Method and apparatus for manufacturing components used for the manufacture of articles

Abstract

Methods of manufacturing wearable articles include: (a) performing a scan of a body part of a user on which the wearable article will be worn; (b) creating a virtual design of a mold insert configured to mold the wearable article, based on the scan; (c) saving the virtual design in a data file; (d) fabricating the mold insert using a laser sintering, fused deposition modeling, and stereolithography technique; (e) inserting the mold insert into a mold; (f) inserting moldable material into a cavity created at least in part by the mold insert; (g) molding the moldable material to produce the wearable article; and (h) removing the wearable article from the mold. The wearable article may include a portion of an article of footwear, such as a portion of a shoe sole.

1 . (canceled) 
     
     
         2 . A method of manufacturing a wearable article, comprising:
 fabricating a mold insert using a technique selected from the group consisting of: laser sintering, fused deposition modeling, and stereolithography;   inserting the mold insert into a mold;   with the mold insert inserted into the mold, inserting moldable material into a cavity defined at least in part by the mold insert;   with the mold insert inserted into the mold, molding the moldable material to produce the wearable article, wherein the wearable article is formed of the moldable material; and   removing the wearable article from the mold.   
     
     
         3 . The method of  claim 2 , wherein the inserting the moldable material includes inserting one of rubber, vinyl, or phylon. 
     
     
         4 . The method of  claim 2 , wherein the wearable article is a watch band. 
     
     
         5 . The method of  claim 2 , wherein the fabricating the mold insert includes forming the mold insert using laser sintering. 
     
     
         6 . The method of  claim 2 , wherein the fabricating the mold insert includes forming the mold insert using fused deposition modeling. 
     
     
         7 . The method of  claim 2 , wherein the fabricating the mold insert includes forming the mold insert using stereolithography. 
     
     
         8 . The method of  claim 2 , wherein the molding the moldable material includes compression molding. 
     
     
         9 . The method of  claim 2 , wherein the molding the moldable material includes injection molding. 
     
     
         10 . The method of  claim 2 , wherein the mold insert is capable of withstanding temperatures within a range of 300-350° F. during the molding. 
     
     
         11 . The method of  claim 2 , wherein the mold insert is capable of withstanding clamping tonnages within a range of 5-20 tons during the molding. 
     
     
         12 . The method of  claim 2 , further comprising performing a scan of a body part of a user on which the wearable article will be worn. 
     
     
         13 . The method of  claim 12 , further comprising creating a virtual design of a mold insert configured to mold the wearable article, based on the results of the scan performed. 
     
     
         14 . The method of  claim 13 , further comprising saving the virtual design in a data file. 
     
     
         15 . The method of  claim 14 , wherein the fabricating uses the data file for creating the mold insert. 
     
     
         16 . A method of manufacturing a wearable article, comprising:
 performing a scan of a body part of a user on which the wearable article will be worn;   creating a virtual design of a mold insert configured to mold the wearable article, based on the results of the scan performed;   saving the virtual design in a data file;   fabricating the mold insert using a technique selected from the group consisting of: laser sintering, fused deposition modeling, and stereolithography, wherein the fabricating is guided at least in part by the data file;   inserting the mold insert into a mold;   with the mold insert inserted into the mold, inserting moldable material into a cavity defined at least in part by the mold insert;   with the mold insert inserted into the mold, molding the moldable material to produce the wearable article, wherein the wearable article is formed of the moldable material; and   removing the wearable article from the mold.   
     
     
         17 . The method of  claim 16 , further comprising heating the mold insert during the molding. 
     
     
         18 . The method of  claim 17 , wherein the fabricating the mold insert includes forming air or fluid flow channels in the mold insert, and wherein the heating the mold insert includes moving heated air or heated fluid throughout the air or fluid flow channels in the mold insert. 
     
     
         19 . The method of  claim 16 , wherein the fabricating the mold insert includes forming air or fluid flow channels in the mold insert. 
     
     
         20 . A method of manufacturing a wearable article, comprising:
 fabricating a mold insert using a technique selected from the group consisting of: laser sintering, fused deposition modeling, and stereolithography;   removably engaging the mold insert in an aperture or opening defined in a mold carrier or plate of a mold;   with the mold insert engaged in the aperture or opening defined in the mold carrier or plate of a mold, inserting moldable material into a cavity defined at least in part by the mold insert;   with the mold insert engaged in the aperture or opening defined in the mold carrier or plate of a mold, molding the moldable material to produce a wearable article, wherein the wearable article is formed of the moldable material; and   removing the wearable article from the cavity.   
     
     
         21 . The method of  claim 20 , further comprising:
 performing a scan of a body part of a user on which the wearable article will be worn;   creating a virtual design of a mold insert configured to mold the wearable article, based on the results of the scan performed; and   saving the virtual design in a data file;   wherein the fabricating uses the data file to guide creation of the mold insert.