Patent Publication Number: US-2022234318-A1

Title: Mold assembly for shaping and cutting sock liners

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application having attorney docket number 22752.384286/170145US03DIV and entitled “Mold Assembly for Shaping and Cutting Sock Liners” is a divisional to U.S. Non-Provisional patent application Ser. No. 15/992,397, entitled “Mold Assembly for Shaping and Cutting Sock Liners,” and filed May 30, 2018, which claims priority to U.S. Provisional Patent Application No. 62/513,143, entitled “Mold Assembly for Shaping and Cutting Sock Liners,” and filed May 31, 2017. The entirety of the aforementioned applications are incorporated by reference herein. 
    
    
     TECHNICAL FIELD 
     Aspects hereof relate to molds for manufacturing articles, e.g., sock liners for use in shoes. Aspects further relate to methods of manufacturing articles utilizing a mold configured for shaping and cutting utilizing a continuous single processing operation. 
     BACKGROUND 
     Manufacturing articles for which a particular shape and/or contour is desired utilizing molds generally requires the use of multiple processing steps. For instance, once a material is appropriately positioned relative to the mold, in a first processing step, a force (e.g., pressure, heat, or the like) is applied to the resultant material/mold assembly to provide the article with the desired three-dimensional contouring. After contouring, in a second processing step, a trimming or cutting operation is performed to trim any excess material extending beyond an edge of the mold such that the remaining processed article is contoured and shaped in accordance with the mold. Such multi-step mold manufacturing is inefficient and prone to error as materials are subjected to multiple forces and/or transported between processing stations. 
     BRIEF SUMMARY 
     Aspects hereof relate to multi-part manufacturing mold assemblies for contouring, shaping and cutting/trimming materials to form articles of manufacture, e.g., sock liners for use in shoes, via a continuous single processing operation. Multi-part molds in accordance with aspects hereof include, at least, an upper mold portion, a lower mold portion and a base portion. At least a portion of the upper mold portion includes a three-dimensional shape that corresponds with a contour of a first surface of an article to be manufactured utilizing the mold assembly. The three-dimensional shape, for instance, may correspond with the contour of a first surface of a sock liner such that upon positioning a desired material in contact with the upper mold portion (and generally upon application of an appropriate force, e.g., heat, pressure, or the like), the material will take on the contour of the three-dimensional shape. Aspects hereof further contemplate that the three-dimensional shape includes a first cutting edge at at least a portion of the perimeter thereof. The first cutting edge may be integral with the three-dimensional shape, may be removably coupled with the three-dimensional shape, or a combination thereof. 
     The lower mold portion, in accordance with aspects hereof, includes a three-dimensional shape that corresponds with a contour of a second, opposite surface of the article to be manufactured utilizing the mold assembly. Continuing with the example provided above, for instance, the three-dimensional shape of the lower mold portion may correspond with the contour of a second surface of the sock liner that opposes the first surface such that upon positioning the desired material in contact with the lower mold portion (and application of an appropriate force), the second surface will take on the contour of the three-dimensional shape provided by the lower mold portion. Aspects hereof further contemplate that the three-dimensional shape of the lower mold portion includes a second cutting edge at at least a portion of the perimeter thereof. The second cutting edge may be integral with the three-dimensional shape, may be removably coupled with the three-dimensional shape, may be provided as a cutting plate component separate from a mold component of the lower mold portion, or a combination thereof. Aspects hereof further provide for at least one vertical channel in the lower mold portion configured for receiving one more springs, the springs providing the appropriate force(s) for contouring, shaping and cutting/trimming, as more fully described below. 
     The base portion, in accordance with aspects hereof, includes at least one cavity shaped for receiving the lower mold portion such that the lower mold portion is retractable in a substantially vertical direction within the cavity of the base portion upon application of an appropriate force to one or more springs positioned within the vertical channels of the lower mold portion. In aspects where a cutting plate is utilized as a component separate from a molding part of the lower mold portion, the base further is configured to support the plate at its appropriate relative position. 
