US Patent 10470522 Light-cured composite insole

The present invention describes a shaped footwear device intended to be used as a supportive insole or orthotic and a system and methods for making the same. The footwear device includes a top foam layer, a light-cured composite material layer, and a bottom textile layer. The footwear device is created by conforming a pre-cured insole assembly to the plantar surface of a foot or foot mold and then exposing the pre-cured insole assembly to light to create a shaped footwear device with a light-cured composite material support plate.