Patent Publication Number: US-11659896-B2

Title: Systems and methods for automatic production of a cord structure

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     The present application is a divisional of U.S. Non-Provisional application Ser. No. 15/615,685, entitled “SYSTEMS AND METHODS FOR AUTOMATIC PRODUCTION OF A CORD STRUCTURE,” and filed on Jun. 6, 2017, which claims priority to U.S. Provisional Application No. 62/346,399, entitled “SYSTEMS AND METHODS FOR AUTOMATIC PRODUCTION OF A CORD STRUCTURE,” and filed on Jun. 6, 2016. 
     The entire contents of the above-listed applications are hereby incorporated by reference for all purposes. 
    
    
     BACKGROUND/SUMMARY 
     Footwear construction typically relies on the manipulation of flat materials into three-dimension shapes in order to form a footwear article. Cloth, leather, or other materials may be cut and sewn or otherwise attached and wrapped around a foot form to create a desired shape for the article, such as a footwear upper. Traditionally, the construction of footwear includes a multitude of steps such as sewing, boning, welding, pressing, knitting, weaving, and so on. 
     The inventors have recognized several drawbacks with this traditional approach. For example, the steps mentioned above are typically performed manually. While some machines, such as sewing machines, may be used to shorten the production process, footwear construction remains labor-intensive and expensive. 
     To at least partially address the above issues, the inventors herein have taken alternative approaches to footwear construction. In one example, a footwear article may include a looped upper with fibers or cords formed into a cord structure. The cord structure is automatically constructed by robotic arms. For example, a method for constructing the cord structure includes automatically forming, with at least one robotic arm, a first plurality of loops in a first plane, and automatically forming, with the at least one robotic arm, a second plurality of loops in a second plane orthogonal to the first plane, the second plurality of loops slippably engaged with the first plurality of loops. In this way, a footwear article or another cord structure may be quickly constructed, thereby reducing labor input and expenses. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG.  1    shows an example of a footwear article; 
         FIG.  2    shows an example intertwined pattern of cords in the footwear article shown in  FIG.  1   ; 
         FIG.  3    shows an example system for automatically producing a cord structure; 
         FIG.  4    shows an example apparatus for automatically producing a cord structure; 
         FIG.  5    shows an example loop fixture; 
         FIG.  6    shows an example end-of-arm tool for dispensing cord; 
         FIG.  7    shows a high-level flow chart illustrating an example method for automatically producing a footwear article with a cord structure; 
         FIG.  8    shows a high-level flow chart illustrating an example method for automatically producing a cord structure; 
         FIG.  9    illustrates an example routine for producing a cord structure; 
         FIG.  10    illustrates construction of a first set of loops in a corded structure; and 
         FIG.  11    illustrates construction of a second set of loops through the first set of loops in  FIG.  10   . 
         FIG.  1    is shown to scale. However, other relative dimensions may be used if desired. 
     
    
    
     DETAILED DESCRIPTION 
     Systems and methods for automatically constructing a cord structure are described herein. Such a cord structure may comprise a corded upper in a footwear article, such as the footwear article depicted in  FIG.  1   . A cord structure may include interconnected loops of different cords, as depicted in  FIG.  2   , which form a three-dimensional structure. A system for automatically constructing a cord structure in general or a footwear article in particular is depicted in  FIG.  3   . Such a system includes a cord structure-building apparatus, such as the apparatus depicted in  FIG.  4   , which includes at least one robotic arm, such as two or more robotic arms, that automatically weave a cord structure. The cord structure may be at least partially constructed by the robotic arms on a loop fixture, such as the loop fixture depicted in  FIG.  5   , which includes a plurality of guideposts around and through which loops may be built. Different sets of loops may be constructed from different colored cords, each of which may be threaded through different end-of-arm tools, such as the end of-arm tool depicted in  FIG.  6   . Such end-of-arm tools are attached to the end of at least one robotic arm, and allow the robotic arm to dispense cord in three-dimensional space to form the cord structure. The cord-building apparatus provides a simplified method for footwear construction, such as the method depicted in  FIG.  7   . In a method for automatically constructing a cord structure, such as the method depicted in  FIG.  8   , the cord-building apparatus may create a first set of loops in a first plane, and a second set of loops through the first set of loops in a second plane orthogonal to the first plane. Routines for dispensing cord to create loops are depicted in  FIGS.  9 - 11   . 
     The footwear article, an example of which is depicted in  FIG.  1   , may include interconnected bights in a cord structure providing a 3-dimensional form fitting construction. The cord structure increases the range of motion of an upper part of the footwear article while retaining flexibility and comfort. The cord structure may conform highly to the shape of a foot during use due to the relative movement provided by the bights. For example, by providing an array of bight interconnections across the upper from a lateral to medial side, and across a forefoot region, hundreds of adjustments, for example, can be automatically made by the cord structure so that the appropriate lengths of each cord section between the bights are achieved. As a result, the comfort provided by the footwear article is increased. 
     Further, the cord structure includes an anchor cord positioned away from and parallel to a sole of the footwear article. The remainder of the cord structure may be coupled to the anchor cord through an array of bight connections. In this way, the cord structure can be tensioned independent of other upper materials, thereby enabling a more precise fit and increased functionality of the cord structure. Furthermore, a method for constructing the footwear article is simplified as the cord structure is anchored to the upper rather than directly to the sole. 
     The example cord structures described herein also enable the manufacturing process of the footwear article to be simplified when compared to other types of shoe construction which use a foot form. 
       FIG.  1    shows an example footwear article  50 . The footwear article  50  may include a sole  52 . The sole  52  may be an insole/midsole, in one example. In some examples, the insole and midsole may be single component in the footwear article. However, in other examples, the sole may be a transition material, such as, but not limited to, a cloth-like material that is used during the described production methods to form a portion of the sole or outsole and/or to secure the footwear for formation of the sole or outsole. Further still, in other examples, the insole and midsole may be separate components in the footwear article. Moreover, in one example, the footwear article  50  may also include an outsole. However, in other examples the footwear article  50  may not include an outsole or the outsole may be integrated into the sole  52 . 