     Aspects hereof further relate to methods of manufacturing articles, e.g., sock liners, utilizing a multi-part manufacturing mold assembly as described herein. The method includes positioning a material between the upper mold portion and the lower mold portion of the mold assembly, causing the upper mold portion and the lower mold portion to cooperate with one another to provide a three-dimensional shape or contour to the material by applying a first force to at least one spring positioned within a vertical channel of the lower mold assembly, and causing the first cutting edge of the upper mold portion and the second cutting edge of the lower mold portion to cooperate with one another to shear the material by applying a second force to the at least one spring, the second force being greater than the first force. 
     This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Illustrative aspects hereof are described in detail below with reference to the attached drawing figures, which are incorporated by reference herein and wherein: 
         FIG. 1  depicts an upper mold portion of a multi-part mold assembly, in accordance with exemplary aspects hereof; 
         FIG. 2  depicts positioning of the upper mold portion of  FIG. 1  in cooperation with a lower mold portion, in accordance with exemplary aspects hereof; 
         FIG. 3  depicts an exploded view of the lower mold portion illustrated in  FIG. 2 , in accordance with exemplary aspects hereof; 
         FIG. 4  depicts the lower mold portion of  FIG. 2  positioned within a cavity of a base portion of the multi-part mold assembly, the base and a portion of the lower mold portion being cut away for ease of illustration, in accordance with exemplary aspects hereof; 
         FIG. 5  depicts a cross section of a multi-part mold assembly in a fully retracted position, in accordance with exemplary aspects hereof; 
         FIG. 6  depicts a cross section of the positioning of an upper mold portion of a multi-part mold assembly in cooperation with a lower mold portion, in accordance with exemplary aspects hereof; 
         FIG. 7  depicts a cross section of the multi-part mold assembly of  FIG. 6  upon a first force being applied to the springs, in accordance with exemplary aspects hereof; 
         FIG. 8  depicts a cross section of the multi-part mold assembly of  FIG. 6  upon a second force being applied to the springs, the second force being greater than the first force, in accordance with exemplary aspects hereof; 
         FIG. 9  depicts positioning of an upper mold portion of a multi-part mold assembly in cooperation with a lower mold portion, the upper and lower mold portions having a material from which a desired article is to be formed positioned there between, in accordance with exemplary aspects hereof; 
         FIG. 10  depicts operation of the multi-part mold assembly of  FIG. 9  as the upper mold portion becomes positioned such that a three-dimensional portion of the upper mold portion comes into contact with a first surface of the material, in accordance with exemplary aspects hereof; 
         FIG. 11  depicts continued operation of the multi-part mold assembly of  FIG. 10  as contouring of the material via contact with and cooperation of the respective three-dimensional portions of the upper and lower mold assemblies is initiated, in accordance with exemplary aspects hereof; 
         FIG. 12  depicts continued operation of the multi-part mold assembly of  FIG. 11  as the lower mold portion becomes fully retracted into a cavity formed in the assembly base such that shearing of the material is performed, in accordance with exemplary aspects hereof; 
         FIG. 13  depicts the operational stage illustrated in  FIG. 12  with a base and a portion of the lower mold portion being cut away for ease of illustration of the compressed springs, in accordance with exemplary aspects hereof; 
         FIG. 14  depicts a schematic diagram of an exemplary sock liner that may be contoured, shaped and cut/trimmed utilizing a multi-part mold assembly as described herein, in accordance with exemplary aspects hereof; and 
         FIG. 15  depicts a flow diagram illustrating a method of manufacturing a sock liner utilizing a multi-part mold assembly, in accordance with an exemplary aspect hereof. 
     
    
    
     DETAILED DESCRIPTION 
     The subject matter herein is described with specificity to meet statutory requirements. However, the description itself is not intended to limit the scope of this patent. Rather, the inventors have contemplated that the claimed subject matter also might be embodied in other ways, to include different elements or combinations of elements similar to the ones described in this document, in conjunction with other present or future technologies. 
