Process for making a foamed shoe sole

A process for making a shoesole comprising:

• (a) forming an unexpanded outsole blank in a first mold from a first resinous molding composition, which contains an agent capable of foaming and cross-linking the resinous molding composition, at a temperature lower than that which can cause the composition to expand and cross-link;
• (b) trimming the unexpanded outsole blank to remove flash and inspecting the weight and size of the unexpanded outsole blanks;
• and
• (c) after step (b), placing in a second mold the unexpanded outsole blank having a predetermined weight and/or size;
• (d)injecting an expandable second molding composition for forming a midsole onto the unexpanded outsole blank placed in the second mold;
• and
• (e) heating the unexpanded outsole blank and the injected second molding composition under pressure to a temperature sufficient to cause the unexpanded outsole blank to undergo cross-linking, and opening the second mold for expansion of the heated outsole blank and the heated second molding composition, whereby the shoesole so produced has good cross-linking characteristics and retains exactly the shape and size of the mold cavity of the second mold.