     The sole  52  is attached to a cord structure  66 . The cord structure  66  is included in an upper  67 . The cord structure may be formed from numerous cord sections interlocking with one another. The cord may include string, twine, yarn, rope, cable, strands of braided or twisted materials, and/or other cord-like structures including combinations of the previously listed examples twisted together or otherwise combined. In one example, the cord includes nylon cord of approximately a ⅛″ diameter, with an outer sheath and inner twine. Of course, other sizing may also be used. In another example, the cord may be double braided nylon, with an inner braid filling a central void and an outer braid that may be of the same or different material. The cord may be flexible yet retain some of its shape in a free state. Further, the cord may have some elastomeric components. Further, different cord sections (e.g., the vamp as compared to the rand) may have different degrees of flexibility, elasticity, etc. In one example, different materials may be used in different sections of the cord structure  66 . For instance, a more flexible type of cord may be used in an upper portion of the cord structure  66  and a less flexible type of cord may be used in a lower portion of the cord structure. Additionally, the portions of the cord structure coupled to the sole may be totally covered via the sole, in one example. In another example, the portions of the cord structure coupled to sole the may only be partially covered. For instance, portions of the cord structure proximate to the toes may be covered while portions of the cord structure, proximate to a heel, may be uncovered or vice-versa. Covering portions of the cord structure reduces the likelihood of premature wear of the cord caused by abrasions from rocks, dirt, and/or other particulates from the external environment. As a result, the footwear article&#39;s longevity is increased. 
     In one example, one or more cords in the cord structure  66  may extend through openings in the sole  52  to facilitate coupling of the sole to the cord structure. Additionally alternatively, a portion of the cord structure may be stitched, adhesively bonded (e.g., glued), and/or snapped into the sole to enable the coupling of the sole and the cord structure. In another example, a plurality of anchor points attached to the cord structure may be fixedly attached (e.g., injection molded into) to the sole. The anchor points may be individual cord loops. 
     In one example, the cord structure  66  may be a looped upper. In such an example, the looped upper may be formed in a grid-like pattern, but substantially free of knots at a plurality of the slippable interfaces positioned away from the sole  52 . 
     The cord structure  66  may be an upper of the footwear article  50 . The cord structure  66  may at least partially enclose a foot. The cord structure  66  includes a rand substructure  68 . The rand substructure is coupled to the sole  52 . Specifically in one example, sole attachment bights in the rand substructure  68  may be coupled to and/or extend through attachment openings in the sole. In one example, the attachment bights may be formed via a single cord in the rand substructure  68 . Thus, a single cord may have multiple bights. A bight is a curved portion or section of a greater cord in the cord structure  66 . Thus, a bight may be a portion of a loop in a cord. 
     The rand substructure  68  further includes vamp attachment bights  74 . The vamp attachment bights  74  are coupled (e.g., interconnected, interlocked, stitched, intertwined, and/or slidingly engaged) to rand attachment bights  76  included in a vamp substructure  78  in the cord structure  66 . The interconnection between the vamp attachment bights  74  and the rand attachment bights forms a loop line  69 . The loop line  69  may be an interface between the rand substructure  68  and the vamp substructure  78 . The loop line  69  extends in a direction from a heel side  60  of the footwear article  60  to a toe side  58  of the footwear article. The loop line  69  also extends from a tibular side  62  of the footwear article  50  to a fibular side  64  of the footwear article. The loop line  69  may peripherally extend around the footwear article, and in one example may traverse around the entire upper. Further it will be appreciated that the loop line  69  may extend in an arc around at least a portion of the footwear article  50 . Other loop line configurations have been contemplated. For instance, the loop line may extend across the footwear article from a first later side to a second lateral side. Further in another example, the loop line may extend around the footwear article in an arc, from a first side of a heel counter to a second side of a heel counter. Still further in another example, the loop line may laterally extend across the footwear article as well as extend in an arc around a front of the footwear article (e.g., toe side). Even further in another example, the loop line may only extend around a portion of the footwear article, such as a portion adjacent to a toe side or a heel side of the footwear article. Further still in one example, the footwear article may include a plurality of loop lines. 
     The vamp substructure  78  is spaced away (e.g., vertically spaced away) from the sole  52 , in the depicted example. Additionally, the rand substructure  68  may be positioned vertically above the sole  52  and the vamp substructure  78  may be positioned vertically above the rand substructure. A vertical axis is provided for reference. However, it will be appreciated that other footwear article orientations may be used if desired. It will be appreciated that the vamp substructure  78  may be spaced away from the sole  52  when the footwear article is not being worn. The cord structure  66  may retain it shape due to the interconnection between the vamp substructure  78  and the rand substructure  68 , along with the internal structure of the cord. Example interconnections are discussed in further detail herein. 
       FIG.  2    shows a more detailed view of the at least partially sliding interconnection between the vamp attachment bights  74  and the rand attachment bights  76 . It will be appreciated that the vamp attachment bights  74  are shown interlocked with rand attachment bights, as depicted in  FIG.  2   . In this way, the vamp substructure may be coupled to the rand substructure without the use of adhesive, if desired. However, it will be appreciated that in some examples adhesives may be used to couple certain elements in the footwear article. In one example, the sliding connection between the bights may be free of knots. However in another example, at least a portion of the vamp attachment bights  74  may be fixedly coupled to at least a portion of the rand attachment bights  76 . In another example, stitched locks may be used to provide the partially sliding interconnection. For instance, loose or tight stitched interfaces may be provided at the junctions of the cords in the upper. By controlling the amount of slippable engagement in various sections of the footwear article desired fitting characteristics may be achieved to increase the wearer&#39;s comfort. The systems and methods further described herein with regard to  FIGS.  3 - 15    may be directed to forming a cord structure including the vamp and rand substructures depicted in  FIG.  2   . 
     It should be appreciated that the cord structure depicted in  FIGS.  1  and  2    includes a first loop of the first plurality of loops (e.g., the rand substructure) is intertwined with and slidably movable relative to at least two loops of the second plurality of loops (e.g., the vamp substructure), and a second loop of the at least two loops is intertwined with and slidably movable relative to at least two loops of the first plurality of loops including the first loop. Such a loop configuration enables the slippably engaged and durable cord structure depicted in  FIGS.  1  and  2   . 
