TR of the plate 200 to be approximated.

[0070] Thus, the arrangement of composite layer 240 with fiber arrays arranged in various directions allows plate 200 to exhibit QI properties, e.g., approximately equal strength or resistance properties in all directions. For example, when plate 200 is installed in sole 104 of footwear 100, bending occurs due to a load applied in the Z direction and the user's tendency to arch their heel off the ground and propel forward from their forefoot. This force is generally perpendicular to the in-plane directions in which plate 200 and fiber material 248 are arranged, i.e., the X and Y directions, and therefore generally perpendicular to the direction in which composite layer 240 is strongest. However, during such bending, top surface 204 of plate 200 is in compression, and bottom surface 208 is in tension as the downward force, i.e., the load, causes deformation of plate 200 and footwear 100. Thus, the composite plies 240 located near the top surface 204 are subjected to a compressive force in the longitudinal or Y direction, and the composite plies 240 near the bottom surface 208 of the plate 200 are subjected to a tensile force in the longitudinal or Y direction. Therefore, to increase the bending resistance BR, the composite plies 240 near the top surface 204 are subjected to a fibrous material. 248 can be arranged so that the fibrous material 248 extends longitudinally, i.e., parallel to the direction in which the compressive force is applied, and the composite layer 240 near the bottom surface 208 can be arranged so that the fibrous material 248 extends longitudinally, i.e., parallel to the direction in which the tension force is applied.

[0071] Additionally, it may be desirable to tailor the bending resistance BR and, therefore, the thrust provided by the plate 200. To that end, the composite plies 240 can be positioned in various operating directions, i.e., the direction in which the axial or orientation of the fibrous material 248 makes the composite ply strongest. The bending resistance BR of the composite ply 240 is greatest when the operating direction FOL is parallel to the longitudinal direction and gradually decreases when the operating direction FOL is offset from the longitudinal direction toward an orthogonal direction, e.g., rotation. Thus, the bending resistance of the composite ply 240 is proportional to the degree to which the operating direction FOL is offset from the bending direction. Furthermore, the combination of composite plies 240 comprising the plate 200 is strongest when all operating directions FOL are oriented parallel to each other and parallel to the longitudinal direction. However, the stack of composite plies 240 comprising the plate 200 can be tailored to achieve a desired bending resistance BR by positioning some of the composite plies 240 in an operating direction that is offset from the longitudinal direction, thereby allowing for greater deflection in response to an applied load and subsequently providing springback or thrust.

[0072] It is contemplated that plate 200 can be manufactured using CFF technology to have localized portions or regions with different properties. For example, posterior segment 212 of plate 200 can be manufactured to be stronger than arch segment 216 and anterior segment 220. To that end, posterior segment 212 can be constructed from composite plies 240 that each define greater EAL and ETL properties than the composite plies 240 in arch segment 216 or anterior segment 220. Furthermore, posterior segment 212 of plate 200 can include greater EAT and ETT than arch segment 216 and anterior segment 220. This is because additive manufacturing processes using CFF technology allow for a wide range of customization and control, such as depositing fiber material 248 in various operating directions FOL, controlling the volume of fiber material 248 within portions and layers, and selecting various materials.

[0073] In some embodiments, the EAT and ETT can vary throughout the plate 200 and between the posterior segment 212, arch segment 216, and anterior segment 220, and between the lateral surface 116 and medial surface 118. For example, the plate 200 can be designed to increase propulsion by manufacturing the anterior segment 220 to have a higher EAT and ETT than the arch segment 216, and to have a greater bending resistance BR in the anterior segment 220 than the arch segment 216. The plate 200, and particularly the anterior segment 220, deforms during wear or use, for example, due to dorsiflexion and plantarflexion movements, particularly within the metatarsophalangeal joints (MTP) of the user's foot. It is well known that potential energy PE increases with increasing deformation, i.e., bending, of a structure, and that potential energy PE is converted to kinetic energy KE as the structure returns to its undeformed state, similar to a spring. When the load is reduced or removed, the front segment 220 of the plate 200 rebounds to its undeformed state, converting potential energy PE into kinetic energy KE to generate a propulsive force PF between the ground and the user's foot. The speed at which the plate 200, particularly the front segment 220, rebounds after deformation can be understood as a bending resistance BR, which is affected by various characteristics of the plate 200, such as the specific EAT and ETT within the front segment 220. Thus, higher EAT and ETT increase the bending resistance BR and propulsive force PF provided by the front segment 220 of the plate 200. Without the plate 200, the footwear 100 and MTP joints of the user's foot often absorb potential energy PE and thus convert less of it into potential energy KE during use. However, due to increased stiffness of the plate 200, such as bending resistance BR and torsional resistance TR, more potential energy PE generated by the user is converted into kinetic energy KE and thus returned to the user.

[0074] With reference to FIG. 7 , plate 200 can be manufactured by a printer 300 configured to print composite structures layer by layer. In the illustrated embodiment, printer 300 includes a housing 304 containing a print bed or platform 308 therein. Platform 308 is supported by supports 312 and operably engaged with vertical rails 316 extending generally in the Z direction within housing 304. Housing 304 further includes lateral rails 320 extending generally in the X direction and longitudinal rails 324 extending generally in the Y direction. Platform 308 can be translated vertically along vertical rails 316 by operation of a drive or motor (not shown) housed within housing 304. A preformed mold or block 328 is supported by platform 308 within housing 304.

