Systems and methods for manufacturing footwear

Abstract

Systems and methods for forming footwear are provided. The method may comprise forming a shoe blank. The shoe blank may comprise an upper portion and an outsole component. The forming the shoe blank may comprise coupling the upper portion to the outsole component. The method may comprise subtractively removing material from the shoe blank, comprising cutting away material from the upper portion. The cutting away the material from the upper portion causes the upper portion to be wearable by a user, forming a wearable shoe. The material removed corresponds to a shape of a pattern. The pattern defines a footwear style of the wearable shoe.

1 . A method for forming footwear, comprising:
 forming a shoe blank,
 wherein:
 the shoe blank is a non-wearable product that comprises:
 an upper portion; and 
 an outsole component, and 
 
 forming the shoe blank comprises coupling the upper portion to the outsole component; and 
 
   subtractively removing material from the shoe blank, comprising cutting away material from the upper portion,
 wherein:
 the cutting away the material from the upper portion causes the upper portion to be wearable by a user, forming a wearable shoe, 
 the material removed corresponds to a shape of a pattern, and 
 the pattern defines a footwear style of the wearable shoe. 
 
   
     
     
         2 . The method of  claim 1 , further comprising applying one or more closures to the wearable shoe. 
     
     
         3 . The method of  claim 2 , wherein the one or more closures comprise one or more of:
 shoelaces;   straps; and   snaps.   
     
     
         4 . The method of  claim 1 , further comprising positioning a shoe last into a cavity of the shoe blank prior to the selectively removing the material from the shoe blank,
 wherein the shoe last, when inserted into the shoe blank, provides internal support to the upper portion as the material is subtractively removed.   
     
     
         5 . The method of  claim 4 , wherein:
 the shoe last comprises a plurality of sections, and   the positioning the shoe last into the cavity comprises securing relative positions of the plurality of sections of the shoe last via one or more locking mechanisms.   
     
     
         6 . The method of  claim 1 , wherein the forming the shoe blank comprises:
 forming the upper portion; and   forming the outsole component.   
     
     
         7 . The method of  claim 6 , wherein the forming the upper portion comprises laminating two or more layers of material together. 
     
     
         8 . The method of  claim 6 , wherein the forming the shoe blank comprises coupling the upper portion to the outsole component. 
     
     
         9 . The method of  claim 8 , wherein the coupling the upper portion to the outsole component comprises securing the upper portion to the outsole component via:
 cementing;   gluing;   sewing;   nailing; or   tacking.   
     
     
         10 . The method of  claim 8 , wherein the coupling the upper portion to the outsole component comprises tightening the upper portion around a shoe last. 
     
     
         11 . The method of  claim 1 , wherein the forming the shoe blank comprises injection-molding material into a shape of the shoe blank. 
     
     
         12 . The method of  claim 1 , wherein the forming the shoe blank comprises 3D printing the shoe blank. 
     
     
         13 . The method of  claim 1 , further comprising applying one or more dyes or pigments to the shoe blank. 
     
     
         14 . The method of  claim 1 , further comprising applying the pattern to a surface of the shoe blank. 
     
     
         15 . The method of  claim 14 , wherein the applying the pattern comprises tracing a pattern stencil.