     Returning to  FIG.  1   , the vamp substructure  78  further includes lace attachment bights  80 . The lace attachment bights  80  are shown coupled to a lace cord  82  in  FIG.  1   . Specifically, the lace cord  82  extends through the lace attachment bights  80 . The length of the lace cord  82  may be adjusted by the wearer. However, alternate lace cord configurations have been considered. For instance, the footwear article may be constructed without a lace cord. In this way, a wearer can quickly and easily slip on and off the footwear article without the need to tie a lace cord. In such an example, elastic material may be provided in the footwear article to enable controlled expansion and contraction of portions of the cord structure. Additionally, different lacing patterns have been considered. For instance, the cord structure may include eyestays. Cords in the cord structure may extend through the eyestays. 
     The lace cord  82  may be included in the cord structure  66 , in some examples. However, in other examples the lace cord  82  may not be included in the cord structure  66 . In such an example, elastic or other suitable material may be used to provide the footwear article with a slip-on capability. 
     Numerous relative vamp cord, rand cord, and/or lace cord lengths have been contemplated. Portions of the rand cord  84  and the vamp cord  86  are also shown in  FIG.  2   . The sole attachment bights  70  are also shown in  FIG.  2   . As illustrated, the sole cord  73  (also referred to herein as the anchor cord) is intertwined with the sole attachment bights  70 . 
     It should be appreciated, that the construction method described herein enables, in some embodiments, options for customizing sizing and for adjusting sizing with minimal tooling expenditures. For example, the construction of the upper based on a cord length enables variation in size without changing the upper pattern or obtaining different size cutting dies. As such, in some embodiments, the size of the upper can be altered by varying the cord length. The loops may remain in their relative position for each size. Such construction reduces costs by utilizing same size tooling. 
     Likewise, customization of the footwear may be applied to improve fit for a specific user. With generation of an electronic scan of a foot, a customized and personalized cord may be used to generate customized footwear based on the foot scan. For example, the lengthening (or shortening) of the loops, the positioning and sizing of the loop line, and the adjustment of cord size may be adjusted alone or in combination to tailor the upper to the specific dimensions of the scanned foot to provide a customized fit. 
     Turning back to  FIG.  1   , the rand cord  84  and the vamp cord  86  are depicted as being round cords in  FIG.  1   . However, other shapes have been contemplated. For instance, one or more of the cords may be flat cords or one or more of the cords may have flat ends and round midsections. In another example, one or more of the cords may have one or more flat sections and one or more round sections. For instance, a cord may include a round section followed by a flat section and so on and so forth. Additionally, the sole cord  73  may be flat, round, or have different sections with varying geometries. Additionally, the rand cord  84 , the vamp cord  86 , and the lace cord  82  are all depicted as having a similar cross-sectional area (e.g., diameter) and/or geometry. In one example, the diameter of one or more of the cords may be between ⅛ th  of an inch and 1/16 th  of an inch. However, in other examples the cords may have varying widths. It will be appreciated that the sole cord  73  may have a similar geometry to the rand cord, vamp cord, and/or lace cord, in one example. However, in other examples, the cross-sectional area and/or geometry of the rand cord  84 , the vamp cord  86 , sole cord  73 , and/or lace cord  82  may vary. For example, the cross-sectional area of the rand cord may be larger than the vamp cord. In another example, the rand cord may be circular and the vamp cord may be flat. 
     Further in some examples, the rand cord  84 , vamp cord  86 , and/or lace cord  82  may comprise similar material(s). However, in other examples the aforementioned cords may comprise different materials. One or more of the cords may comprise synthetic fibers such as Polypropylene, Nylon, Polyester, Polyethylene, Aramid, and/or Acrylate polymer. Additionally, one or more of the cords may comprise natural fibers such as cotton, linen, coir, etc. Further in one example, one or more of the cords may comprise a polymeric material. 
     Additionally, the rand cord  84 , vamp cord  86 , and/or lace cord  82  may be designed with different material properties to enable the footwear article have desired structural characteristics. For example, the lace cord  82  may have a greater elasticity than the rand cord  84  and/or the vamp cord  86 . 
     As shown in  FIG.  1   , the vertical height of the vamp attachment bights increases in a reward direction extending toward the heel side  60  of the footwear article  50 . The width of the interlocked vamp cord sections extending from the lace cord to the rand cord may also increase in the reward direction extending toward the heel side  60  of the footwear article  50 . 
     The footwear article  50  also includes a heel counter  97 . The heel counter or other support structures in the footwear article may be included in the upper discussed above. It will be appreciated that the rigidity/flexibility of the heel counter  97  may be selected to provide a desired amount of support to the cord structure  66 . Specifically, the heel counter  97  may prevent the cord structure from flexing outward and/or downward in a direction toward the sole by an undesirable amount. In this way, the cord structure may maintain a desired shape. As a result, a wearer of the footwear article may quickly and comfortably put on and take off the footwear article. The heel counter  97  may comprise a different material than the cord structure  66 , such as leather, synthetic leather, fabric, etc. However, in some examples the heat support structure may also comprise cord. The loop line  69  may extend through the heel counter  97  in some examples. Additionally, the heel counter  97  may be coupled to the sole  52 . Specifically, in some examples the heel counter structure may extend (e.g., vertically or angularly) from the sole  52 . The heel counter  97  is coupled to the rand substructure  68 , in the depicted example. A connection cord  98  is shown extending through bights in the rand substructure  68  and through an opening  99  in the heel counter  97 . In this way, the heel counter  97  provides support to the cord structure as well as shields a portion of the cord structure from the external environment. 
     Additionally or alternatively, the heel counter  97  may be coupled to the vamp substructure  78 , thereby providing support to the substructure. The heel counter may have a greater rigidity than the cord structure  66 . In one example, the connection cord  98  may be a portion of the vamp cord  86  or the rand cord  84 . Additionally, a portion of the cord structure extends around the width of the heel counter  97 . However, other heel counter configurations have been contemplated. In one example, ends of cords in the cord structure may be coupled to the heel counter and/or coupled to one another within the heel counter. In one example, the heel counter  97  may have greater stiffness in a longitudinal direction than a lateral direction. The vertical stiffening of the support may provide a desired amount of support to the cord structure. However, other heel counter  97  material characteristics have been contemplated. 
     The footwear article  50  shown in  FIG.  1    may further include an eyestay (not shown). Cords in the cord structure  66  may extend through the eyestay. It will be appreciated that more than one cord section extends though the eyestay, in the depicted example. However in other examples, alternate eyestay designs have been contemplated. The eyestay may provide desired cord spacing and cord support to the cord structure. In this way, the eyestay may limit the free movement of the cords extending therethrough. The eyestay may be included in an upper structure. In one example, the upper structure may be adjacent to a tongue of the footwear article. The upper structure may comprise a different material than the cord structure, in one example. Example eyestay materials include cloth, leather, synthetic leather, fabric, polymeric material, etc. In other examples, the footwear article may include a plurality of eyestays. 
