Customized ballet shoes using elastic arrangement for each foot region, and method and system for manufacturing the same

Abstract

The present invention relates to providing ballet shoes optimized for the wearer's foot structure by scanning the user's foot in three dimensions (3D), converting the scanned data into a mesh form to analyze the spacing of different parts of the foot, and applying appropriate elasticity to each part according to the analyzed spacing information. In particular, the ballet shoes according to the present invention include an elastic support means in the shape of a roly-poly toy inside the front part of the shoe to provide stability and comfort during high-difficulty movements such as the pointe, which support body weight on the toes, thereby improving the dancer's center of gravity recovery and ability to maintain balance. Through this, it is possible to produce customized ballet shoes that reduce foot fatigue, decrease the risk of injury, and simultaneously satisfy both the functionality and aesthetics of the ballet shoes.

Description

Technology Field

[65535] The present invention relates to a customized ballet shoe using elastic arrangement by foot part, and a method and system for manufacturing the same. It relates to a technology that scans a user's foot, converts it into 3D mesh data, and then adjusts elasticity by foot part to provide a ballet shoe optimized for the wearer's movements and posture. Background Technology

[0002] Conventional ballet shoes are generally manufactured according to standardized molds, which limits their ability to adequately reflect the individual foot shapes or movement characteristics of diverse users. Most ballet shoes are produced based on common size units and fixed materials, and this manufacturing method makes it difficult to account for detailed body structures such as instep height, ball width, and toe length.

[0003] In particular, the 'Pointe,' a movement in which body weight is supported on the toes, is one of the key movements in ballet. Since the load is concentrated at the tips of the toes during this movement, it is crucial that the ballet shoes fit the wearer's feet accurately and provide stable support. However, standard ballet shoes do not adequately compensate for pressure on the toes or balance issues during the Pointe, leading to frequent problems such as toe pain, friction, and strain on the ankles.

[0004] Recently, there have been ongoing attempts to apply 3D scanning technology and personalized insole manufacturing technology to some sports shoes or medical footwear, but in the field of ballet shoes, most products are still limited to simple size adjustments. In other words, they are provided with adjustments only to length or width, and technology that precisely reflects the user's foot shape to design customized elasticity or support structures for specific areas is not being applied.

[0005] Therefore, there is a need for a new type of ballet shoe manufacturing technology that takes into account the specificity of ballet movements and the individual body structure of dancers, enabling more detailed design by region and improved functionality. Prior art literature

[0006] Korean Patent Publication No. 10-2019-0082273 Korean Patent Publication No. 10-2011-0093770 The problem to be solved

[0007] The objective of the present invention is to provide a customized ballet shoe system, a manufacturing method, and a ballet shoe produced thereby, which can simultaneously achieve the maintenance of a dancer's balance, reduction of fatigue, and improvement of movement stability.

[0008] First, the purpose is to precisely obtain foot shape information by scanning the user's foot in three dimensions (3D), and to determine the required degree of elasticity for each part of the foot by analyzing the spacing of each part based on the foot data converted into a 3D mesh form.

[0009] In addition, the purpose is to implement a customized elastic arrangement optimized for the user's foot structure by applying different elastic materials or composite materials to specific areas.

[0010] Furthermore, in order to prevent the center of gravity from shifting forward when supporting body weight on the toes, such as in a pointe movement, it is intended to provide a roly-poly type elastic support means inside the front part of the ballet shoe. means of solving the problem

[0011] To achieve the above objective, a method for manufacturing a customized ballet shoe suitable for a user's foot structure according to the present invention comprises: a first step of scanning the user's foot to obtain three-dimensional shape data; a second step of aligning the shape data by converting it into a mesh structure; a third step of analyzing the mesh data by dividing the anatomical parts of the foot; a fourth step of calculating elasticity values ​​based on the analysis results; a fifth step of designing the structure of the ballet shoe based on the calculated elasticity values; a sixth step of applying a material corresponding to the designed structure; and a seventh step of integrating the ballet shoe manufacturing information to create and manufacture a ballet shoe model.

[0012] In addition, the first step is characterized by multi-dimensionally capturing the shape of the foot using a structured light scanner or photogrammetry-based equipment and acquiring point cloud data.

[0013] Additionally, the second step is characterized by performing positional alignment between point clouds acquired at multiple viewpoints, removing outliers or abnormal regions, and interpolating or remeshing missing regions.