[0075] As shown in FIG. 7 , the printer 300 further includes a first head 332 and a second head 336 within the housing 304. In the illustrated embodiment, the first and second heads 332, 336 are positioned side-by-side, although other configurations are possible. Additionally, a scanner 340 is provided proximate the first head 332, although the scanner 340 may be positioned elsewhere within the housing 304. In some embodiments, the scanner 340 is a laser scanner capable of detecting and measuring the dimensions and shape of an object on the platform 308, although other types of scanners, such as a 3D camera, a light detection and ranging (LIDAR) device, or the like, may be used. In the illustrated embodiment, the first head 332 includes a first nozzle 344 and is associated with a first supply 348 located within the housing 304. Additionally, the second head 336 includes a second nozzle 352 and is associated with a second supply 356 located within the housing 304. The first nozzle 344 and the second nozzle 352 may each include a cutter (not shown) that can chop or cut the substrate material 244 and / or the fibrous material 248 during operation. However, in some embodiments, the cutter (not shown) is provided as a separate component separate from the first nozzle 344 and the second nozzle 352.

[0076] In the illustrated embodiment, first supply 348 and second supply 356 are provided as bobbins or spools each holding a particular material, and preferably, first and second supply 348, 356 hold different materials. In the illustrated embodiment, first supply 348 holds substrate material 244 and second supply 356 holds fibrous material 248, although other configurations are contemplated. In other embodiments, printer 300 may include three or more printer heads, or only one printer head. Additionally, in some embodiments, printer 300 may include three or more supply parts, or only one supply part. In some embodiments, two or more supply parts are associated with a single head, while in other embodiments, one supply part serves two or more heads.

[0077] The first and second heads 332, 336 and the scanner 340 are operably coupled to the longitudinal rails 324 and the lateral rails 320 to form a housing 360 that can also translate vertically within the housing 304. The first and second heads 332, 336 are configured to translate along the longitudinal rails 324 and the lateral rails 320 by drive motors (not shown), and the housing 360 can further translate vertically within the housing 304 relative to the platform 308. In addition, the platform 308 can translate vertically relative to the housing 360. Thus, the platform 308 and the housing 360, including the first and second heads 332, 336, are configured to be moved relative to one another by dedicated motors (not shown) to provide several degrees of freedom and range of motion for precise and convenient movement during the printing process.

[0078] 7 , first head 332 is configured to receive substrate material 244 stored on first supply 348 during a particular step or operation of manufacturing. First nozzle 344 is therefore configured to be compatible with substrate material 244, such that first head 332 is configured to be actuated to apply substrate material 244 via first nozzle 344 to components disposed on platform 308. Additionally, second head 336 is configured to receive fibrous material 248 stored on second supply 356 during a particular step or operation of manufacturing. Second nozzle 352 is therefore configured to be compatible with fibrous material 248, such that second head 336 is configured to be actuated to continuously apply fibrous material 248 via second nozzle 352 to components disposed on platform 308. In some steps or operations, both the first head 332 and the second head 336 are activated simultaneously to apply the substrate material 244 and the fiber material 248, respectively, to components on the platform 308. In other steps or operations, only one of the first head 332 and the second head 336 is activated, while the other is deactivated, to apply the substrate material 244 and the fiber material 248, respectively. The fiber material 248 may be deposited or applied to fuse to the substrate material 244 and / or to other strands or fiber material 248 during the printing process. Additionally, pressure can be applied using the second nozzle 352 to continuously compress and direct the fiber material 248 into a desired shape, for example, as the fiber material 248 fuses.

[0079] The printer 300 includes a controller (not shown) programmed to control the printing process based on a set of instructions, e.g., source code, corresponding to a design model of a 3D component such as the plate 200. In particular, the design model is generated using a software program, e.g., a browser-based or web-based software program, and aspects of the plate 200 and printing process are predetermined for use with the printer 300. For example, the plate 200 can be specifically designed in the software according to specific inputs, e.g., foot size, dimensions, shape, contour, and stiffness, measured or collected using various sources, e.g., laser scanners, gait analysis, force profiles, images, medical records, and user preferences. Once the inputs are loaded into the software and, e.g., prioritized and considered amongst themselves, the software can be used to optimize the design of the plate 200 to suit the user. In some cases, a technician trained to use the software and / or the printer 300 can assist the user in optimizing the plate 200 for performance and / or a specific use, such as a medical application. The software then generates the design model in a transferable format, e.g., a file, compatible with the printer 300. The design model is communicated to the printer 300 via an internet connection, a Bluetooth® connection, a radio frequency connection, a USB or Ethernet cable, a digital storage disk, or any other medium suitable for communication between the software and the printer 300.

[0080] FIG. 8A shows a flow diagram of an exemplary method for designing and 3D printing a composite plate. In step S100, measurements and preferences are collected from various sources, such as those described above, and entered as input data into a software program for analysis. In some examples, the software program can automatically perform step S104 by analyzing the input data to automatically generate an optimized design model of the plate. In other examples, a technician or expert can assist in performing step S104 by reviewing and modifying the input data to correct errors, inconsistencies, or unique customization preferences. In step S108, the software program generates a design model based on the provided input data. The design model is thus a first representation of the customized plate, with various attributes presented to the user. One important attribute is the material and composition selected for the customized plate in the design model. In step S112, the software program can automatically recommend specific materials based on the input data, but the user can also manually select the materials to use. For example, some types of substrate material 244 or fiber material 248 are more expensive than others, so the user may want to reduce the costs associated with the recommended materials.

[0081] In step S116, after the design model is generated and materials are selected, a software program is programmed to optimize the design model for 3D printing. Specifically, the software program analyzes various aspects of the design model to identify areas requiring additional reinforcement, such as edges that may benefit from applying curvatures, fillets, or openings that may benefit from being wrapped with additional fiber material 248. The software program also generates warnings or notifications related to areas having thicknesses below a minimum thickness threshold associated with the particular material, geometry, and composite ply 240 specified in the design model. If warnings and notifications remain unresolved, depending on their severity, the software program may not allow the user to proceed beyond step S116.

