Efficient Die Cutting Pattern For Footwear Manufacture

A method of manufacturing parts of an article of footwear from a bulk material, the bulk material defining a width direction and a length direction, the method comprising:

• providing at least one gang die with a first cutting member and a second cutting member, the first and second cutting members being fixed together, the first cutting member configured to cut a first part from the bulk material, the second cutting member configured to cut a second part from the bulk material, the second part having a distinct shape from the first part, the at least one gang die configured to cut the first and second parts along a common internal cutting line that defines a first edge of the first part and a second edge of the second part;
• and
• actuating the at least one gang die relative to the bulk material during at least one stroke to cut a first group of parts and a second group of parts from the bulk material, the first group of parts including the first part and the second part, the second group of parts including the first part and the second part, the first part of the second group corresponding in shape to the first part of the first group, the second part of the second group corresponding in shape to the second part of the first group;
• the first group cut along a common external cutting line that partly defines a first boundary of the first group and that partly defines a second boundary of the second group, the first boundary having a first curvature, and the second boundary having a second curvature that is inverse to the first curvature;
• the first part of the first group being cut from a first location on the bulk material, the first part of the second group being cut from a second location on the bulk material, the first location being offset from the second location in both the width direction and the length direction.

A method of manufacturing parts of an upper of an article of footwear from a bulk material, the method comprising:

• providing at least one gang die with a first cutting member and a second cutting member, the first and second cutting members being fixed together, the first cutting member configured to cut a first part from the bulk material, the second cutting member configured to cut a second part from the bulk material, the second part having a distinct shape from the first part, the at least one gang die configured to cut the first and second parts along a common internal cutting line that defines a first edge of the first part and a second edge of the second part;
• and
• actuating the at least one gang die relative to the bulk material during at least one stroke to cut a first group of parts and a second group of parts from the bulk material, the first group of parts including the first part and the second part, the second group of parts including the first part and the second part, the first part of the second group corresponding in shape to the first part of the first group, the second part of the second group corresponding in shape to the second part of the first group;
• the first group cut along a common external cutting line that partly defines a first boundary of the first group and that partly defines a second boundary of the second group, the first boundary having a first curvature, and the second boundary having a second curvature that is inverse to the first curvature;
• the first group being inverted relative to the second group.