[0014] In addition, the third step is characterized by calculating the mesh spacing, cell density, rate of change in curvature, center deviation, etc., based on each part such as the toes, instep, ball of the foot, sole, and heel, and determining the physical support requirement or pressure concentration of the corresponding part.

[0015] In addition, the seventh step is characterized by being performed using a 3D printing method or a multi-injection molding method.

[0016] Additionally, it may further include an 8th step of analyzing the ignition pressure, presence or absence of pain, or balance imbalance of a specific area using feedback data received from the user after the 7th step, and reflecting this in the design correction.

[0017] In addition, the data generated in steps 1 through 8 is stored together with user identification information and is characterized by being utilized for re-production or automatic design recommendations for the same user or other users with similar conditions. Effects of the invention

[0018] According to the present invention, the following effects can be achieved.

[0019] First, the present invention can provide customized ballet shoes optimized for an individual's foot structure by precisely adjusting elasticity for each part of the foot based on mesh data obtained by scanning the user's foot in three dimensions.

[0020] In addition, the present invention can alleviate pain and instability caused by situations where the load is concentrated on the toes, such as during pointe movements, thereby enabling the dancer to maintain a more stable posture and perform movements.

[0021] In addition, the present invention can minimize the accumulation of fatigue caused by pressure repeatedly applied to the toes and reduce excessive tension in the ankle and toe areas.

[0022] Furthermore, the present invention can prevent the posture from collapsing due to the repeated phenomenon of the center of gravity shifting forward when supporting body weight on the toes.

[0023] Furthermore, the present invention can improve a dancer's ability to maintain balance and restore posture, thereby enhancing the completeness and sustainability of the performance during a show. Brief explanation of the drawing

[0024] FIG. 1 is a block diagram illustrating a ballet shoe manufacturing system (1000) according to the present invention. FIGS. 2, FIGS. 4 to 6 illustrate detailed block diagrams of a conversion unit (1020), an analysis unit (1030), a design unit (1040), and a production unit (1050) constituting a ballet shoe production system (1000) according to the present invention. Figure 3 is a drawing illustrating an example of a mesh structure generated based on user's foot shape data. FIG. 7 is a flowchart illustrating a method for manufacturing customized ballet shoes according to the present invention. FIG. 8 is a drawing illustrating an example of a woven structure in which the weft and warp threads are crossed. FIG. 9 is a drawing illustrating an embodiment in which a multi-stage elastic structure is applied to the front part of a ballet shoe according to the present invention. FIG. 10 is a drawing illustrating an embodiment of the shape of a toe center restoration structure. Specific details for implementing the invention

[0025] The present invention enables the realization of ballet shoes optimized for the wearer's foot structure by scanning the user's foot in three dimensions (3D), converting the scanned data into a mesh form to analyze the spacing of different parts of the foot, and applying appropriate elasticity to each part according to the analyzed spacing information. Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the attached drawings. However, embodiments of the present invention may be modified in various different forms, and the scope of the present invention should not be interpreted as being limited by the embodiments described below.

[0027] Figure 1 illustrates a ballet shoe manufacturing system (1000) according to the present invention.

[0028] Referring to FIG. 1, the ballet shoe manufacturing system (1000) according to the present invention is configured to include a scanning unit (1010), a conversion unit (1020), an analysis unit (1030), a design unit (1040), a manufacturing unit (1050), a storage unit (1060), a management server (1070), a communication unit (1080), a control unit (1090), and a display unit (1100) in order to efficiently and precisely perform the ballet shoe manufacturing procedure.

[0029] [Scanning Department (1010)]

[0030] First, the scanning unit (1010) performs the function of precisely scanning the user's actual foot in a three-dimensional (3D) manner to obtain the three-dimensional shape of various parts, such as the toes, instep, sole, and heel, in a digital format.

[0031] The scanning unit (1010) is configured to take into account the user's foot shape, posture, and even detailed differences in curvature, and can apply 3D scanning technologies such as structured light, laser scanning (LiDAR), and photogrammetry.

[0032] In the case of the structured light method, a light pattern is projected onto the foot and the deformed pattern is analyzed with a camera to calculate the shape, while the photogrammetry method is a method that creates a 3D model by integrating 2D images taken from multiple angles.

[0033] In this process, automatic exposure control and surface reflection correction algorithms can be used together to minimize distortion caused by lighting in the shooting environment, the reflectivity of the foot surface, and the shooting angle.