[0082] In step S120, a simulation can be run against the design model within the software program, but this step S120 is optional for the user and need not be performed. In some instances, it can be used to troubleshoot any outstanding warnings or notices before the simulation proceeds, or the user can compare simulation data between various material selections or between various modifications to the input data. In step S124, the user can further modify or revise the input data and material selections, among other aspects, to generate a new design model and, if desired, a new simulation.

[0083] In step S128, the user prompts the software program to generate the design model in a transferable file format, as described above. Additionally, printing instructions are generated by the software program for communication with printer 300 or equivalent. In some embodiments, the printing instructions may be generated by a controller (not shown) of printer 300 after receiving the digital model from the software program. The user may transfer or send the file containing the design model and printing instructions to printer 300 via various communication methods, as described above.

[0084] In step S132, the user activates the printer 300 to begin the printing process according to the design model and printing instructions, including sub-processes described in more detail below. After the printer 300 completes the printing process, the user removes the printed model of the plate 200 from the printer 300 (S136) and, if necessary, separates the printed model from the preform mold 328. The term "printed model" is used herein to refer to the plate 200 immediately after the printing process is completed, and is also used to include the plate 200 and unfinished or unprocessed versions of the plate 200. In some examples, the user determines whether any treatment is necessary or desired, which is also described in more detail below. If necessary, the user proceeds to process the printed model of the plate 200 in step S140. Finally, once the printed model of the plate 200 is determined to be in a completed state, the plate 200 can be placed in the desired location on the footwear 100.

[0085] FIG. 8B shows a flowchart of an exemplary method for operating the printer 300, relating to the subprocess of step S132 in FIG. 8A. In step S200, a startup or warm-up process is initiated after the printer 300 is powered on. The warm-up process may take several minutes. Next, in step S204, the user selects and installs a first supply 348 having the desired substrate material 244, and the printer 300 supplies the substrate material 244 to the first head 332. Next, in step S208, the user selects and installs a second supply 356 having the desired fiber material 248, and the printer 300 supplies the fiber material 248 to the second head 336. In process S212, the user selects an appropriate preformed mold 328 for the particular component to be printed, e.g., a printed model of the plate 200. The user then places the preformed mold 328 in the appropriate orientation on the platform 308 within the printer 300. Next, in step S216, the user uses a software program to generate print processing instructions in a transferable file format and transmits them to the printer 300.

[0086] In step S220, the user considers characteristics associated with the printing process instructions, such as print duration, cycles, pauses and / or interruptions, and material volume, to determine when to start the printing process. The software program can provide recommended optimal start times to avoid downtime. For example, the printing process may include an 8-hour cycle and a 2-hour cycle. Therefore, it may be optimal to start the printing process at the end of the workday, e.g., around 5:00 p.m., so that the 8-hour cycle can be completed overnight and the shorter 2-hour cycle can be completed the next day. In this way, the user can make the printer 300 available for shorter cycles during the workday, e.g., during regular business hours, and also keep the printer 300 productive during non-working hours, e.g., overnight. After considering the characteristics of the printing process and recommendations provided by the software program, the user determines when to start the printer 300 and start the printing process.

[0087] Next, in step S224, the user initiates the printing process and attends to the printer 300 as needed. For example, the printing process may require the user to replenish the first supply 348 of substrate material 244 or replace the substrate material 244 with a different type. Next, in step S228, after the printer 300 completes the printing process, the user can remove the printed model from the printer 300 and separate the preformed model from the printed model of the plate 200. To do so, various hand tools, such as a screwdriver, chisel, hammer, etc., may be used. As shown in step S232, the user performs a quality inspection of the printed model of the plate 200 to identify any defects or risks. In one example, the quality inspection may include a simple visual inspection of the printed model of the plate 200 to identify any visible defects, such as cracks, improper voids or shapes, loose strand ends or loops, etc. In another example, the user may perform non-destructive testing on the printed model of the plate 200 to verify that its strength is satisfactory in each direction compared to design data. The user may also measure the weight and / or volume of the printed model to verify its composition by comparing it to the design data. Other tests may be performed to identify any defects associated with the printed model and / or deviations from the design data.

[0088] In step S236, the user determines whether defects identified from the quality inspection in step S232 pose a significant risk to the performance and / or quality of the printed model. If the user determines that defects present a significant risk, the user can determine whether those defects can be repaired by another process. Furthermore, in step S240, the user can also determine whether the costs associated with the repair, e.g., time and materials, are economical before deciding whether to perform the repair. If the defects are determined to be repairable and economical, the user submits the printed model for such repair, which may include additional printing or handling processes, as in step S244. If the defects are not repairable or uneconomical in step S248, the printed model can be discarded in accordance with any relevant local regulations. If no defects exist, the user can proceed to step S252.

[0089] In step S252, the user determines whether the printed model should undergo any treatment processes. Such treatment processes may include applying coatings, compressing, sanding, and / or polishing to alter the properties of the printed model, attaching pins or rods to the printed model to aid in installation on footwear 100, and other finishing techniques. In step S256, the user performs, or arranges for the performance of, any appropriate treatment processes that result in the printed model becoming a finished plate 200. After the treatment processes are completed in step S260, the user performs a quality inspection again to identify any defects or risks. If defects are identified, the user again decides whether to perform repairs in step S268. If repairs are worthwhile and economical, they are performed in step S272. After the repairs are completed, a quality inspection is performed again in step S264 for a final check. If no defects are identified in the quality inspection in step S264, whether after repairs or not, the user proceeds to step S276, where the plate 200 is installed or assembled on footwear 100 in its completed state.

