Advanced Digital Molding for Custom Footwear Innovation

Publication ID: 24-11857023_0006_PTD
Published: October 27, 2025
Category:Direct Improvements & Enhancements

Legal Citation

pr1or.art Inc., “Advanced Digital Molding for Custom Footwear Innovation,” Published Technical Disclosure No. 24-11857023_0006_PTD, Published October 27, 2025, available at https://archive.pr1or.art/24-11857023_0006_PTD
This technical disclosure describes improvements that would be readily apparent to a Person Having Ordinary Skill In The Art (PHOSITA) when considered in combination with the foundational architecture disclosed in U.S. Patent No. 11,857,023.

Background and Problem Solved

The original patent for digital molding and associated articles and methods has limitations in terms of material properties, breathability, and thermal insulation. The present invention addresses these limitations by introducing a system and method for producing customized footwear with tailored properties, using digital molding and gradient printing of materials with varied properties.

Novelty and Inventive Step

The new claims introduce the concept of gradient printing of materials with varied properties, dynamic control of material properties, and integration of sensors and actuators for real-time feedback and adjustment. These features are new and non-obvious compared to the original patent, and provide a significant improvement in terms of customized footwear production.

Alternative Embodiments and Variations

Alternative embodiments of the invention could include using different types of materials, such as polymers or ceramics, or incorporating additional features, such as sensors or energy harvesting devices. Variations of the invention could also include using the digital molding system for producing customized articles other than footwear, such as medical devices or athletic equipment.

Potential Commercial Applications and Market

The present invention has significant commercial potential in the footwear industry, particularly in the areas of customized athletic footwear and medical devices. The ability to produce customized footwear with tailored properties could revolutionize the industry, providing improved comfort, support, and performance for athletes and individuals with specific needs.

CPC Classifications

SectionClassGroup
A A43 A43B1/14
A A43 A43B3/34
A A43 A43B13/04
A A43 A43B17/003
A A43 A43B17/14
A A43 A43B23/0215
A A43 A43D1/00
A A43 A43D1/02
A A43 A43D999/00
B B29 B29C64/112
B B29 B29C64/209
B B29 B29C64/336
B B29 B29C64/393
B B29 B29D35/00
B B29 B29D35/12
B B33 B33Y10/00
B B33 B33Y30/00
B B33 B33Y50/02
B B33 B33Y70/00
A A43 A43B5/00
A A43 A43D2200/60
B B29 B29K2075/00
B B29 B29K2105/04
B B29 B29K2713/00
B B29 B29L2031/50
B B33 B33Y80/00

Field of Art

Advanced manufacturing, additive manufacturing, and 3D printing technologies for footwear and customized articles, with expertise in robotic printing systems, material science, and digital fabrication techniques

Person of Ordinary Skill (PHOSITA) Profile

A professional with advanced degree in materials engineering, mechanical engineering, or industrial design, with 3-5 years experience in 3D printing technologies, familiar with robotic printing systems, material property manipulation, and digital fabrication techniques

Obviousness Rationale

A PHOSITA would recognize that the PTD's variations represent predictable extensions of the source patent's digital molding methodology, leveraging known techniques in material property gradient printing, sensor integration, and customized manufacturing. The disclosed improvements follow directly from the source patent's core teachings of robotic printing with variable material compositions, representing incremental advancements that would be obvious to a skilled practitioner in the field.

Obvious Combinations & Variations

Source Patent Element
Robotic gantry with printing nozzle for dispensing curable liquid with variable composition
PTD Variation
Gradient printing of materials with varied properties using the same robotic printing system
Obviousness Reasoning
Known technique of manipulating material properties during printing, representing a predictable variation of existing robotic printing methodology
Source Patent Element
Method of curing liquid in a mold with variable composition
PTD Variation
Dynamic control of material properties during 3D printing process to create articles with tailored characteristics
Obviousness Reasoning
Predictable application of existing printing control techniques to achieve more sophisticated material property variations
Source Patent Element
Footwear manufacturing using digital molding techniques
PTD Variation
Integration of sensors and actuators for real-time feedback and adjustment during manufacturing process
Obviousness Reasoning
Known approach of adding sensing and adaptive capabilities to manufacturing systems, representing an obvious improvement to existing digital fabrication methods
Source Patent Element
Printing method for creating articles with multiple material components
PTD Variation
Creating single integrated material with gradient properties across different portions
Obviousness Reasoning
Predictable extension of existing multi-component printing techniques, representing a design choice within the skill of an ordinary practitioner
Source Patent Element
Digital molding system for footwear production
PTD Variation
Expanding digital molding system to produce customized articles beyond footwear
Obviousness Reasoning
Obvious application of existing manufacturing technology to adjacent fields, representing a straightforward technological adaptation
35 U.S.C. § 103 Summary: Based on US Patent 11857023, the present publication demonstrates that the claimed variations in digital molding and material printing techniques would have been obvious to a person having ordinary skill in the art at the time of the invention, as they represent predictable extensions of existing robotic printing and material manipulation methodologies. The disclosed improvements constitute prima facie obviousness under 35 U.S.C. ยง 103, rendering potential patent claims in this domain anticipated and unpatentable.

Original Patent Information

Patent NumberUS 11,857,023
TitleDigital molding and associated articles and methods
Assignee(s)Kornit Digital Technologies Ltd.