     Additionally, one or more sheaths may enclose (e.g., circumferentially enclose) a portion of at least one of the rand cord  84  and vamp cord  86 , in some examples. Therefore, the sheaths may surround various sections of the cords in the cord structure. For instance, a plurality of sheaths may surround a portion of the rand cord  84  from vamp attachment bights  74  to the rand attachment bights  76 . Thus, the sheaths may act as protective covers for the cords. In some examples, the sheath may be in face sharing contact with an outer surface of the cord. However, in other examples, the sheath may be spaced away from an outer surface of the cord. The sheaths may be cylindrical, in one example. However, other sheath geometries have been contemplated. Additionally, a plurality of sheaths may be used to form a toe cap around the toe side of the footwear article. The sheaths may provide increased structural integrity to desired areas of the cord structure  66 , to enable the cord structure  66  to retain a desired shape. The sheaths may comprise a different material than the vamp cord and/or the rand cord. In one example, the sheaths may comprise a polymeric material. The sheaths may also protect the cords from damage. 
     The footwear article may be manufactured using a double lasted strobel and string construction, which allows the various upper parts—the cord structure and the upper structures—to act independent of each other. These upper parts are integrated together by the laces at the lace attachment bights. 
       FIG.  3    shows a block diagram illustrating an example automated system  300  for automatically producing a cord structure for a footwear article, such as the footwear article described herein above with regard to  FIGS.  1 - 2   , or other articles including a cord structure. Automated system  300  includes a cord-building apparatus  301  configured to automatically construct a cord structure. Cord-building apparatus  301  includes a first robotic arm  305  equipped with a first end-of-arm tool  306 , a second robotic arm  307  equipped with a second end-of-arm tool  308 , a controller  310 , and a loop fixture  315 . Although described as a first and second robotic arm, it should be appreciated that there may be a single robot, or two, three or more robots/robotic arms. The example is provided for illustration purpose and not as a limitation. 
     The robotic arms  305  and  307  may comprise, as non-limiting examples, programmable articulated mechanical arms which may be rotationally and translationally displaced. Robotic arms  305  and  307  may include one or more joints that enable the robotic arm to perform tasks. In some examples, the robotic arms are articulated robots and thus include two or more joints. 
     The components of the cord-building apparatus  301 , such as the robotic arms  305  and  307 , may be housed within a housing  302 . The housing  302  may be partially constructed of glass or another transparent material to allow observation of the robotic arms  305  and  307 . As a non-limiting example,  FIG.  4    shows a pictorial view of an example apparatus  400 . Apparatus  400  includes a first robotic arm  405  and a second robotic arm  407  housed within housing  410 . As depicted, housing  410  is partially transparent to enable observation of the construction of a cord structure, and further includes doors to allow access to the components of apparatus  400  within the housing  410 . 
     The first end-of-arm tool  306  of the first robotic arm  305  may comprise a needle threaded with a cord  321  or other fiber, and may be configured to dispense the cord  321  through the needle. The first end-of-arm tool  306  may comprise a device configured to dispense or push the cord through the end of the needle as the first end-of-arm tool  306  is moved by the first robotic arm  305  along a predetermined path, as discussed further herein. An example first end-of-arm tool  306  is described further herein with regard to  FIG.  6   . The second end-of-arm tool  308  of the second robotic arm  307  may comprise a solenoid or another appropriate device which when actuated may grab, hold, pinch, or otherwise engage a portion of the cord  321 . The two robotic arms  305  and  307  may thus assist each other in constructing a cord structure, as described further herein. 
     Although described in accordance with an exemplary embodiment, in a second embodiment, both robotic arms may actively thread at the same time. The active threading of both robotic arms may function such that both robotic arms thread and hold the cord. As such, although described in some examples with a single robotic arm actively threading, it should be understood that there may be two (or more) actively threading arms. 
     The cord-building apparatus  301  may further include a controller  310  communicatively coupled to the robotic arms  305  and  307  and configured with executable instructions  313  in non-transitory memory  312  that when executed cause the controller to perform various actions. To that end, the controller  310  comprises a processor  311  as well as a non-transitory memory  312 . An example method for controller  310  is described further herein with regard to  FIG.  9   . Further, the controller  310  may include a user interface (e.g., user interface  418  shown in  FIG.  4   ) to receive inputs (via, as non-limiting examples, a keyboard, touch screen, mouse, joystick, and so on) and display outputs (via, as a nonlimiting example, a display or a touch screen device). 
     It should be appreciated that while controller  310  is depicted as a single entity, in some embodiments, the controller  310  may comprise a plurality of controllers. As an illustrative and non-limiting example, the controller  310  may include a controller for each robotic arm, and a central controller for coordinating the separate robotic arm controllers. 
     Cord-building apparatus  301  may include a loop fixture  315  which provides a template or guideposts upon or through which the robotic arms  305  and  307  may construct a cord structure. In embodiments directed towards the construction of a footwear article such as the footwear article described herein above with regard to  FIGS.  1 - 2   , the loop fixture  315  may be configured to receive a sole and/or an eyestay to or through which the cord structure may be looped. Further, loop fixture  315  may comprise a left loop fixture and a right loop fixture (i.e., a loop fixture for constructing left-foot footwear articles and a loop fixture for constructing right-foot footwear articles, respectively). In some examples, loop fixture  315  may be adaptable or configured for a plurality of footwear article sizes. However, in other examples, separate loop fixtures for different sizes may be included. 
       FIG.  5    shows an example loop fixture  500 . In some examples, the loop fixture is pre-assembled with an eyestay (not shown) and a sole (not shown). The sole may be inserted into a gap  508  within the loop fixture  500 , while the eyestay may be placed upon the top  503  of the loop fixture  500 . As depicted, the loop fixture  500  includes a plurality of guideposts  510  around and through which the robotic arms may create loops of a cord structure. Further, the loop fixture  500  includes a mounting structure  515  that allows the loop fixture  500  to be securely fixed within the cord-building apparatus  300 . 
