Footwear and method of manufacture thereof

Abstract

A footwear and method of manufacture wherein the present invention includes capture and acquisition of a three-dimensional volumetric scan of feet of a user wherein the scan data is employed to manufacture a customized midsole for a sandal. The present invention includes a midsole that has an upper surface and a bottom surface wherein the upper surface is formed to mateably accommodate the hindfoot, midfoot and forefoot of the wearer. The midsole is manufactured from a cork-rubber blend in a preferred embodiment and includes a opposing side to which a strap member is secured thereto. The strap member has at least one strap segment configured to extend over the top of the wearer's foot. An outsole is secured to the bottom surface of the midsole. The outsole is manufactured from a closed cell polymer foam.

What is claimed is: 
     
         1 . A method of manufacturing footwear wherein the method comprises the steps of:
 procuring stock blank,   acquiring a three-dimensional volumetric scan of a wearer's feet, wherein the three-dimensional scan of the wearer's feet includes a hindfoot, midfoot and forefoot region of the wearer's feet, wherein the three-dimensional volumetric scan creates a data file;   saving the data file, wherein the data file containing data for the three-dimensional volumetric scan is stored on suitable computer media;   modifying the data file, wherein the data file is modified so as to alter at least one area to accommodate a physical requirement of a foot of a wearer;   loading the data file, wherein the data file is loaded into a controller for milling equipment;   milling the stock blank, wherein the stock blank is milled in accordance with the data file to create a midsole, said midsole having a bottom surface and an upper surface;   attaching a strap member to the bottom surface of the midsole; and   securing an outsole, wherein the outsole is secured to the bottom surface of the midsole.   
     
     
         2 . The method of manufacturing footwear as recited in  claim 1 , wherein the strap member includes at least one strap segment, said strap segment configured to extend from a first side of the midsole to a second side of the midsole over a top of the wearer's feet. 
     
     
         3 . The method of manufacturing footwear as recited in  claim 2 , wherein the stock blank is manufactured from a cork-rubber blend. 
     
     
         4 . The method of manufacturing footwear as recited in  claim 3 , wherein the strap member includes a lower portion, said lower portion being secured to the bottom surface of the midsole, said lower portion being intermediate the outsole and midsole. 
     
     
         5 . The method of manufacturing footwear as recited in  claim 4 , wherein said upper surface of said midsole is shaped to mateably accommodate a bottom of the wearer's feet that includes a hindfoot, midfoot and forefoot region. 
     
     
         6 . The method of manufacturing footwear as recited in  claim 5 , and further including a step of transferring the data file, wherein the data file is transferred from the computer media to the controller of the milling equipment.