     Aspects hereof contemplate a multi-part manufacturing mold assembly (e.g., a manufacturing mold assembly having at least two discrete portions) for use in manufacturing articles, for instance, sock liners, from non-rigid materials. The multi-part mold assembly provides for contouring, shaping and cutting/trimming materials to form articles of manufacture via a continuous single processing operation. For instance, the multi-part mold assembly, in exemplary aspects, includes an upper mold portion having a three-dimensional contouring or shaping portion and a first cutting edge, a lower mold portion having a three-dimensional contouring or shaping portion and a second cutting edge, and a base portion into which the lower mold portion at least partially may retract during use. In aspects, the lower mold portion includes one or more vertical channels, each vertical channel housing a spring. Upon application of a first force upon the springs, the upper mold portion and the lower mold portion may cooperate to contour (e.g., provide three-dimensional shape to) a material from which an article of manufacture is to be made. In aspects, application of the first force upon the springs may cause the lower mold portion to partially retract into a cavity formed in the base portion. Upon application of a second force upon the springs, the second force being greater than the first force, the first cutting edge of the upper mold portion and the second cutting edge of the lower mold portion may interact to shear (in a scissor-like motion) the material that extends beyond the position of the respective cutting edges, for instance, beyond the perimeter of cooperative three-dimensional portions of the upper and lower mold portions. In aspects, application of the second force upon the springs may cause the lower mold portion to fully retract into the cavity formed in the base portion. The result is an article that is contoured, shaped and cut/trimmed utilizing a single processing operation, that is, application of force to a multi-part mold assembly, as described herein. Processing articles utilizing a multi-part mold assembly in accordance with aspects hereof improves efficiency and reduces waste from deformed or otherwise misshapen articles as fewer processing steps are required to achieve a contoured, shaped and cut/trimmed article and movement between processing stations for contouring, shaping and cutting/trimming is eliminated. 
     Aspects hereof relate to a multi-part manufacturing mold assembly for manufacturing articles, e.g., sock liners, garments or garment portions, from non-rigid materials. Non-rigid materials may include, by way of example and not limitation, knit materials, woven materials, mesh materials, non-woven materials, leather materials, foamed materials, elastomeric polymers (e.g., ethylene vinyl-acetate (EVA)) and the like, or any combination thereof. Non-rigid materials utilized in the manufacture of articles often are fed, by way of example only, from material stock (e.g., material rolls or webs) having large quantities of material. Material from a material stock may be fed into a manufacturing system at an appropriate processing station of a plurality of processing stations sequentially arranged in an assembly line. 
     As will be discussed throughout, it is contemplated that a multi-part mold assembly in accordance with aspects hereof may include at least three discrete portions cooperating with one another to mold a desired article. 
     Activation of the springs permit substantially vertical movement of the lower mold portion (and cutting plate, where appropriate) up and down relative to the base portion. As used herein, the terms “up” and “down” refer to opposing movements in the latitudinal direction. As used herein, “substantially vertical movement” refers to vertical movement in the latitudinal direction relative to the base portion that may or may not also include horizontal movement to a lesser extent than the vertical movement. Substantially vertical movement results in a discernible vertical progression either up or down and may include, but does not necessarily include, a concurrent discernible horizontal progression. 
     As will be discussed throughout, it is contemplated that aspects provided herein also are directed to a method of manufacturing articles (or portions thereof) formed from non-rigid materials utilizing a multi-part manufacturing mold assembly. Articles may include, by way of example and not limitation, apparel, outerwear, sock liners, other portions of footwear, and the like. 