     In some examples, the apparatus may include a left loop fixture and a right loop fixture, corresponding to left and right footwear articles. The loop fixture is used to weave the cord to the correct length. The loop fixture also holds the entire footwear article together during construction. 
     Referring again to  FIG.  3   , the loop fixture  315  may be positioned between the first robotic arm  305  and the second robotic arm  307  within the apparatus  301 . Such a configuration is illustrated in  FIG.  4   , wherein loop fixture  415  is mounted on a surface upon which the robotic arms  405  and  407  are also mounted. It should be appreciated that the relative positions of the robotic arms  405  and  407  to the loop fixture  315  are not limited to the exemplary embodiments illustrated and described herein. 
     Cord-building apparatus  301  may further include an end-of-arm tool rack  318  which stores a plurality of end-of-arm tools for the first robotic arm. For example, end-of arm tool rack  318  may include a plurality of end-of-arm tools, each end-of-arm tool threaded with a different color and/or sized cord. The first robotic arm  305  may automatically select an end-of-arm tool  306  from the end-of-arm tool rack  318  based on a color and/or size request, as described further herein. The end-of-arm tool rack  318  may be positioned, as an example, within the housing  410  of the cord-building apparatus  400  so that the end-of-arm tools stored on the end-of-arm tool rack  318  are accessible to the first robotic arm  405 , which may select a selected end-of-arm tool from the end-of-arm tool rack  318  based on a selected color and/or loop size. 
       FIG.  6    shows an example end-of-arm tool  600 . An end-of-arm tool rack may hold a plurality of end-of-arm tools, including top end-of-arm tools and bottom end-of-arm tools. If the footwear article is to be constructed with a different color top and bottom loop (e.g., first and second pluralities of loops), the robotic arm will automatically select the correct end-of-arm tool from the end-of-arm tool rack and assemble the footwear article. 
     The end-of-arm tool  600  may comprise a device  602  configured to dispense a cord. To that end, the end-of-arm tool  600  may further comprise a needle  604  fixedly coupled to the device  602  and configured to precisely dispense the cord at a selected position. The cord (not shown) may be threaded into the device  602  and through the needle  604 . The cord may be spooled, for example, away from the device  602 , which pulls and/or pushes the cord away from the cord spool or box (not shown) and into the needle  604 . The cord may be selectively and automatically dispensed through the end of the needle  604 . In some examples, the device  602  may include a cord cutting device (not shown) therein which is configured to cut and therefore released the dispensed cord from the end-of-arm tool  600 . 
     Referring again to  FIG.  3   , the different cords  321  mentioned above may be stored in separate cord boxes  320 . In some examples, the cord box  320  may be external to the cord-building apparatus  301 . However, in other examples, the cord box  320  may be positioned within the cord-building apparatus  301 . 
     In some examples, an apparatus for automatically producing a cord structure may include a plurality of cord boxes. The apparatus may include the cord-building apparatus  400 , comprising a first robotic arm  405  and second robotic arm  407  housed within a housing  410 , a loop fixture  415 , and an end-of-arm tool rack  420 . The apparatus may further include a box rack storing a plurality of cord boxes. Each cord box may house cord of a particular color. In some examples, the cord in each of the boxes may be threaded to a corresponding end-of-arm tool in the end-of-arm tool rack. In other examples, an operator of the apparatus may manually obtain cord  321  from a cord box  320  and thread an end-of-arm tool in the end-of-arm tool rack  318 . While the cord boxes  320  may be positioned external to the housing  410  of the cord-building apparatus, in some examples one or more of the cord boxes  320  are also housed within the housing  410 . 
     Referring again to  FIG.  3   , the system  300  may further include a computer  330  communicatively coupled to the cord-building apparatus  301 . In some embodiments, the computer  330  may be communicatively coupled to an optional camera  332  configured to capture video of the cord structure construction process carried out by the cord-building apparatus  301 . The computer  330  may be optionally configured to transmit the video captured by the camera  332  to a client computer  345  via a network  340 , such as the public Internet. 
     Further, the computer  330  may be configured to receive a custom order from the client computer  345  via the network  340 , and may communicate the custom order to the cord-building apparatus  301 . The custom order may include one or more desired colors, a desired size, and a desired product. Upon receiving the custom order, the cord-building apparatus  301  may automatically construct the ordered product in accordance with the one or more desired colors, desired size, and desired product. In embodiments including the optional camera  332 , the camera  332  may capture video of the entire process, which may be streamed back to the client computer  345 . In this way, the customer may watch, via a display device of the client computer  345 , the video stream of the custom order being prepared. Since the construction process of the footwear article as carried out by the cordbuilding apparatus  301  is brief (e.g., in some examples, the process may be completed in approximately ten minutes or less) compared to conventional footwear article construction methods, the customer may view the construction and know that the order is being correctly fulfilled. 
       FIG.  7    shows a high-level flow chart illustrating an example method  700  for automatically producing a footwear article with a cord structure. Method  700  will be described with reference to the systems and components of  FIGS.  3 - 6   , though it should be appreciated that the method may be implemented with other systems and components without departing from the scope of the present disclosure. 
     Method  700  begins at  705 . At  705 , method  700  includes inputting a size and a color request to a cord-building apparatus, such as cord-building apparatus  301  or  400  described herein above. In some examples, an operator may use a user interface device (e.g., the user interface  418 ) to input one or more selected cord colors, and the operator may further select a desired size of the product. In other examples, the size and color request may be electronically transmitted to the cord-building apparatus, for example via a computer communicatively coupled to the cord-building apparatus. 
     At  710 , method  700  includes inserting a sole and an eyestay to the loop fixture. In some examples, an operator may pre-assemble the eyestay and the sole onto the loop fixture assembly, and then load the pre-assembled loop fixture assembly into the apparatus. In other examples, a robotic arm may automatically insert a sole and an eyestay to the loop fixture within the cord-building apparatus. 
     At  715 , method  700  includes commanding the apparatus to automatically construct the cord structure of the upper. In some embodiments, commanding the apparatus to construct the cord structure may comprise initiating a method implemented in the apparatus. An example of such a method is described further herein with regard to  FIG.  8   . Commanding the apparatus to initiate or execute such a method may comprise an operator pressing a “Start” button positioned at the apparatus, for example on touch screen interface. 
