Claims
- 1. A method of manufacturing a custom shoe sole, said method comprising the following steps:
(a) forming a negative impression of a foot within a foam member; (b) vacuum forming a seal about said negative impression; (c) positioning a casting frame about said negative impression; (d) filling said casting frame with a casting material; (e) removing said casting frame after said casting material is hardened; (f) positioning a liner upon said positive impression; (g) securing a cover member about said casting frame; (h) inputting a polymer within said cover member and said casting frame; and (i) removing said custom shoe sole from casting frame after polymer has hardened.
- 2. The method of manufacturing of claim 1, wherein said step of positioning said casting frame includes penetrating a flange of said casting frame into said foam member.
- 3. The method of manufacturing of claim 1, wherein said casting material is comprised of a combination of wax and spherical members.
- 4. The method of manufacturing of claim 3, wherein said spherical members have an outer diameter of between 0.5 mm to 4.0 mm.
- 5. The method of manufacturing of claim 4, wherein said outer diameter is 4.5 mm.
- 6. The method of manufacturing of claim 3, wherein said spherical members are comprised of a metal.
- 7. The method of manufacturing of claim 3, wherein spherical members are comprised of copper.
- 8. The method of manufacturing of claim 1, wherein casting frame is comprised of a flat structure having a central opening with an inner flange extending traversely from and about said central opening.
- 9. The method of manufacturing of claim 8, wherein said casting frame includes an outer flange surrounding said inner flange.
- 10. The method of manufacturing of claim 1, wherein said liner is comprised of a piece of leather.
- 11. A method of manufacturing a custom shoe sole, said method comprising the following steps:
(a) forming a negative impression of a foot within a foam member; (b) vacuum forming a seal about said negative impression; (c) positioning a casting frame about said negative impression; (d) filling said casting frame with a casting material; (e) removing said casting frame after said casting material is hardened forming a positive impression; (f) applying a layer of adhesive to said positive impression; (g) positioning a liner upon said positive impression; (h) securing a cover member about said casting frame; (i) inputting a polymer within said cover member and said casting frame; and (j) removing said custom shoe sole from casting frame after polymer has hardened.
- 12. The method of manufacturing of claim 11, wherein said step of positioning said casting frame includes penetrating a flange of said casting frame into said foam member.
- 13. The method of manufacturing of claim 11, wherein said casting material is comprised of a combination of wax and spherical members.
- 14. The method of manufacturing of claim 13, wherein said spherical members have an outer diameter of between 4 mm to 6 mm.
- 15. The method of manufacturing of claim 14, wherein said outer diameter is 4.5 mm.
- 16. The method of manufacturing of claim 13, wherein said spherical members are comprised of a metal.
- 17. The method of manufacturing of claim 13, wherein spherical members are comprised of copper.
- 18. The method of manufacturing of claim 11, wherein casting frame is comprised of a flat structure having a central opening with an inner flange extending traversely from and about said central opening.
- 19. The method of manufacturing of claim 18, wherein said casting frame includes an outer flange surrounding said inner flange.
- 20. The method of manufacturing of claim 1, wherein said liner is comprised of a piece of leather.
CROSS-REFERENCE TO RELATED DISCLOSURE DOCUMENT
[0001] This application incorporates subject matter contained within Disclosure Document No. 491,681 received within the U.S. Patent and Trademark Office on Mar. 30, 2001. Disclosure Document No. 491,681 is incorporated by reference into this patent application.