Crocs, Inc.

In some embodiments, a shoe assembly comprises a vamp and a sole. The vamp includes a middle section, and the vamp and the middle section are formed of a continuous piece of a first molded material. The vamp also includes a first aperture and a second aperture. The sole includes a forefoot section and a heel section that are joined by a midfoot section. The forefoot section, the heel section, and the midfoot section are formed of a continuous piece of a second molded material. The second molded material is an EVA-based material. The first aperture of the vamp receives a part of the forefoot section and the second aperture receives a part of the heel section. When the shoe assembly is placed on a flat surface, the forefoot section is in direct contact with the flat surface.

A method of manufacturing a shoe component may include injecting a material into a mold cavity to create a thin sheet of molded material formed as a single piece with molded holes extending through the molded material and formed as part of the injection molding process. The thin sheet of molded material may be in a shape that can be secured together to form a shoe upper including a vamp, a medial portion, and a lateral portion. The method may include removing, from the mold cavity, the sheet of molded material, folding the sheet of molded material, optionally cementing a first portion of the sheet of molded material to a second portion of the sheet of molded material, and cementing a third portion of the sheet of molded material to a sole to form a shoe. The completed shoe may also include an insole, a tongue, and laces.