[0034] The data obtained at the end is stored in the form of a dense point cloud or surface data, which is used as an input value for a conversion unit (1020) for subsequent analysis and precision design.

[0035] [Conversion unit (1020)]

[0036] The conversion unit (1020) is configured to include a mesh conversion module (1021), a mesh matching module (1022), and a noise removal module (1023) as shown in FIG. 2, and performs the function of converting the user's foot shape data into a precise mesh structure.

[0037] The mesh conversion module (1021) plays the role of converting point cloud or curved surface data obtained from the scanning unit (1010) into three-dimensional mesh data by dividing it into a polygonal grid structure consisting of triangles (triangle mesh) or quadrilaterals (quad mesh).

[0038] In the mesh conversion module (1021), first, edges are formed between point groups defining the outer shell of the foot shape, and a polygonal face is formed based on the edges to perform conversion into a digital shape.

[0039] Mesh transformation methods can be implemented through various techniques such as Delaunay triangulation, Poisson surface reconstruction, and ball-pivoting algorithms, and each technique is selectively applied depending on the data density or surface characteristics.

[0040] The converted mesh is generated in a high-resolution form to precisely reflect the curvature, protrusions, and skeletal contours of the foot, and can also be configured to support multiple levels of resolution (LOD) to reduce data volume.

[0041] FIG. 3 illustrates a foot shape in which 3D scan data is converted into a polygonal mesh structure by a mesh conversion module (1021), and the conversion result is saved in a standard 3D file format such as STL, OBJ, and PLY, and is directly utilized in the subsequent design and simulation process.

[0042] The mesh alignment module (1022) performs the function of forming an aligned and consistent three-dimensional mesh shape by correcting various errors such as positional misalignment between frames, disconnected boundary lines, and duplicate point clouds that may occur during the scanning process. This is an essential process, especially when reconstructing data acquired at multiple points in time (e.g., the inside and outside of the foot, the front and the side, etc.) into a single integrated shape.

[0043] In the matching process, the Iterative Closest Point (ICP) algorithm is used to iteratively align each point cloud, or the Random Sample Consensus (RANSAC) algorithm is used to remove outliers and calculate a stable transformation matrix.

[0044] The aligned results are implemented to ensure not only spatial coordinate alignment but also surface orientation and boundary continuity. If necessary, areas with steps or gaps are automatically interpolated based on the direction vectors of surrounding point clouds and curvature to connect them into smooth surfaces. This process guarantees the alignment and quality of the base geometry, enabling accurate area recognition and elastic design in subsequent analysis stages.

[0045] The noise removal module (1023) performs the function of obtaining high-quality digital data that accurately reflects the actual foot shape by automatically detecting and removing various abnormal elements present in the mesh data.

[0046] Due to variations in illumination in the scanning environment, reflectivity of the foot surface, sensor resolution, or accumulated errors, the mesh may contain ideally protruding surfaces, abnormal holes, unrealistic steps, overlapping points, etc.

[0047] The noise removal module (1023) automatically detects abnormal regions through statistical-based outlier detection techniques, such as average distance-based (outlier removal), neighbor density-based (clustering threshold), or curvature discontinuity detection. The detected noise is deleted or aligned, and if the region is converted into a defect, the topological continuity and geometric consistency of the mesh are restored by interpolating using information such as the gradient, curvature, and normal vector of adjacent faces, or by remeshing to create new cells.

[0048] The processing result of the noise removal module (1023) serves as a basis for determining the accuracy of subsequent analysis, as well as maintaining the resolution of the mesh data and improving computational efficiency.

[0049] [Analysis Department (1030)]

[0050] As shown in FIG. 4, the analysis unit (1030) is configured to include a part division module (1031), a gap analysis module (1032), and an elasticity value calculation module (1033), and performs the role of dividing the user's foot according to anatomical standards and quantitatively analyzing the mesh structure of each part to calculate the required elasticity value for each part.

[0051] The part division module (1031) performs the function of dividing the main regions according to the anatomical structure of the foot for the noise-removed mesh data.

[0052] Specifically, the toes (incisors), ball of the foot (anterior midfoot), instep (upper midfoot), sole (lower midfoot), and heel (hindfoot) are identified and boundaries are established automatically or semi-automatically. During this process, the mesh's curvature gradient, coordinate height difference (Z-axis distribution), angle of surface inclination, and changes in inter-cell density are comprehensively analyzed to extract boundary lines that clearly reveal the characteristics of each region. In particular, segmentation is performed based on characteristics where curvature increases sharply at the boundary between the toes and the ball of the foot, and where differences in height relative to the Z-axis and angle of surface inclination are distinct between the instep and the sole.