[0090] As part of steps S204 and S208, the user identifies the specific materials specified by the design model, namely, the substrate material 244 and the fiber material 248. In doing so, the user can consider the variable costs associated with the substrate material 244 and the fiber material 248. Generally, the fiber material 248 is more expensive than the substrate material 244, and in some cases, the fiber material 248 may be more scarce or difficult to purchase in sufficient quantities. Therefore, plates using large amounts of the fiber material 248 are often more expensive and, in some cases, more sensitive to supply chain disruptions and resource fluctuations. Furthermore, conventional manufacturing methods involve material removal and therefore require larger amounts of excess material to account for such removal, e.g., cutting blanks from larger sheets of material. In contrast, additive manufacturing eliminates the need for such excess material. Optimized use of the fiber material 248 in additive manufacturing methods of the present invention, such as CFF technology, allows users to achieve improved plate performance, e.g., increased, customized stiffness, while minimizing costs. Thus, the additive manufacturing methods of the present invention can be optimized according to a variety of factors, including cost, availability, and performance, among others.

[0091] Next, the user loads the first supply 348 and second supply 356 containing the specified materials into the printer 300, and in particular, the user supplies a portion of the substrate material 244 from the first supply 348 to the first head 332 and a portion of the fibrous material 248 from the second supply 356 to the second head 336.

[0092] After the printer 300 is activated in step S224 to begin the printing process, the printer 300 operates according to instructions associated with the design model, selectively activating the first head 332 and the second head 336 to print the plate 200 layer by layer. In some examples, the printer 300 prints the plate 200 from bottom up, such that the bottom surface 208 is printed before the top surface 204. In other examples, the geometry and / or aspects of the plate 200 are printed layer by layer in a reverse orientation, such that the top surface 204 is printed before the bottom surface 208. Thus, the printer 300 instructs the first head 332 and the second head 336 to print the composite layers 240 of the plate 200 in an optimized orientation and manner, as informed by the design model. Upon completion of the printing process, the plate 200 is provided with an unfinished printed model comprised of anywhere from two to thousands of composite layers 240.

[0093] 9A and 9B, the printed model can then be processed in a compression mold 370, such as a marriage mold. Specifically, the printed model can be received in a negative mold 374 of a first block 378 corresponding to a particular shape and geometry, while a second block 382 is configured to operate with the first block 378 during the compression molding process. In some embodiments, the second block 382 includes a positive mold 386 extending therefrom and configured to protrude into the negative mold 374 of the first block 378 during the compression molding process. In other embodiments, the second block 382 includes a flat surface that encloses the printed model within the negative mold 374 of the first block 378.

[0094] During the compression molding process, the first block 378 and the second block 382 are compressed against each other with the printed model positioned therebetween. The magnitude of compression, i.e., the force of pressure measured in units of Newtons (N) or pounds per square inch (PSI), can vary over time throughout the compression molding process, or the magnitude of compression can remain constant throughout the compression molding process. Additionally, heat can be applied to the printed model via the first block 378 and / or the second block 382, ​​or heat can be applied directly to the printed model. Heat can be applied for various periods of time, at various temperatures, through various media, such as steam, glycol, hot water, hot air, or through a heat exchanger. Furthermore, cooling can be applied to the printed model via the first block 378 and / or the second block 382, ​​or cooling can be applied directly to the printed model. Cooling can be applied for various periods of time, at various temperatures, through various media, such as glycol, cold water, cold air, or through a heat exchanger.

[0095] Additionally, the compression molding process can include the injection of a volume of resin, such as thermoplastic polyurethane (TPU), acrylonitrile butadiene styrene (ABS), epoxy, vinyl, nylon, polyetherimide (PEI), polyetheretherketone (PEEK), polylactic acid (PLA), or liquid crystal polymer, among others, to serve as a coating for the printed model. That is, the printed model may be coated with resin during the compression molding process. Various aspects of the compression molding process can be adjusted or modified to achieve specific coating characteristics or to accommodate specific resin materials. For example, a thicker coating may require a longer compression time, thermal temperature, and volume of resin to apply to the printed model. In some embodiments, the resin material is transparent or translucent so that the composite layer 240 is visible through the coating. In other embodiments, the resin is opaque, and thus the composite layer 240 is hidden beneath the coating.

[0096] During the compression molding process, the printed composite layers 240 can change their properties and aspects in response to compression, heat, and / or coating. For example, the substrate material 244 can have a lower melting point or heat deflection temperature than the fiber material 248. Thus, the substrate material 244 of the printed model can be melted and molded according to the negative impression 374 of the first block 378, thereby molding or forming the plate 200 during the compression molding process. In one example, the compression molding process can compress the printed model so that one or more of the composite layers 240 reduce in thickness TL, thereby reducing the total thickness TT. The substrate material 244 can also be heat-fused by the compression molding process, and it is envisioned that the composite layers 240 are heat-fused to one another during the compression molding process. Thus, the compression molding process can transform the composite layers 240 of the plate 200 from separate, interlocked layers into a monolithic matrix of substrate material 244 impregnated with multiple continuous strands of fiber material 248. The heat fusion during compression molding increases the rigidity of the plate 200, and the rigidity of the bending resistance BR, torsion resistance TR, and the like increases.

