Superfeet Worldwide, Inc.

Mike Zhuang

Eric Paris Hayes

Daniel Wakeland

Embodiments are directed to manufacturing footwear. A first outer mold shell and a second outer mold shell may be provided. A first inner mold body and a second inner mold body may be manufactured. The first and second inner mold bodies may have respective first and second inner mold surfaces. The second inner mold surface, together with the first inner mold surface, may define an internal mold volume. The first and second inner mold bodies may be removably coupled to the respective first and second outer mold shells to form first and second hybrid side rings. The first hybrid side ring and the second hybrid side ring may be installed in an automated injection molding machine. The installed first hybrid side ring may be moved toward the installed second hybrid side ring to provide the internal mold volume. One or more liquids may be injected into the internal mold volume.

Footwear construction with hybrid molds

A midsole of footwear with an incorporated orthotic support. The midsole includes a soft and flexible member and a more rigid orthotic support. The orthotic support includes a heel cup and an arch support portion that extends forwardly from the heel cup. Embodiments produce the midsole by positioning the orthotic insert between an upper portion of the footwear and an outsole. Then, soft and flexible material is injected into the space surrounding the orthotic. The soft and flexible material subsequently cures forming the multi-part unitary midsole.

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Ferndale, WA, United States of America

Mike Zhuang