     Referring now to  FIG. 1 , an exemplary upper mold portion  100  of a multi-part mold assembly is illustrated, in accordance with exemplary aspects hereof. The upper mold portion  100  includes a substantially planar plate portion  110  and two portions  112 A,  112 B having a three-dimensional shape. The exemplary upper mold portion  100  of  FIG. 1  (and all other FIGs. provided and described herein for the sake of description) may be utilized to form a sock liner for use in a shoe, for instance, a sock liner  1400  as illustrated in  FIG. 14 . It will be understood and appreciated by those having ordinary skill in the art that reference to and illustration of a sock liner merely is for ease of description and a multi-part mold assembly in accordance with aspects described herein may be utilized for other articles for which molding is desired. Reference to and illustration of a sock liner is not intended to limit the scope hereof in any way. 
     The two portions  112 A,  112 B of the upper mold portion  100  having a three-dimensional shape are shaped to correspond to a contour of a first surface of an article to be manufactured, i.e., a pair of sock liners. It is understood that a multi-part mold assembly in accordance with aspects hereof need not provide for molding of a pair of sock liners but may provide for molding of any number of sock liners (e.g., one or ten) in accordance with aspects hereof. A perimeter of each of the portions  112 A,  112 B of the upper mold portion  100  having a three-dimensional shape includes a cutting edge  114 A,  114 B. As contouring surfaces for two sock liners are illustrated in the exemplary upper mold portion  100 , the cutting edge  114 A,  114 B extends around each of the perimeters of the three-dimensional portions  112 A,  112 B. It will be understood and appreciated by those having ordinary skill in the art that a cutting edge  114 A,  114 B may be provided at any location of the upper mold portion  100  where cutting or trimming of excess material is desired. Providing the cutting edge  114 A,  114 B at the perimeter of the three-dimensional shape that corresponds to a shape of the desired article of manufacture, however, permits contouring, shaping, and cutting/trimming utilizing a single processing step. 
     Aspects hereof contemplate that the cutting edge  114 A,  114 B may be integral to the upper mold portion  100  or may be removably coupled therewith. In particular exemplary aspects, the cutting edge  114 A,  114 B is removably coupled with the upper mold portion  100  such that upon dulling (or other defect) of the cutting edge  114 A,  114 B, replacement of the entire upper mold portion  100  is not necessary. 
     The illustrated upper mold portion  100  additionally includes a pair of guide pins  116  and a pair of receiving holes  118  configured to receive guide pins associated with a base portion of the multi-part mold assembly, as more fully described below. The guide pins  116  and receiving holes  118  aid in positioning and maintaining the portions of the multi-part mold assembly in their appropriate relative locations. 
     Turning now to  FIG. 2 , positioning of the upper mold portion  100  of  FIG. 1  in cooperation with a lower mold portion  200  and a base  224  is illustrated, in accordance with exemplary aspects hereof. The lower mold portion  200  includes a substantially planar plate portion  210  and two portions  212 A,  212 B having a three-dimensional shape. The two portions  212 A,  212 B of the lower mold portion  200  having a three-dimensional shape are shaped to correspond to a contour of a second surface of an article to be manufactured, i.e., a pair of sock liners, the second surface being opposite the first surface (e.g., a top and bottom of a planar portion of material from which the article is manufactured). A perimeter of each of the portions  212 A,  212 B of the lower mold portion  200  having a three-dimensional shape includes a cutting edge  214 A,  14 B. As three-dimensional portions  212 A,  212 B for two sock liners are illustrated in the exemplary lower mold portion  200 , the cutting edge  214 A,  214 B extends around each of the perimeters of the three-dimensional portions  212 A,  212 B. It will be understood and appreciated by those having ordinary skill in the art that a cutting edge  214 A,  214 B may be provided at any location of the lower mold portion  200  where cutting or trimming of excess material is desired. Providing the cutting edge  214 A,  214 B at the perimeter of the three-dimensional shape that corresponds to a shape of the desired article of manufacture, however, permits contouring, shaping, and cutting/trimming utilizing a single processing step. 