[0097] Furthermore, the fibrous material 248 may become entangled or rearranged during the compression molding process, resulting in changes to the stiffness, flexibility, and directional strength properties of the printed model. It is contemplated that the compression molding process may melt or deform the fibrous material 248 due to exposure to heat and pressure. It is also contemplated that the fibrous material 248 may be heat-sealed to the substrate material 244 and / or its periphery via the compression molding process. Thus, the compression molding process can transform the composite layer 240 of continuous strands of fibrous material 248 from separate, spaced-apart layers into a monolithic web of fibrous material 248 impregnated within the matrix of the substrate material 244. Heat sealing during compression molding increases the stiffness of the plate 200, enhancing stiffness properties such as bending resistance (BR) and torsional resistance (TR). Additionally, if a coating is applied to the printed model during the compression molding process, the coating can impart specific properties to the printed model, such as surface roughness, moisture resistance, or vibration damping, among other features.

[0098] Accordingly, plate 200 can be formed in a variety of shapes and sizes and can be provided as part of footwear 100, such as sole 104 or upper 102. In some embodiments, plate 200 is provided as part of upper 102, e.g., as part of insole 126. Plate 200 can be configured to be at least partially customized to affect or enhance gait, posture, stance, propulsion, and mobility, among other needs. For example, plate 200 may be configured to reduce pain and / or improve performance for users with medical issues or deformities. Fiber reinforcements can increase stiffness in localized regions of plate 200, such as posterior segment 212, anterior segment 220, or arch segment 216, or some combination thereof. Additionally, stiffness can be increased by the array and orientation of fibers made of a generally stiff material, or by, for example, printing the fiber material in a smaller, denser array, or by adding additional composite layers, particularly in areas, or by depositing fibers around perimeter 232. Thus, the bending resistance BR and torsional resistance TR (which account for and are related to the moment of inertia MOI and modulus of elasticity values) can be increased and customized for specific applications. Fiber reinforcement can also provide directional stiffness in localized regions of the plate 200, as well as quasi-isotropic QI properties, by implementing additive manufacturing methods using CFF technology.

[0099] Example 1

[0100] 10-17, an embodiment of plate 400 is shown in several unfinished states, with individual composite layers 404 visible from a top plan view. Specifically, plate 400 is shown at successive stages of an exemplary trial of an additive manufacturing process, i.e., a printing process, as performed in a layer-by-layer construction using an exemplary CFF technique, with samples including a first composite layer 404a (see FIG. 10), a second composite layer 404b (see FIG. 11), a third composite layer 404c (see FIG. 12), a fourth composite layer 404d (see FIG. 13), a fifth composite layer 404e (see FIG. 14), a sixth composite layer 404f (see FIG. 15), a seventh composite layer 404g (see FIG. 16), and an eighth composite layer 404h (see FIG. 17). As can be seen from FIGS. 10-17, plate 400 defines a centerline axis 228 that bisects toe end 140 and heel end 146. Centerline axis 228 is disposed at a centerline angle 408 relative to reference axis 224. In the illustrated embodiment, centerline angle 408 is approximately -4 degrees, although other configurations are possible. Additionally, various aspects were measured during an exemplary test printing process and recorded in Table 1 below. Thus, the first layer corresponds to first composite layer 404a, etc., in FIG. 10.

[0101] [Table 1]

[0102] It will be understood that plate 400 can include several more composite layers in addition to the eight composite layers 404a-h, and plate 400 can undergo a compression molding process to which a coating is applied. It will be understood that the term "array" as used herein can include various types of patterns and arrangements, such as, for example, bostrophedon arrays, various polygonal tessellation arrays, concentric circular or elliptical patterns, curvilinear geometric motifs, or any other 2D or 3D pattern formed by continuous strands.

[0103] Referring to FIG. 10 , first composite layer 404a is a base layer comprised of strands of substrate material 244 printed on substrate array 412a oriented at base angle 416a relative to reference axis 224. Base angle 416a may be approximately 45 degrees, although other configurations are possible. In the illustrated embodiment, base layer 404a is comprised entirely of substrate material 244, which may function as a shell or protective layer to contain fibrous material 248 deposited in subsequent layers (see FIGS. 11-17 ). However, in some embodiments, base layer 404a may be removed prior to installation or assembly within footwear 100.

[0104] Referring to FIG. 11 , the plate 400 includes a second composite layer 404b including continuous strands of fibrous material 248 printed in a first fiber array 412b oriented parallel to the reference axis 224. The first fiber array 412b is therefore oriented at a first fiber angle 416b (not shown) that is different from the base angle 416a. Additionally, the first fiber array 412b of the second composite layer 404b includes turns 420 in the form of U-shaped hairpin bends disposed along portions of the periphery 232 of the plate 400. Additionally, the second composite layer 404b includes peripheral elements 236 that engage with one or more of the turns 420 along various portions of the first fiber array near the periphery 232. The peripheral elements 236 are formed from the fibrous material 248 and provide additional reinforcement, although the peripheral elements 236 may be formed from other materials and / or provided in more or fewer locations. In other embodiments, the peripheral element 236 may be positioned further inward from the periphery 232, or the peripheral element 236 may not be provided. With reference to Table 1, the second composite layer 404b has a layer thickness TL of 0.1 mm and a thickness of 1.57 cm 3 of which the fiber material 248 constitutes 96.8%.

[0105] 12 , the plate 400 includes a third composite layer 404c including continuous strands of fiber material 248 printed in a second fiber array 412c oriented at a second fiber angle 416c relative to the reference axis 224. In the illustrated embodiment, the second fiber angle 416c is approximately −45 degrees. Thus, the second fiber angle 416c is different from the first fiber angle 416b (not shown). Additionally, the second fiber array 412c of the third composite layer 404c includes turns 420 disposed along a portion of the periphery 232 of the plate 400. Additionally, the third composite layer 404c includes peripheral elements 236 that engage one or more of the turns 420 along various portions of the second fiber array 412c near the periphery 232. With reference to Table 1, the third composite layer 404c has a layer thickness TL of 0.1 mm and a thickness of 1.56 cm. 3 of which the fiber material 248 constitutes 96.8%.

