Method and apparatus for vacuum molding multi-layer footwear

An apparatus for forming remoldable multi-layer footwear, said apparatus comprising:

• a boot having a plurality of layers of material, said plurality of layers include natural and synthetic thermoplastic material of various segments, patterns and shapes located in different areas of said boot for varying flexibility at different areas of said boot, said plurality of layers being secured to each other by polymeric glue, said polymeric glue being capable of maintaining its adhesive effectiveness over repeated heating and cooling, said polymeric glue having a melting point higher than a softening temperature of synthetic components of said plurality of layers,
• heat means for heating said boot to a temperature greater than said softening temperature of said synthetic components of said plurality of layers and less than said melting point of said polymeric glue so as to soften said boot, and
• pressure means for surrounding said boot and sealing an enclosed area around said boot when said boot is located on a foot of a wearer and for pressurizing said enclosed area so as to compress said boot against the foot of the wearer by pressure differential and mold said boot to the configuration of the foot of the wearer.

A method for molding multi-layer footwear to the foot of a wearer, said method comprising:

• heating a boot to a temperature above a softening temperature of synthetic components of a plurality of layers of material which form said boot, said plurality of layers being secured to each other by a polymeric glue having a melting point above said softening temperature of said synthetic components of said plurality of layers, said heating being to a temperature less than said melting point of said polymeric glue,
• enclosing an area including said boot on a foot of a wearer, and
• pressurizing said area so that pressure differential compresses said plurality of layers of said boot against the foot of the wearer to form a custom-fit boot while said polymeric glue maintains its adhesive effectiveness.