     Aspects hereof contemplate that the cutting edge  214 A,  214 B may be integral to the lower mold portion  200  or may be removably coupled therewith. In particular exemplary aspects, the cutting edge  214 A,  214 B is removably coupled with the lower mold portion  200  such that upon dulling (or other defect) of the cutting edge  214 A,  214 B, replacement of the entire lower mold portion  200  is not necessary. In a further exemplary aspect, a cutting plate may be provided as the substantially planar portion  210  of the lower mold portion  200 . In accordance with this exemplary aspect, the cutting plate  210  includes at least one aperture  220  therein (as best seen in  FIG. 3 , depicting an exploded view of the lower mold portion illustrated in  FIG. 2 ) that is shaped to receive the three-dimensional portion  212 A,  212 B of the lower mold portion  200 . The at least one aperture  220  includes the second cutting edge  214 A,  214 B at at least a perimeter portion thereof. 
     As best seen in the cross section of  FIG. 5 , the lower mold portion  200  includes at least one vertical channel  510 . The vertical channels  510  are configured for receiving springs  222  that provide the force necessary for contouring, shaping and cutting/trimming, in accordance with aspects hereof, as more fully described below. 
     A multi-part mold assembly in accordance with aspects hereof further includes a base portion  224 . As best seen in the exploded view of  FIG. 3 , the base portion  224  includes at least one cavity  226  therein shaped for receiving the lower mold portion  200  such that the lower mold portion  200  is retractable in a substantially vertical direction (up and down) within the cavity  226  of the base portion  224  upon an appropriate force being applied to a plurality of springs  222  positioned within the plurality of vertical channels  510  ( FIG. 5 ).  FIG. 5  illustrates the lower mold portion  200  in a substantially fully retraced state within the cavity  226  of the base  224 . As illustrated in  FIG. 2 , the base portion includes guide holes  218  for receiving the guide pins  116  of the upper mold assembly  100 . 
     With reference to  FIG. 4 , depicted is the lower mold portion  200  of  FIG. 2  positioned within the cavity  226  ( FIG. 3 ) of the base portion  224 , the base portion  224  and a portion of the lower mold portion  200  being cut away for ease of illustration, in accordance with exemplary aspects hereof. As can be seen, vertical channels  510  in the lower mold portion  200  permit springs  510  to be positioned, expanded and compressed therein such that the second mold portion  200  may move in the substantially vertical direction within the base  224  upon application of appropriate forces, as more fully described below. 
     Turning now to  FIGS. 6, 7 and 8 , depicted are cross sections of a multi-part mold assembly  600  in accordance with aspects hereof, the relative positioning of the portions comprising the multi-part mold  600  being illustrated at various stages of the contouring, shaping and cutting/trimming process operation, in accordance with exemplary aspects hereof.  FIG. 6  depicts a cross section of the positioning of an upper mold portion  610  of the multi-part mold assembly  600  prior to cooperative engagement of the upper mold portion  610 , the lower mold portion  614  and base portion  612 . The lower mold portion  614  is received within a cavity of the base portion  612  and springs  618  are received within vertical channels  616  in the lower mold portion  614 . The springs  618  are substantially fully expanded within the vertical channels  616 . 
       FIG. 7  depicts a cross section of the multi-part mold assembly  600  of  FIG. 6  upon a first force being applied to the assembly  600 , in accordance with exemplary aspects hereof. As can be seen, the upper portion  610  is in contact with the base portion  612  at appropriate locations. The first force is sufficient to initiate contouring and three-dimensional shaping of an appropriate material that may be positioned between the upper mold portion  610  and the lower mold portion  614 . The springs  618  within the vertical channels  616  still are substantially fully expanded as the first force is insufficient to cause substantial spring compression. It will be understood and appreciated by those having ordinary skill in the art, however, that in some aspects hereof, slight to moderate compression of the springs  618  within the vertical channels  616  may occur upon application of the first force. However, even in such aspects, spring compression will be lesser than when the second force is applied. 