[0106] 13 , the plate 400 includes a fourth composite layer 404d including continuous strands of fiber material 248 printed in a third fiber array 412d oriented at a third fiber angle 416d relative to the reference axis 224. In the illustrated embodiment, the third fiber angle 416d is approximately 90 degrees. Thus, the third fiber angle 416d is different from the second fiber angle 416c. Additionally, the third fiber array 412d of the fourth composite layer 404d includes turns 420 disposed along a portion of the periphery 232 of the plate 400. Additionally, the fourth composite layer 404d includes peripheral elements 236 that engage one or more of the turns 420 along various portions of the third fiber array 412d near the periphery 232. With reference to Table 1, the fourth composite layer 404d has a layer thickness TL of 0.1 mm and a width of 1.53 cm. 3 of which the fiber material 248 constitutes 98.0%.

[0107] 14 , the plate 400 includes a fifth composite layer 404e including continuous strands of fiber material 248 printed in a fourth fiber array 412e oriented at a fourth fiber angle 416e relative to the reference axis 224. In the illustrated embodiment, the fourth fiber angle 416e is approximately 45 degrees. Thus, the fourth fiber angle 416e is different from the third fiber angle 416d. Additionally, the fourth fiber array 412e of the fifth composite layer 404e includes turns 420 disposed along a portion of the periphery 232 of the plate 400. Additionally, the fifth composite layer 404e includes peripheral elements 236 that engage one or more of the turns 420 along various portions of the fourth fiber array 412e near the periphery 232. The fifth composite layer 404e has a layer thickness T L of 0.1 mm and a layer volume V L of 1.56 cm , as shown in Table 1. 3 Fiber materials account for 96.8%.

[0108] 15 , the plate 400 includes a sixth composite layer 404f including continuous strands of fiber material 248 printed in a fifth fiber array 412f oriented at a fifth fiber angle 416f relative to the reference axis 224. In the illustrated embodiment, the fifth fiber angle 416f is approximately −45 degrees. Thus, the fifth fiber angle 416f is different from the fourth fiber angle 416e. Additionally, the fifth fiber array 412f of the sixth composite layer 404f includes turns 420 disposed along a portion of the periphery 232 of the plate 400. Additionally, the sixth composite layer 404f includes peripheral elements 236 that engage one or more of the turns 420 along various portions of the fifth fiber array 412f near the periphery 232. With reference to Table 1, a layer thickness TL of 0.1 mm and a thickness of 1.54 cm 3 Measurements are provided for the sixth composite layer 404f, which includes a layer volume VL of 96.8%, of which the fibrous material 248 constitutes 96.8%.

[0109] 16 , the plate 400 includes a seventh composite layer 404g including continuous strands of fibrous material 248 printed in a sixth fiber array 412g oriented at a sixth fiber angle 416g relative to the reference axis 224. In the illustrated embodiment, the sixth fiber angle 416g is approximately 90 degrees. Thus, the sixth fiber angle 416g is different from the fifth fiber angle 416f. Additionally, the sixth fiber array 412g of the seventh composite layer 404g includes turns 420 disposed along a portion of the periphery 232 of the plate 400. Additionally, the seventh composite layer 404g includes peripheral elements 236 that engage one or more of the turns 420 along various portions of the sixth fiber array 412g near the periphery 232. The seventh composite layer 404g has a layer thickness TL of 0.1 mm and a thickness of 1.54 cm. 3 The layer volume VL is 98.0% of which is the fiber material 248.

[0110] 17 , the plate 400 includes an eighth composite layer 404h including continuous strands of fibrous material 248 printed in a seventh fiber array 412h oriented at a seventh fiber angle 416h relative to the reference axis 224. In the illustrated embodiment, the seventh fiber angle 416h is approximately 90 degrees. Thus, the seventh fiber angle 416h is different from the sixth fiber angle 416g. Additionally, the seventh fiber array 412h of the eighth composite layer 404h includes turns 420 disposed along a portion of the periphery 232 of the plate 400. Additionally, the eighth composite layer 404h includes peripheral elements 236 that engage one or more of the turns 420 along various portions of the seventh fiber array 412h near the periphery 232. The eighth composite layer 404h has a layer thickness TL of 0.1 mm and a thickness of 1.56 cm. 3 The layer volume VL is 96.8% of which is made up of fiber material 248.

[0111] Thus, one exemplary CFF technique involves the deposition of multiple layers of continuous strands of fibrous material 248, stacked or arranged perpendicularly within a continuous composite layer 404, arranged in different arrays 412, and arranged at various angles 416 relative to the reference axis 224. Furthermore, each fiber array 412 includes continuous strands of fibrous material 248 that extend continuously in-plane between the toe end 140 and the heel end 146 of the plate 400. That is, the CFF technique used to manufacture the plate 400 includes several composite layers 404 in which the fibrous material 248 is deposited in fiber arrays 412 that are uniform and continuous throughout the posterior segment 212, the arch segment 216, and the anterior segment 220, and the fiber arrays 412 are also uniform between the medial surface 118 and the lateral surface 116 of the plate 400. Furthermore, each fiber array 412 includes fiber arrays 412 that are distinct and separated from the fiber arrays 412 of adjacent composite layers 404. 248 To this end, a cutter (not shown) in the printer 300 is used to define the continuous strands of each fiber array 412.