[0053] If the accuracy of automatic segmentation is low or geometric boundaries are unclear in specific areas, user intervention is allowed through manual correction or semi-automatic marker designation functions, and each area is partitioned into independent segments with an identification code (ID) to enable individual recognition.

[0054] The interval analysis module (1032) performs the function of quantifying the structural characteristics of the mesh in each divided part and quantitatively extracting the physical properties required for the part—especially the indicators that affect the elastic distribution.

[0055] The analysis items mainly consist of inter-node spacing, cell density (density per unit area), local curvature, angular deviation, and surface area (area per patch).

[0056] The spacing analysis module (1032) calculates each indicator and analyzes the average value, standard deviation, distribution pattern, etc., to predict the load concentration, support requirements, and cushioning requirements for each part. For example, the forefoot or hindfoot of the sole is a part where body weight is concentrated, and it is characterized by narrow cell spacing and high surface density, while conversely, the instep or the upper surface of the toes is judged to have wide spacing and gentle curvature, resulting in less load burden.

[0057] The results of this characteristic analysis are directly utilized in the next step, calculating elasticity values, and provide foundational information for quantifying the support requirements of each part.

[0058] The elasticity value calculation module (1033) performs the function of quantifying the elasticity characteristics required by a corresponding part based on various indicators such as mesh structure characteristics for each part derived from the spacing analysis module, namely cell spacing, density, curvature, and surface slope.

[0059] The calculated elasticity value is not a simple qualitative indicator, but a quantitatively defined material property value such as the required compressive rebound force per unit area (N / mm²), material hardness (Shore A / B series), tensile elastic modulus (Young's modulus), and recovery rate (%).

[0060] In particular, since the forefoot (boundary between the toes and the ball of the foot) and rearfoot (heel), where weight is concentrated, exhibit characteristics of high mesh density and abrupt changes in local curvature, it is concluded that high-elasticity materials requiring high resilience and rebound are necessary for these areas.

[0061] On the other hand, low-elasticity or medium-elasticity materials are suitable for areas requiring flexible movement and relatively low load, such as the instep. These elasticity values ​​can be derived using predefined reference tables or algorithm-based formulas, and if necessary, they can be adjusted by incorporating ergonomic factors such as the user's weight, gender, and ballet movement patterns as variables.

[0062] The calculated results are stored as separate datasets for each part and are directly input into the subsequent elastic structure design module.

[0063] [Design Department (1040)]

[0064] The design unit (1040) is configured to include an elastic structure design module (1041), a material application module (1042), a toe restoration structure design module (1043), and a toe restoration structure application module (1044) as shown in FIG. 5, and performs the role of designing an appropriate structure and material according to the elastic value of each part analyzed and reflecting it in the actual ballet shoe structure.

[0065] The elastic structure design module (1041) performs the function of precisely designing an elastic structure to be applied to each part of the ballet shoe based on the elastic values ​​for each part calculated above.

[0066] Design factors include not only material properties but also the thickness of the material (in mm), the cross-sectional shape of the structure (e.g., grid type, porous molding, multilayer plate type), arrangement direction (pattern placement considering the direction of force application), and arrangement density (insertion amount per unit area).

[0067] For example, the forefoot is a section where repeated landing and propulsion occur, and since rebound elasticity and shock absorption functions are required simultaneously, a high-elasticity structure with a thickness of 10 to 15 mm can be designed internally in a hexagonal cell shape or a unidirectional grid pattern. On the other hand, since fatigue reduction and vibration damping are important for the heel area, it is designed with a double or triple laminated structure in which a medium-elasticity material is placed on the upper side and a high-elasticity layer is placed on the lower side, and in some cases, a viscoelastic gel, air pocket, or a gentle curved gradient structure may be applied together.

[0068] Such designs are implemented as CAD-based digital models and output as processing data that can be directly utilized in subsequent manufacturing stages.

[0069] The material application module (1042) performs the function of selecting an elastic material suitable for the structure based on the design information derived from the elastic structure design module (1041) and precisely placing or inserting it into each part of the ballet shoe.