       FIG. 8  depicts a cross section of the multi-part mold assembly  600  of  FIG. 6  upon a second force being applied to the assembly  600 , the second force being greater than the first force, in accordance with exemplary aspects hereof. As can be seen, the second force is sufficient that the lower mold portion  614  is retracted relative to the base portion  612  causing the cutting/trimming portion of the operation to be initiated. Though less evident in  FIG. 8 , in this state, the springs  618  are compressed within the vertical channels  616 . 
     Turning now to  FIG. 9-13 , operation of a multi-part mold assembly  900  to contour, shape and cut/trim a material from which a pair of sock liners will be formed sequentially is illustrated, in accordance with aspects hereof. With initial reference to  FIG. 9 , depicted is the positioning of an upper mold portion  910  of the multi-part mold assembly  900  prior to cooperative engagement of the upper mold portion  910 , the lower mold portion  914  and base portion  912 . The upper and lower mold portions  910 ,  914  have a material  920  positioned there between from which a desired article (a pair of sock liners) is to be formed, in accordance with exemplary aspects hereof. The material  920  is substantially planar and includes a first surface facing the upper mold portion  910  and a second surface (not visible) facing the lower mold portion  914 . In particular exemplary embodiments, the first surface may be comprised of an ethylene vinyl-acetate (EVA) material and the second surface may be comprised of a mesh material, the EVA material and the mesh material being adhered to one another, for instance, through application of heat, pressure, or the like. 
     The upper mold portion  910  includes a portion (not visible) that includes a three-dimensional shape corresponding with an edge shape and a three-dimensional contour of the first surface of the to-be-formed pair of sock liners. The portion having the three-dimensional shape includes a first cutting edge  916  at the perimeter thereof. 
     The lower mold portion  914  includes a portion (not visible) that includes a three-dimensional shape corresponding with an edge shape and three-dimensional contour of the second surface of the to-be-formed pair of sock liners. The second surface is opposite the first surface (e.g., a top and bottom surface, respectively, of the planar material  920 ). The illustrated lower mold portion  914  further includes a second cutting edge  918  at a perimeter thereof. Though not visible in  FIG. 9 , the lower mold portion  914  additionally includes a plurality of vertical channels therein, each vertical channel housing a spring (as more fully described with reference to  FIG. 13 ). 
       FIG. 10  depicts the multi-part mold assembly  900  of FIG. as the upper mold portion  910  becomes positioned such that a three-dimensional portion of the upper mold portion (not visible) comes into contact with the first surface of the material  920 , in accordance with exemplary aspects hereof. Note that the three-dimensional portions of the upper mold portion  910  and the lower mold portion  914  align with one another, as do the first cutting edge  916  and the second cutting edge  918 . It will be understood that by “align,” what is meant is that the upper mold portion  910  and the lower mold portion  914  are positioned such that they cooperate to form the processed article (e.g., the pair of sock liners). Use of the term “align” is not intended to mandate any particular exact planar alignment but rather cooperative alignment of the various portions of the assembly  900 . 
       FIG. 11  depicts continued operation of the multi-part mold assembly  900  of  FIG. 10  as contouring and three-dimensional shaping of the material  920  via contact with and cooperation of the respective three-dimensional portions of the upper mold portion  910  and the lower mold portion  914 , as well as the base portion  912 , is initiated, in accordance with exemplary aspects hereof. Stated differently,  FIG. 11  depicts the multi-part mold assembly  900  of  FIG. 10  as a first force is applied thereto. The first force is sufficient to bring the first surface of the material  920  into contact with the upper mold portion  910  to initiate contouring and three-dimensional shaping of the material  920 . Though not illustrated in  FIGS. 9-12 , springs within vertical channels of the lower mold portion still are substantially fully expanded as the first force is insufficient to cause substantial spring compression. It will be understood and appreciated by those having ordinary skill in the art, however, that in some aspects hereof, slight to moderate compression of the springs within the vertical channels may occur upon application of the first force. However, even in such aspects, spring compression will be lesser than when the second force is applied. As illustrated in  FIG. 11 , a lesser distance separates the first cutting edge  916  and the second cutting edge  918 , but during application of the first force, substantial cutting/trimming of the material  920  does not occur. 