[0112] Additionally, the fiber angle 416 differs from the fiber angle 416 of an adjacent composite layer 404. Furthermore, the fiber array 412 of each composite layer 404 defines a fiber surface area FSAL of the composite layer 404, which can then be quantified as a percentage of the total surface area SAL defined by the composite layer 404. In one example, the fiber array 412 comprises at least about 90% of the layer surface area. Because the composite layer 404 extends across the entire plate 400 and partially defines the plate 400 and its periphery 232, the layer surface area SAL is generally equal to the in-plane surface area (SAP) of the plate 400. Thus, the fiber surface area of ​​the fiber array 412 corresponds to the in-plane surface area of ​​the plate 400. To that end, the fiber array 412 is continuously printed across substantially the entire in-plane surface area SAP of the plate 400, i.e., the fiber array 412 comprises at least about 90% of the in-plane surface area SAP of the plate 400. It will be understood that the fiber fraction FPL of the layer volume VL corresponds proportionally to the fiber surface area FSAL covered by the fiber array 412. However, in some embodiments, the fiber fraction FPL may not correspond to the fiber surface area FSAL due to the introduction of third elements and / or materials or due to concentration of the fiber material 248 in particular regions or sections of the composite layer 404 and / or plate 400. In some embodiments, the fiber surface area FSAL of each fiber array 412 differs from the fiber surface area FSAL of the fiber array 412 of an adjacent composite layer 404.

[0113] With reference to FIG. 18 , another embodiment of a plate 500 is provided for use in a sole structure 504 for footwear 100. The plate 500 and sole structure 504 of FIG. 18 are similar to plates 200, 400, and sole structure 104, and therefore, like reference numerals are used to indicate like elements. In FIG. 18 , the plate 500 includes a medial fork 508 and a lateral fork 512 separated by a gap 516 within the front segment 220. The plate 500 narrows, or is measured in the X direction, relative to a reference plane 224 moving longitudinally toward the heel end 146. That is, the plate 500 narrows from the front segment 220 to the arch segment 216 and from the arch segment 216 to the rear segment 212. In the illustrated embodiment, the sole 504 further includes an outsole 520 and a midsole 528 to which the plate 500 is attached.

[0114] Like plates 200 and 400, plate 500 is fabricated by additive manufacturing, and plate 500 includes multiple composite layers (not shown) including variously oriented fiber material 248 and substrate material 244. Thus, plate 500 is sized and shaped to have customized bending resistance BR and torsional resistance TR. For example, due to the location of gap 516 between inner fork 508 and outer fork 512, front segment 220 of plate 500 has smaller material volumes VL and VT than those of plates 200 and 400. This reduces bending resistance BR and torsional resistance TR compared to plates 200 and 400. In addition, rear segment 212 also defines reduced VL and VT compared to plates 200 and 400. However, arch segment 216 of plate 500 defines VT and VL that are equal to or greater than the VT and VL of plates 200 and 400. Thus, the plate 500 is tailored to provide a particular bending resistance BR and torsional resistance TR compared to the plates 200, 400 by modifying the shape and size of the plate 500.

[0115] Additionally, the inner fork 508 and the outer fork 512 of the plate 500 may be configured to have different characteristics from one another. For example, the inner fork 508 may have a greater stiffness, e.g., bending resistance BR, than the outer fork 512 to provide the user with increased propulsion on or near the medial side of the ball of the foot, i.e., near the distal toe. In contrast, the outer fork 512 may have a greater flexibility, e.g., a lower bending resistance BR, than the inner fork 508 to provide the user with increased comfort on or near the lateral side of the ball of the foot, e.g., near the distal toe.

[0116] 1-3 and 18 , plate 500 is provided as part of a sole structure 504 configured to be assembled with upper 102. In particular, plate 500 is configured to be disposed between outsole 520 and upper 102, such that plate 500 contacts both outsole 520 and upper 102. To that end, plate 500 extends through midsole 528, and specifically, rear segment 212 of plate 500 extends through slot 532 formed through midsole 528. In the illustrated embodiment, plate 500 gradually curves along front segment 220 and arch segment 216 relative to horizontal plane H, such that plate 500 has increased curvature relative to horizontal plane H along arch segment 216 and rear segment 212 compared to the curvature of front segment 220.

[0117] When assembled, the rear segment 212 of the plate 500 rests on the platform 536 flush with the bed 540 of the midsole 528. When the upper 102 is attached to the midsole 528, the insole 126 of the upper 102 is positioned along the bed 540 of the plate 500 and the rear segment 212. Thus, when the sole 504 is assembled, the plate 500 extends in the X and Y directions and is positioned at a downward angle relative to the horizontal plane H, which is coplanar with the bed 540 of the midsole 528 and / or at least a portion of the insole 126 of the upper 102. The downward angle is at least about 5 degrees, but may be 10 degrees or more. At such a downward angle, in combination with the specified curvature, the plate 500 is configured to deflect under an applied load during use, thereby allowing the plate 500 to rebound and thus provide propulsion for the user's gait during light loads, such as simple walking. In combination with the particular shape and size of the plate 500, as described above, the plate 500 is positioned within the sole 504 to increase responsiveness, thereby making propulsion easier, i.e., with less force, than a plate laid flat along the midsole 528.