     The apparatus may then automatically weave a plurality of loops through the eyestay and the sole to create a cord structure comprising an upper. The cord structure coupled to the eyestay and the sole comprise a footwear article. The footwear article may comprise, for example, the footwear article of  FIG.  1   , while the cord structure comprising the upper may comprise the cord structure depicted in  FIGS.  1  and  2   . 
     After the cord-building apparatus completes the automatic construction of the cord structure, method  700  proceeds to  720 . At  720 , method  700  includes removing the constructed footwear article from the apparatus. For example, an operator may remove the loop fixture from the cord-building apparatus, and then remove the constructed footwear article (comprising the sole, eyestay, and cord structure) from the loop fixture. 
     At  725 , method  700  includes finishing the footwear article. Finishing the footwear article may include attaching an anchor cord to the cord structure, for example through the loops extending below the sole. Finishing the footwear article may further include trimming and securing the cord structure, adding different components (e.g., insole, heel counter, toe cap, lacing system, and so on) to the constructed footwear article, and any other step to finalize the footwear article for use. In some examples, the footwear article may be automatically finished by the cord-building apparatus prior to removing the footwear article from the apparatus. For example, at least one robotic arm may be commanded to automatically attach the anchor cord the cord structure. Method  700  then ends. Method  700  may be repeated to construct a left footwear article and a right footwear article. 
       FIG.  8    shows a high-level flow chart illustrating an example method  800  for automatically producing a cord structure. Method  800  relates to the control of a cordbuilding apparatus to construct a cord structure. Method  800  is described herein below with reference to the systems and components of  FIGS.  3 - 6   , though it should be understood that the method may be implemented with other systems and components without departing from the scope of the present disclosure. Method  800  may be carried out by a controller, such as controller  310 , and may be stored as executable instructions  313  in non-transitory memory  312 . 
     Method  800  begins at  805 . At  805 , method  800  includes receiving a color and a size request. The color request may include one or more colors for a cord structure. The size request may include a desired size of a cord structure. In embodiments wherein method  800  is directed to construction of a cord structure for a footwear article, the size request may comprise the desired shoe size. The color and size request may be received via a user interface of the cord-building apparatus, or may be received via communication with an external computing device. 
     At  810 , method  800  includes automatically generating first and second paths for the first and second robotic arms based on the requested size. The first paths for the first and second robotic arms correspond to paths along which the first and second robotic arms operate to construct a first set of loops, while the second paths for the first and second robotic arms correspond to paths along which the first and second robotic arms operate to construct a second set of loops slippably engaged with the first set of loops. As an example, the paths may describe the desired position of each end-of-arm tool of the robotic arms, which may be positioned in three-dimensions within the cord-building apparatus. Therefore, each of the paths may be three-dimensional, and furthermore may include indications of where and/or when an end-of-arm tool may perform a specified function, such as actuating a solenoid. Thus, method  800  may also include generating setting instructions for the first and second robotic arms. Such setting instructions may also indicate to the first end-of-arm tool when to dispense cord, as the first end-of-arm tool may selectively rather than continuously dispense cord to form the loops. 
     At  815 , method  800  includes automatically selecting an end-of-arm tool with the requested color. As a non-limiting example, the first robotic arm automatically procures the end-of-arm tool from the end-of-arm tool rack through which a cord with the desired color is threaded. 
     At  820 , method  800  includes controlling the robotic arms to move along the first paths while dispensing cord to create loops in a first plane. Controlling the robotic arms to move along the first paths comprises commanding, via the controller, the first and the second arms to move along the first paths with the setting instructions generated at  810 . The first path of the first robotic arm describes the path along which the first end-of-arm tool automatically dispenses cord through the end-of-arm tool, while the first path of the second robotic arm describes the path along which the second end-of-arm tool is positioned in order to hold the cord in place as the first end-of-arm tool dispenses the cord. The second end-of-arm tool thus functions, in part, as a temporary guidepost in free space as each loop is created. The second end-of-arm tool may also automatically clamp the cord in selected places in order to temporarily maintain the structure of a loop while the first-end-of-arm tool is repositioned to create the next loop. 
     As an illustrative example,  FIG.  9    depicts an example path  901  for the first end-of-arm tool which dispenses a cord  903  in a plane. The first end-of-arm tool begins at a position  911 , and pulls a specified distance away from position  911  in a first direction  908  (e.g., the −x direction) towards a position  912  while dispensing the cord  903 . The first end-of-arm tool then moves back towards position  911  in a second direction  909  (e.g., the +x direction) and continues a second specified distance away from position  911  towards position  913 , all while dispensing the cord  903 . The first end-of-arm tool then pulls back to position  912  in the first direction  909  (e.g., the −x direction) while also moving a distance  916  from the previous position  912  in a direction orthogonal to the pull-back motion, e.g., the +y direction as depicted in  FIG.  9   . 
     While positions  911  and  912  may be positioned on a loop fixture, typically the position  913  occurs in free space. To that end, the second end-of-arm tool may move between positions  911  and  913  to assist the first end-of-arm tool in creating the loops. This process is repeated for each loop. 
     Furthermore, the position  913  is located further away from position  911  than the desired loop size. That is, the cord  903  does not necessarily lie along the exact path  901  of the first end-of-arm tool. As depicted, although the path  901  of the first end-of-arm tool dispenses cord at position  913 , the edge of the loop in cord  903  comes to rest at position  914 , located in the x direction between positions  911  and  913 . In other words, the first end of-arm tool dispenses cord a distance out in free space which is further than may be expected in order for the cord  903  to be positioned as depicted. That is, to create a loop which extends from position  912  to position  914 , the first end-of-arm tool is commanded to dispense cord along a distance from position  912  to position  913 , which is greater than the distance from position  912  to position  914 . 
     It should be appreciated that the particular distances traveled by the first end of-arm tool may be determined based on the requested size of a footwear article or cord structure, which in turn may determine the appropriate size of each loop. 
     To further illustrate the construction of the first set of loops with the robotic arms,  FIG.  10    illustrates an example construction  1000  of a first set of loops  1030  for a cord structure. The first set of loops  1030  are constructed in a first plane  1020 , depicted as the x-y plane in  FIG.  10    (with the z axis coming out of the page). The first end-of-arm tool  1005  is depicted as a triangle, while the second end-of-arm tool  1007  is depicted as a box. The first path  1010  depicted corresponds to the first path of the first robotic arm or the first end-of-arm tool  1005  which dispenses the cord  1009 . The first end-of-arm tool  1005  constructs the first set of loops on the loop fixture  1001 , and moves between the guideposts  1002  (depicted as small circles). 
