# US 10,368,612 B2 · Footwear manufacturing with precutting > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,368,612 B2 - Document ID: US10368612B2 - Status: Granted - Kind: B2 - Application number: 15/509,101 - Filed: 2016-05-25 - Published: 2017-09-21 - Granted: 2019-08-06 - Earliest claimed: 2015-05-29 - Assignees: NIKE, Inc. - Applicants: NIKE, Inc. - Inventors: Bruce J. Kilgore - Web page: https://patentgrep.com/patent/US10368612B2 ## CPC - A43B 23/0235: {Different layers of different material} - A43B 9/00: Footwear characterised by the assembling of the individual parts - A43B 23/0245: {characterised by the constructive form} - A43B 23/042: {Uppers made of one piece (one piece slippers A43B3/106; one piece sandals A43B3/124)} - A43B 23/07: Linings therefor {(lining laminated with upper A43B23/026)} - B29D 35/10: having preformed soles or heels joined on to preformed uppers using a moulding technique, e.g. by feeding or injecting plastics material between the parts to be joined - A43B: CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR - B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00) ## Abstract A method of manufacturing an article of footwear from a flat pattern is provided. The method includes cutting a first cut in a first material through the top surface (502) and the bottom surface of the first material. The method continues with coupling an overlay (500) on the first material top surface (502) such that the overlay (500) extends over the first cut and obscures the first material top surface (502). The method continues with forming the flat pattern having the first material with the first cut and the overlay (500) into a dimensional article of footwear configured to receive a foot. The first material bottom surface is more interior to the dimensional article of footwear than the top surface (502). ## Claims ### Claim 1 A method of manufacturing an article of footwear from a flat pattern, the method comprising: cutting a first cut in a first material of the flat pattern, the first material having a top surface and an opposite bottom surface, the first cut extending through the top surface and the bottom surface; coupling an overlay on the first material top surface, the overlay extending over the first cut such that the first cut is obscured on the first material top surface by the overlay; and subsequent to coupling the overlay, forming the flat pattern having the first material with the first cut and the overlay into a dimensional article of footwear configured to receive a foot, wherein the first material bottom surface is more interior to the dimensional article of footwear than the top surface. ### Claim 2 (depends on 1) The method of claim 1, wherein the first material is a rolled good from which a plurality of flat pattern portions are formed. ### Claim 3 (depends on 2) The method of claim 2, wherein the first material is a nonwoven material. ### Claim 4 (depends on 1) The method of claim 1, wherein the first material forms an upper portion and a coextensive footbed portion. ### Claim 5 (depends on 4) The method of claim 4, wherein the first cut forms a portion of the upper portion. ### Claim 6 (depends on 4) The method of claim 4, wherein the first cut forms a portion of the footbed portion. ### Claim 7 (depends on 4) The method of claim 4, wherein the first cut forms an acute angle between an intersection of the upper portion and the footbed portion. ### Claim 8 (depends on 1) The method of claim 1, wherein the first cut forms an aperture. ### Claim 9 (depends on 1) The method of claim 1, wherein the first cut forms an origin aperture. ### Claim 10 (depends on 1) The method of claim 1, wherein the coupling of the overlay is comprised of adhering, stitching, or welding the overlay to the first material. ### Claim 11 (depends on 10) The method of claim 10, wherein the overlay is not coupled to the first material at the first cut. ### Claim 12 (depends on 10) The method of claim 10, wherein the overlay is independently moveable at the first cut. ### Claim 13 (depends on 1) The method of claim 1, wherein the first cut forms a portion of a perimeter of the first material. ### Claim 14 (depends on 1) The method of claim 1, wherein the first cut is within an internal area of the first material. ### Claim 15 (depends on 1) The method of claim 1 further comprising: cutting a second cut, the second cut extending through the first material and the overlay; and coupling a second overlay to the overlay, wherein the second cut is obscured by the second overlay. ### Claim 16 A method of manufacturing an article of footwear from a flat pattern, the method comprising: cutting a first cut in a first material of the flat pattern, the first material having a top surface and an opposite bottom surface, the first cut extending through the top surface and the bottom surface; coupling an overlay on the first material top surface, the overlay extending over the first cut such that the first cut is obscured on the first material top surface by the overlay and the overlay is independently moveable at the first cut; and forming the flat pattern having the first material with the first cut and the overlay into a dimensional article of footwear configured to receive a foot, wherein the first material bottom surface is more interior to the dimensional article of footwear than the top surface. ### Claim 17 A method of manufacturing an article of footwear from a flat pattern, the method comprising: forming a first cut in a first material of the flat pattern, the first material having a top surface and an opposite bottom surface, the first cut extending through the top surface and the bottom surface; coupling an overlay on the first material top surface, the overlay extending over the first cut; forming a second cut, the second cut extending through the overlay; coupling a second overlay to the overlay, wherein the second cut is obscured by the second overlay; and forming the flat pattern having the first material with the first cut and the overlay into a dimensional article of footwear configured to receive a foot, wherein the first material bottom surface is more interior to the dimensional article of footwear than the top surface.