[0118] Accordingly, plates 200, 400, 500 can be formed in a variety of shapes and sizes and can be provided as part of footwear 100, such as sole 104 or upper 102. In some embodiments, plate 400 is provided as part of upper 102, such as part of insole 126. Plates 200, 400, 500 can be configured to be at least partially customized to affect or improve gait, posture, stance, propulsion, and agility, among other needs. For example, plates 200, 400, 500 may be configured to alleviate pain and / or improve performance for users with medical issues or deformities. Fiber reinforcements can increase the stiffness of localized regions of plates 200, 400, such as in posterior segment 212, anterior segment 220, or arch segment 216, or some combination thereof. Additionally, stiffness can be increased by arraying and orienting fibers made of a generally stiff material, or by, for example, printing the fiber material in smaller, denser arrays, or by adding additional composite layers, particularly in regions, or by depositing fibers around the perimeter 232. Thus, the moment of inertia (MOI) and modulus of elasticity (MOD), and their associated bending resistance (BR) and torsional resistance (TR), can be increased and customized for specific applications. Fiber reinforcement can also provide directional stiffness in localized regions of the plates 200, 400, 500, as well as quasi-isotropic QI properties, by implementing additive manufacturing methods using CFF technology.

[0119] FIG. 19 illustrates another embodiment of a plate 600 manufactured by the additive manufacturing process described above. The plate 600 is configured as a single sole structure 104, and the plate 600 includes the entire sole structure 104 to which the upper 102 (see FIGS. 1-3) is attached. In particular, the plate 600 includes multiple traction elements 604 monolithically disposed as part of the plate 600. Thus, the same additive manufacturing process, and in some instances, the same material, can be used to manufacture the plate 600 and the traction elements 604. The traction elements 604 are thus composite elements including the substrate material 244 and the fiber material 248, as described above in connection with FIGS. 1-18. Referring to FIG. 20, which is a cross-sectional view of one of the traction elements 604 of FIG. 19, the fiber material 248 is wound in concentric circular paths within the traction element 604. Additionally, the traction element 604 defines an outer diameter D that narrows as the traction element 604 extends away from the plate 600. Thus, the concentric paths of the fibrous material 248 tighten or expand within the traction element 604 in proportion to the diameter D. In this manner, the traction element 604 is reinforced to have strength-to-weight characteristics similar to the plates 200, 400, 500 described above.

[0120] 21 , a schematic diagram of one example of an opening 620 that may be provided in a plate 600 is shown. In the illustrated embodiment, a fibrous material 248 extends in a concentric circular path around the opening 620, proportional to the diameter D1 defined by the opening 620. In this manner, the fibrous material 248 is used to reinforce the opening 620 in the plate 600. Such openings 620 may be formed in the plate 600 as through holes, or as voids or cavities that are not exposed to the exterior of the plate 600.

[0121] It is contemplated that any of the plates described herein may include embedded functionality in addition to the structural rigidity characteristics described above. For example, it is contemplated that the fabric material 248 may have or be modified to have an electrically conductive material, a thermally conductive material, an electrically insulating material, a thermally insulating material, an optically transparent material, or a fluid-permeable material. Additionally or alternatively, a device (not shown) may be embedded within any of the plates of the present disclosure. In one example, the device (not shown) may be a sensor, such as a transducer, accelerometer, geolocation sensor, temperature sensor, humidity sensor, or moisture sensor. Furthermore, the device (not shown) may be capable of providing a tactile feedback to the user, thereby informing the user to avoid prolonged standing, sitting, or immobility. The device (not shown) may also be an object or structural element, such as an air-filled or fluid-filled bladder or pod. It is further contemplated that the device (not shown) may be capable of harvesting and storing energy caused by deformation of the plate and / or footwear during use, such as, for example, a piezoelectric transducer.

[0122] Other configurations are possible in other embodiments. For example, specific features and combinations of features presented with respect to particular embodiments in the above discussion can be utilized in other embodiments and other combinations, as appropriate. Furthermore, any of the embodiments described herein can be modified to include any of the structures or methods disclosed in connection with other embodiments. Additionally, the present disclosure is not limited to the types of footwear articles specifically shown. Furthermore, the footwear article aspects of any of the embodiments disclosed herein may be modified to function with any type of footwear, apparel, or other athletic equipment.

[0123] As previously mentioned, while the present invention has been described above with reference to particular embodiments and examples, it will be understood by those skilled in the art that the invention is not necessarily so limited, and that numerous other embodiments, examples, uses, modifications, and departures from the embodiments are intended to be encompassed by the claims appended hereto. The entire disclosure of each patent and publication cited herein is incorporated by reference as if each such patent or publication were individually incorporated by reference. Various features and advantages of the present invention are set forth in the following claims. [Industrial Applicability]

[0124] Numerous modifications to the present invention will be apparent to those skilled in the art in light of the foregoing description. Accordingly, this specification is to be construed as illustrative only and is presented for the purpose of enabling one skilled in the art to make and use the invention. The exclusive rights to all modifications that come within the scope of the appended claims are reserved.

Claims

1. 1. A method of using a three-dimensional printer and a compression mold to manufacture a plate for a footwear product, the method comprising: providing a supply of substrate material to be supplied to a first head of the printer; providing a supply of fibrous material to be fed to a second head of the printer; providing a preformed model on a platform within said printer; providing a design model to the printer, wherein the first head and the second head are selectively activated and deactivated to print at least two composite layers onto the preformed model; The at least two composite layers are separated from the preformed model and received within the compression mold.

2. each of the at least two composite layers includes a continuous fiber strand provided by the second head; The method of claim 1.

3. the plate includes an anterior segment having a first stiffness, an arch segment having a second stiffness, and a posterior segment having a third stiffness; The method of claim 1.

4. the first stiffness is greater than the second stiffness, and the third stiffness is greater than the first stiffness; The method of claim 3.

5. the first stiffness, the second stiffness, and the third stiffness are equal; The method of claim 3.

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