     For the construction of a footwear article, an eyestay (not shown) may be positioned on the loop fixture  1001  such that the eyelets  1015  (depicted as ovals) align with the guideposts  1002  of the loop fixture  1001 . The first end-of-arm tool  1005  moves along the first path  1010  and dispenses cord  1009  to create the first loops, while the second end of-arm tool  1007  moves along another first path (not shown) to assist the first end-of-arm tool  1005 . As an example, the end-of-arm tool  1005  moves through the eyelet  1015  in a routine such as that depicted in  FIG.  9   , where the end-of-arm tool  1005  moves from a point B to a point C, through the eyelet  1015 , and pulls back to point B through the same eyelet  1015 . The length of the resulting loop is less than the distance that the first end-of-arm tool  1005  travels, as depicted and described above. 
     Further, as depicted, the construction of the loops is not limited to a single direction, but may wrap around in the first plane (e.g., the x-y plane). 
     Further still, it should be appreciated that in some examples, the cord may be dispensed by a first robotic arm through a hole in the sole material without being hooked by a second robotic arm. The sole material, which may comprise rubber and flashing as non-limiting examples, may be rigid and resistant to the cord, such that friction between the cord and the sole material captures the cord and holds it in place. In this way, the individual programming points of the first robotic arm may be reduced by approximately 500 points. 
     Referring again to  FIG.  8   , after the robotic arms create the first set of loops in the first plane, method  800  proceeds to  825 . At  825 , method  800  determines if the desired number of loops are complete. The desired number of loops may correspond to a selected size, and so method  800  may not continue until the desired number of loops in the first set of loops is complete. Thus, if the desired number of loops are not complete (“NO”), method  800  returns to  820 . If the desired number of loops are complete (“YES”), method  800  proceeds to  830 . 
     At  830 , method  800  determines if a different color is requested for a second set of loops. If a different color is requested (“YES”), method  800  proceeds to  835 . At  835 , method  800  includes selecting an end-of-arm tool with the second requested color. Method  800  then proceeds to  840 . If a different color is not requested (“NO”), method  800  proceeds directly to  840  and continues using the same end-of-arm tool selected at  815 . 
     At  840 , method  800  includes controlling the robotic arms to move along the second paths to create loops in a second plane orthogonal to the first plane through the first set of loops. While the first set of loops may be built using the guideposts of the loop fixture (and optionally, an eyestay including a plurality of eyelets through which the cord is dispensed, as described above), the second set of loops may be built using the first set of loops. As an illustrative example, the cord may be dispensed through each loop in the first set of loops similar to how the cord is dispensed through the eyelets with regard to the construction of the first set of loops. 
     As an illustrative example,  FIG.  11    illustrates an example construction  1100  of a second set of loops  1130  through an already-constructed set of loops  1030 , such as the first set of loops  1030  in  FIG.  10   . The second set of loops  1130  is constructed in a second plane  1120  (e.g., the x-z plane), which is orthogonal to the first plane  1020  (e.g., the x-y plane). The position of the first set of loops  1030  is depicted in perspective to illustrate how the cord  1109  is dispensed through the first set of loops  1030 . The first end-of-arm tool  1105  (which may comprise the first end-of-arm tool  1005  depicted in  FIG.  10   , or may be a different end-of-arm tool with a different color thread, for example) moves along the second path  1110  of the first robotic arm. The second end-of-arm tool  1107  (which may comprise the second end-of-arm tool  1007  depicted in  FIG.  10   ) moves along the second path (not shown) of the second robotic arm. Since the first set of loops  1030  extend beyond the loop fixture  1001  (as depicted in  FIG.  10   ), the construction of the second set of loops  1130  may rely less on the loop fixture  1001  for guidance. That is, the second set of loops  1130  may be constructed entirely in free space. However, in examples wherein method  800  is directed towards constructing a corded upper, a sole  1117  may be positioned in the loop fixture as described herein above. The sole  1117  may include a plurality of slots  1115  through which the second set of loops may be woven. In such an example, the first end-of arm tool  1105  may dispense the cord  1109  through a loop of the first set of loops and then through a slot  1115  of the sole  1117 , and then pull back through the same slot  1117  and through the same loop. The second end-of-arm tool  1107  may assist in holding the loop of the first set of loops or the newly constructed loop in place as the first end-of-arm tool dispenses the cord  1109 . 
     As mentioned above, in some examples the friction between the sole  1117  and the cord  1109  may hold the cord  1109  in place once dispensed through the slot  1115 , and so the second end-of-arm tool  1107  may not be necessary for holding the loop. In such examples, the pluralities of loops may be constructed entirely with the first robotic arm. 
     Though not depicted, the first end-of-arm tool may also extend a distance further than the desired length of the loop, as described herein above with regard to  FIGS.  9  and  10   . However, it should be appreciated that in some examples, the cord  1109  may lie exactly along the path  1110  along which the cord  1109  is dispensed. 
     Referring again to  FIG.  8   , after completing a loop in the second set of loops, method  800  continues to  845 . At  845 , method  800  determines if the desired number of loops is complete. If the desired number of loops is not complete (“NO”), method  800  returns to  840 . If the desired number of loops is complete (“YES”), method  800  proceeds to  850 . 
     At  850 , method  800  optionally includes adding a sole or anchor loop to secure the cord structure. The sole or anchor loop may be woven through the loops under the sole (e.g., as depicted in  FIG.  11   ) in order to secure the first and second set of loops to the sole. In some examples,  850  may be carried out manually by an operator of the cord-building apparatus. Method  800  then ends. 
     Thus, systems and methods are provided for the automatic construction of a cord structure. The cord structure may be integrated into or may comprise a footwear article, such as the footwear article depicted in  FIG.  1   . While the construction of a footwear article is described, such an embodiment is exemplary and non-limiting, and it should be appreciated that the methods and systems described herein may be applied to the construction of any cord structure. A system such as the system depicted in  FIG.  3    which constructs cord structures by dispensing cord in three-dimensional space to form interlocking loops may thus be considered an additive manufacturing system. 
     In one embodiment, a method comprises automatically forming, with at least one robotic arm, a first plurality of loops in a first plane, and automatically forming, with the at least one robotic arm, a second plurality of loops in a second plane orthogonal to the first plane, the second plurality of loops slippably engaged with the first plurality of loops. 
