Method of manufacturing spray-on footwear

1. A method of constructing footwear comprising:

spraying a spray-on fabric onto a plurality of exterior footwear surfaces of a three dimensional last, the spray-on fabric comprising a plurality of fibers that are combined with a polymer and a solvent, the solvent adapted to enable the spray-on fabric to be dispensed from the source in at least one of a liquid form and a semi-liquid form;

allowing the spray-on fabric to cure on the three dimensional last to form a flexible non-woven first fabric upper, the first fabric upper having a thickness extending from a first upper exterior to a first upper interior, the first upper interior being adjacent the three dimensional last; the first fabric upper having an upper bottom;

removing the first fabric upper from the three dimensional last;

joining a sole to the upper bottom.

2. The method of claim 1 , comprising:

turning the first fabric upper inside out so that the first upper exterior becomes a second upper interior, and the first upper interior becomes a second upper exterior, the second upper exterior having the upper bottom.

3. The method of claim 1 , comprising:

measuring the thickness of the first fabric upper after the spray-on fabric is sprayed on the three dimensional last.

4. The method of claim 1 , comprising:

measuring the thickness of the first fabric upper as the spray-on fabric is sprayed on the three dimensional last.

5. The method of claim 1 , comprising:

spraying additional spray-on fabric onto the three dimensional last in preselected regions of the three dimensional last so that the thickness varies from a first region to a second region.

6. The method of claim 1 ,

wherein the plurality of exterior footwear surfaces include a first plurality of recesses and a first plurality of projections;

wherein during the spraying step, the spray-on fabric extends into the first plurality of recesses and over the first plurality of projections,

wherein after a turning step of turning the first fabric upper inside out, the second upper exterior includes a second plurality of projections that correspond to the first plurality of recesses, and a second plurality of projections that correspond to the first plurality of recesses.

7. The method of claim 1 , comprising:

placing the sole adjacent the upper bottom; and

adhering the sole to the upper bottom so the adhesive engages the plurality of fibers on the upper bottom of the first fabric upper.

8. The method of claim 1 comprising:

spraying a polymeric layer onto at least one of the plurality of exterior footwear surfaces and the first fabric upper to produce a structural component of the first fabric upper with an automated machine.

9. The method of claim 1 comprising:

placing a strip of polymeric material on the exterior of the three dimensional last; and

spraying the first spray-on fabric over the polymeric material to produce a structural component of the first fabric upper.

10. A method of constructing footwear comprising:

spraying a first spray-on fabric onto a plurality of exterior footwear surfaces of a three dimensional last;

applying a material to at least one of the spray-on fabric and the exterior footwear surfaces of the three dimensional last;

allowing the first spray-on fabric to cure on the three dimensional last to form a flexible non-woven first fabric upper, the first fabric upper having a thickness extending from a first upper exterior to a first upper interior, the first upper interior being adjacent the three dimensional last;

removing the first fabric upper and the material from the three dimensional last; and

joining a sole to the first fabric upper.

11. The method of claim 10 comprising:

turning the first fabric upper inside out so that the first upper exterior becomes a second upper interior, and the first upper interior becomes a second upper exterior;

wherein during the joining step, the first fabric upper is turned inside out.

12. The method of claim 10 :

wherein the material is a polymeric material applied over a preselected region of at least one of the three dimensional last and the spray-on fabric sprayed on at least one of the plurality of exterior surfaces, the material adding rigidity to the first fabric upper.

13. The method of claim 10 ,

wherein the material is a strip of plastic that becomes joined with the spray-on fabric, the strip of plastic adding rigidity to the first fabric upper.

14. The method of claim 10 ,

applying a coating layer to preselected regions of the second upper exterior after the turning step;

wherein the coating layer comprises a polymer that adds structural rigidity to the first fabric upper in a preselected region.

15. The method of claim 10 comprising:

applying a coating layer to a preselected region of the first upper exterior,

wherein the coating layer comprises a second spray-on fabric having at a different property than the first spray-on fabric.

16. The method of claim 10 comprising:

wherein the material is a woven material applied over a preselected region of at least one of the three dimensional last and the spray-on fabric sprayed on at least one of the plurality of exterior surfaces, the material adding rigidity to the first fabric upper.

17. The method of claim 10 , comprising:

measuring the first spray-on fabric as it is applied to achieve the thickness of the first fabric upper.

18. The method of claim 17 ,

wherein the spray-on fabric comprises a plurality of fibers, a polymer and a solvent,

wherein the solvent is adapted to enable the spray-on fabric to be dispensed from a nozzle in at least one of a liquid form and a semi-liquid form.

19. The method of claim 18 comprising:

allowing the solvent to evaporate before the removing step.

20. A method of constructing footwear comprising:

applying a spray-on fabric including a plurality of fibers on a three dimensional last in the form of a human foot;

allowing the spray-on fabric to cure to form a flexible non-woven fabric upper;

removing the fabric upper from the three dimensional last;

turning the fabric upper inside out; and

joining a sole to the fabric upper while the fabric upper is turned inside out.