     With reference to  FIG. 12 , depicted is continued operation of the multi-part mold assembly  900  of  FIG. 11  as the lower mold portion  914  becomes fully retracted into the cavity (not visible) formed in the base portion  912  such that cooperation of the first cutting edge  916  and the second cutting edge  918  causes shearing of the material  920 , in accordance with exemplary aspects hereof. Stated differently,  FIG. 12  depicts the multi-part mold assembly  900  of  FIG. 11  upon application of a second force, the second force being greater than the first force, in accordance with aspects hereof. The second force is sufficient that the lower mold portion  914  is retracted relative to the base portion  912  causing the cutting/trimming portion of the operation to be initiated. 
     Turning to  FIG. 13 , the operational stage illustrated in  FIG. 12  is depicted with the base portion  912  and a portion of the lower mold portion  914  being cut away for ease of illustration, in accordance with exemplary aspects hereof. As can be seen, in the depicted operational state, the second force is sufficient that the lower mold portion  914  is retracted relative to the base portion  912  causing the cutting/trimming portion of the operation to be initiated. In this state, the springs  924  are compressed within the vertical channels  922 . 
     Turning now to  FIG. 15 , depicted is a flow diagram illustrating a method  1500  of manufacturing a sock liner utilizing a multi-part mold assembly, in accordance with an exemplary aspect hereof. As indicated at block  1510 , a material is positioned between an upper mold portion and a lower mold portion of the multi-part manufacturing mold assembly. The upper mold portion has at least a portion that includes a three-dimensional shape corresponding with a contour and a dimensional shape of a first surface of the sock liner, the three-dimensional shape having a first cutting edge at at least a portion of a perimeter thereof. The lower mold portion includes at least a portion that includes a three-dimensional shape corresponding with a contour and a dimensional shape of a second, opposite surface of the sock liner, the three-dimensional shape of the lower mold portion having a second cutting edge at at least a portion of a perimeter thereof. The lower mold portion includes at least one spring positioned in a vertical channel thereof. 
     As indicated at block  1512 , the upper mold portion and the lower mold portion are caused to cooperate with one another (for instance, upon application of an appropriate first force) to provide a three-dimensional shape to the material positioned there between by applying. As indicated at block  1514 , the first cutting edge of the upper mold portion and the second cutting edge of the lower mold portion are caused to cooperate with one another to shear the material positioned there between by applying a second force to the at least one spring, the second force being greater than the first force. 
     As can be seen, aspects hereof relate to a multi-frame manufacturing apparatus for manufacturing articles, for instance, sock liners, formed of a non-rigid material. Aspects hereof further relate to a method of manufacturing articles, for instance, sock liners, utilizing a multi-frame manufacturing apparatus. A multi-frame manufacturing apparatus having a structure as described herein permits interchangeability of the position of multiple manufacturing frames enabling processing of one or more articles to progress while material for another article is being loaded onto the apparatus. A multi-frame manufacturing apparatus having a structure as described herein further permits processing of a portion of a non-rigid material separated from a larger material stock, the portion being held in a non-tensioned state during processing and, accordingly, reducing waste occasioned by deformed and consequently unusable articles. 
     Although the multi-frame manufacturing apparatus and method of manufacturing articles formed from non-rigid materials utilizing a multi-frame manufacturing apparatus are described above by referring to particular aspects, it should be understood that modifications and variations could be made without departing from the intended scope of protection provided by the following claims. It will be understood that certain features and sub-combinations are of utility and may be employed without reference to other features and sub-combinations. This is contemplated by and is within the scope of the claims. 
     While specific elements and steps are discussed in connection to one another, it is understood that any element and/or steps provided herein is contemplated as being combinable with any other elements and/or steps regardless of explicit provision of the same while still being within the scope provided herein. Since many possible aspects may be made of the disclosure without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.