[0070] The materials used include various rubber elastomers or foam materials such as EVA (ethylene-vinyl acetate), TPE (thermoplastic elastomer), PU (polyurethane), and silicone rubber; if necessary, multilayer composite structures combining two or more materials (e.g., a soft top layer and a hard bottom layer) can also be implemented.

[0071] The application method may vary depending on the design type and manufacturing method. For example, in 3D printing-based direct molding methods, additive manufacturing with an accurate shape based on a CAD model is possible, while in thermoforming or injection molding methods, precision molding is performed according to the mold.

[0072] Furthermore, in the case of insertable structures, materials can be precisely inserted into the interior of the insole or the core layer, or laminated integrally with the outer shell. The finally applied elastic material contributes substantially not only to structural completeness but also to compression response, recovery speed, and shock absorption performance during actual wear, simultaneously enhancing user comfort and operational stability.

[0073] The toe restoration structure design module (1043) performs the function of designing an elastic support structure that allows the center of gravity to be restored in a vertical direction without shifting in situations where the ballet shoe wearer concentrates their weight on the toes, such as during a pointe movement.

[0074] The toe restoration structure design module (1043) determines the shape, material, and arrangement method of a structure to be located in the front part (inner space of the toe) of the ballet shoe, in particular. During the design process, the local curvature of the toe area, the amount of change in inclination upon contact with the ground, and the range of movement of the center of gravity are analyzed to derive a structural shape that is advantageous for center restoration.

[0075] Generally, a hemispherical or ellipsoidal convex structure is adopted, and this shape utilizes the 'roly-poly' principle of automatically returning weight shifted to one side back to the center.

[0076] The recovery structure may be formed from a single material, but for a more precise recovery response, it may be designed as a multilayer structure with different hardness between the upper and lower layers, or as a composite structure including a core layer that disperses compressive stress in the center.

[0077] In addition, the design is optimized by considering the arrangement angle of the structure, pressure resistance, and torsional restoring force, and center of gravity recovery performance can be pre-verified through virtual ignition simulation in CAD.

[0078] The toe restoration structure application module (1044) performs the function of maintaining balance and automatically restoring the center of gravity when the user supports their weight on their toes by physically implementing a structure with a center restoration function formed during the design stage inside the front part of the ballet shoe. This structure is designed so that the toes are restored around a constant center axis during high-load movements such as the pointe, and structural stability, the user's fit, durability, and the continuity of the manufacturing process are all considered during the application process.

[0079] In the toe restoration structure application module (1044), the method of applying the structure is broadly divided into two methods.

[0080] The first is the insert method, in which the designed restoration structure is fabricated as a separate part and then seated in the front space inside the ballet shoe as an inlay or support pad.

[0081] In this case, the structure is inserted into the lower part of the insole (93) or the inner lining of the ballet shoe during or after the manufacturing process, and the mold structure or insertion slot is precisely designed to be accurately aligned with the toe position. The structure to be inserted can be designed with smooth surface curvature, edge fillet, and compression counter-surface, taking into account the contact characteristics with the user's toe bone structure (e.g., phalange arrangement). Additionally, heat fusion, press-fit fixation, adhesive layers, etc., can be used to increase the bonding strength of the insertion position, and if necessary, it may be manufactured as a replaceable structure to facilitate correction after fitting.

[0082] The second method is an integrated structure molding method. This is a method in which the restoration structure is integrated with the ballet shoe shell, insole (93), or bottom layer and molded together, and is implemented through injection molding, compression molding, multilayer lamination, or direct 3D printing.

[0083] The one-piece method has a low likelihood of displacement or detachment of the structure even under repeated wear and compressive loads, and provides overall integrated support and repulsion. In the molding process, the shape of the elastic structure (e.g., hemispherical, elliptical, or curved composite structure) and the internal filling layer (e.g., gel core, air cell, spring unit, etc.) are considered together, and a separate wear-resistant layer or a surface texture for shock dispersion may be added to the ground contact area.

[0084] The materials primarily used include TPE (thermoplastic elastomer), PU (polyurethane) blends, high-density EVA, and silicone rubber, which possess high resilience and elastic rebound. Each material is selected based on criteria such as compressive modulus, recovery response rate, heat resistance, and flexibility. In composite structures, materials with different elastic properties are topologically combined to ensure both support and comfort. For example, by placing a high-elasticity core in the center and a soft cushioning layer on the outside, fatigue can be reduced while center resilience is maximized. Additionally, to enable multi-axial load distribution design, rib or cavity structures can be formed within the structure to distribute energy absorption and rebound responses in a balanced manner.

