System and method of forming a toe seam

1. A method of forming hosiery comprising:

knitting a foot portion;

knitting a first circumferential toe portion adjoined to the foot portion and having a first stitch length knitted with first and second yarns in a plaited relationship to create a first bulk along the first stitch length;

knitting a second circumferential toe portion adjacent the first circumferential toe portion, the second circumferential toe portion having at least two knitted courses, each of the at least two knitted courses having a second stitch length that is less than the first stitch length and a second bulk that is less than the first bulk;

knitting a toe clip adjacent the second circumferential toe portion to complete a hosiery blank, the toe clip and at least a portion of the second circumferential toe portion being removable;

removing the toe clip and at least a portion of the second circumferential toe portion;

stitching the first circumferential toe portion to form a toe seam.

2. The method of claim 1 further comprising knitting the second circumferential toe portion with at least three courses.

3. The method of claim 1 wherein the

second circumferential toe portion is knitted with a third yarn.

4. The method of claim 1 wherein the third yarn is a non-elastomeric yarn.

5. An article of hosiery, comprising:

a foot portion comprising a plurality of knitted courses each having a first stitch length and a first bulk along the first stitch length;

a circumferential toe portion adjoined to the foot portion and having a second stitch length greater than the first stitch length and knitted with first and second yarns in a plaited relationship to create a second bulk that is greater than the first bulk;

at least one thread stitched in the circumferential toe portion forming a toe seam.

6. A knitted blank for forming an article of hosiery, comprising:

a foot portion;

a first circumferential toe portion adjoined to the foot portion and having a first stitch length knitted with first and second yarns in a plaited relationship to create a first bulk along the first stitch length;

a second circumferential toe portion adjacent the first circumferential toe portion, the second circumferential toe portion having at least two knitted courses, each of the at least two knitted courses having a second stitch length that is less than the first stitch length and a second bulk that is less than the first bulk; and

a toe clip adjacent the second circumferential toe portion, the toe clip and at least a portion of the second circumferential toe portion being removable in preparation for forming a toe seam.

7. The knitted blank of claim 6 wherein the second circumferential toe portion has at least three knitted courses.

8. A method of forming a knitted blank for an article of hosiery, comprising:

knitting a foot portion;

knitting a first circumferential toe portion adjoined to the foot portion and having a first stitch length knitted with first and second yarns in a plaited relationship to create a first bulk along the first stitch length;

knitting a second circumferential toe portion adjacent the first circumferential toe portion, the second circumferential toe portion having at least two knitted courses, each of the at least two knitted courses having a second stitch length that is less than the first stitch length and a second bulk that is less than the first bulk; and

knitting a toe clip adjacent the second circumferential toe portion to complete a hosiery blank, the toe clip and at least a portion of the second circumferential toe portion being removable in preparation for forming a toe seam.

9. The method of claim 8 further comprising knitting the second circumferential toe portion with at least three knitted courses.

10. The method of claim 8 wherein the second knitting step further comprises knitting the second circumferential toe portion with a third yarn.

11. The method of claim 8 wherein the third yarn is a non-elastomeric yarn.