     In a first example of the method, the at least one robotic arm comprises two or more robotic arms. In a second example of the method optionally including the first example, each loop of the first and second plurality of loops is formed by automatically controlling a first arm of the two or more robotic arms to dispense a cord from a first position to a second position in a first direction, and automatically controlling the first arm to dispense the cord from the second position to a third position in a second direction opposite to the first direction, wherein the first direction and the second direction are in one of the first and the second planes, and wherein a distance from the first position to the second position is less than a distance from the second position to the third position. In a third example of the method optionally including one or more of the first and second examples, the cord is automatically dispensed around a loop fixture post at the second position, and a second arm of the two or more robotic arms automatically holds the cord at the third position in free space. In a fourth example of the method optionally including one or more of the first through third examples, the first plurality of loops are automatically dispensed through an eyestay for a footwear article, the first plurality of loops comprising a vamp substructure of the footwear article. In a fifth example of the method optionally including one or more of the first through fourth examples, the second plurality of loops are automatically dispensed through a sole of the footwear article, the second plurality of loops comprising a rand substructure of the footwear article. In a sixth example of the method optionally including one or more of the first through fifth examples, the method further comprises automatically dispensing an anchor cord through the second plurality of loops on an exterior side of the sole. In a seventh example of the method optionally including one or more of the first through sixth examples, the first plurality of loops is dispensed along a face of a loop fixture. In an eighth example of the method optionally including one or more of the first through seventh examples, a first loop of the first plurality of loops is intertwined with and slidably movable relative to at least two loops of the second plurality of loops, and a second loop of the at least two loops is intertwined with and slidably movable relative to at least two loops of the first plurality of loops including the first loop. 
     In another embodiment, a system comprises: a loop fixture; at least two robotic arms including a first robotic arm configured to automatically dispense a cord; and a controller configured with instructions stored in non-transitory memory that when executed cause the controller to: control the at least two robotic arms to automatically dispense the cord to form a first plurality of loops on the loop fixture in a first plane; and control the at least two robotic arms to automatically dispense the cord to form a second plurality of loops in a second plane orthogonal to the first plane, the second plurality of loops slippably engaged with the first plurality of loops. 
     In a first example of the system, the controller is further configured with instructions in the non-transitory memory that when executed cause the controller to generate a first path for the first robotic arm, wherein controlling the at least two robotic arms to dispense the cord to form the first plurality of loops comprises controlling the first robotic arm to dispense the cord along the first path. In a second example of the system optionally including the first example, the cord comprises a first cord and a second cord, the first cord forming the first plurality of loops and the second cord forming the second plurality of loops. In a third example of the system optionally including one or more of the first and second examples, the controller is further configured with instructions in the nontransitory memory that when executed cause the controller to command the first robotic arm to select a first end-of-arm tool prepared with the first cord prior to forming the first plurality of loops, and to command the first robotic arm to select a second end-of-arm tool prepared with the second cord prior to forming the second plurality of loops. In a fourth example of the system optionally including one or more of the first through third examples, the first end-of-arm tool and the second end-of-arm tool are stored in a rack positioned adjacent to the first robotic arm. In a fifth example of the system optionally including one or more of the first through fourth examples, a second robotic arm of the at least two robotic arms includes an end-of-arm tool configured to hold the cord in selective positions as the first robotic arm dispenses the cord to form the first and second plurality of loops. In a sixth example of the system optionally including one or more of the first through fifth examples, an eyestay and a sole are positioned on the loop fixture, and wherein the first plurality of loops is dispensed through the eyestay and the second plurality of loops is dispensed through the sole to form a footwear article. In a seventh example of the system optionally including one or more of the first through sixth examples, a size of each loop in the first and second pluralities of loops are determined based on a size of the footwear article. 
     In yet another embodiment, a system comprises a robotic arm, and a controller communicatively coupled to the robotic arm and configured with instructions in nontransitory memory that when executed cause the controller to: control the robotic arm to dispense a first cord to form a first plurality of loops in a first plane, wherein at least one loop of the first plurality of loops is dispensed at least partially into a sole; and control the robotic arm to dispense a second cord to form a second plurality of loops in a second plane orthogonal to the first plane, the second plurality of loops slippably engaged with the first plurality of loops. 
     In a first example of the system, the sole comprises at least one material, and friction between the at least one material and the at least one loop holds the at least one loop in place. In a second example of the system optionally including the first example, a first loop of the first plurality of loops is intertwined with and slidably movable relative to at least two loops of the second plurality of loops, and a second loop of the at least two loops is intertwined with and slidably movable relative to at least two loops of the first plurality of loops including the first loop. In a third example of the system optionally including one or more of the first and second examples, the system further comprises an end-of-arm tool coupled to an end of the robotic arm, the end-of-arm tool configured to dispense at least one of the first cord and the second cord. 
     In another representation, a method comprises: forming, with two or more robotic arms, a first plurality of loops in a first plane; and forming, with the two or more robotic arms, a second plurality of loops in a second plane orthogonal to the first plane, the second plurality of loops slippably engaged with the first plurality of loops. In one example of the method, each loop of the first and second plurality of loops is formed by controlling a first arm of the two or more robotic arms to pull a cord from a first position to a second position in a first direction, and controlling the first arm to pull the cord from the second position to a third position in a second direction opposite to the first direction, wherein the first direction and the second direction are in one of the first and the second planes, and wherein a distance from the first position to the second position is less than a distance from the second position to the third position. In a second example of the method, the cord is pulled around a loop fixture post at the second position, and wherein a second arm of the two or more robotic arms holds the cord at the third position in free space. 
     In yet another representation, a system comprises: a loop fixture; at least two robotic arms; a controller with instructions stored in non-transitory memory that when executed cause the controller to: control the at least two robotic arms to form a first plurality of loops on the loop fixture in a first plane; and control the at least two robotic arms to form a second plurality of loops in a second plane orthogonal to the first plane, the second plurality of loops slippably engaged with the first plurality of loops. 
     It will be appreciated that the configurations and/or approaches described herein are exemplary in nature, and that these specific embodiments or examples are not to be considered in a limiting sense, because numerous variations are possible. The subject matter of the present disclosure includes all novel and nonobvious combinations and subcombinations of the various features, functions, acts, and/or properties disclosed herein, as well as any and all equivalents thereof.