[0085] [Production Department (1050)]

[0086] As illustrated in FIG. 6, the production unit (1050) is configured to include a production information integration module (1051), a ballet shoe production module (1052), and a fitting and correction module (1053), and performs the role of actually producing a customized ballet shoe based on the designed structure and material information, and providing a final finished product by correcting it after the user wears it and reflecting feedback.

[0087] The manufacturing information integration module (1051) performs the function of integrating various design data including previously generated mesh information by part, elasticity value, structural design, material information, toe restoration structure, etc., and finally generating a digital model that can be manufactured.

[0088] The production information integration module (1051) merges design data for each component to complete the entire ballet model based on 3D CAD, and the model includes mesh coordinates, structural layers, material mapping information, thickness change information, etc.

[0089] The file format supports extensions suitable for STL, OBJ, AMF, or FDM-based 3D printing, and includes metadata such as post-processing instructions, molding pressure conditions, and material mixing ratios to ensure compatibility with manufacturing equipment.

[0090] In addition, it can be linked with user-specific body data and fitting records, and is configured to be connected to a storage unit (1060) and a management server (1070) to facilitate data history management, repetitive production, or model modification.

[0091] The ballet shoe production module (1052) performs the function of producing a real ballet shoe based on an integrated digital model.

[0092] This module can utilize various manufacturing technologies, and the choice depends on the complexity of the design structure, the required characteristics of the elastic structure, and the processability of the material.

[0093] For example, 3D printing methods (FDM, SLA, SLS, etc.) are suitable for designs that include complex internal lattice structures and porous elastic layers, and thermoforming or overmolding methods may be used when soft materials need to be precisely molded.

[0094] In addition, a hybrid manufacturing method can be applied in which the outer shell, inner insole (93), and restoration structure are manufactured individually and then assembled by bonding or sewing.

[0095] In this process, process conditions are established by considering structural dimensional precision, bonding stability between materials, and finishing quality; if necessary, quality inspection and alignment correction are performed during intermediate manufacturing stages. Consequently, this module realizes a custom-designed, high-performance ballet shoe in physical form and subsequently links to a wearer fitting and correction module.

[0096] The fitting and correction module (1053) performs the function of fitting the manufactured ballet shoes onto the user's actual feet, checking factors such as fit, pressure, balance maintenance performance, and recovery response, and adjusting the structure or material arrangement of some parts if necessary.

[0097] The fitting and correction module (1053) includes a final verification step to evaluate whether the initial design values ​​of the ballet shoe fit the actual user well, and the user can provide feedback on the degree of pressure or balance maintenance characteristics felt in areas such as the toes, ball of the foot, and heel after wearing. This feedback is entered digitally or recorded after being personally verified by an administrator, and problematic areas such as improper or unbalanced elastic structure, lack of center-restoring response, or excessive friction are manually corrected through heat molding, compression correction, insert replacement, or surface finishing rework.

[0098] In addition, the fitting and correction module (1053) is linked with human biomechanical analysis data for repeated fitting, so that previous fitting history can be stored in the system and compared and analyzed to enable automatic modification design to an optimal structure for each user.

[0099] [Storage unit (1060)]

[0100] The storage unit (1060) is configured to systematically store and manage all digital data generated or processed in the ballet shoe production system (1000), and performs the function of long-term preservation of basic information for user-customized design and repetitive production. The storage targets include original point cloud data obtained by 3D scanning the user's foot, mesh data converted into a polygonal grid, results of anatomically dividing major parts of the foot, mesh spacing analysis information for each part, calculated elasticity values, design models of applied elastic structures (CAD design data), types and placement locations of selected materials (material mapping data), shape information of toe restoration structures, and even the final fitting and correction history.

[0101] This information is managed not in the form of simple files, but as structured datasets for each user, and each user is assigned a unique identifier (user ID, session ID, or biometrically-linked identifier) ​​to enable independent tracking and comparative analysis of production and modification history over multiple iterations. The storage formats include various forms of structured data such as JSON, XML, STL, OBJ, and CSV, as well as 3D model files, which are managed based on a hierarchical folder structure or relational / unstructured databases (including NoSQL).

[0102] The storage method is basically composed of a file system based on a local server or embedded storage, and considering long-term storage and multi-user accessibility, it can adopt a structure that is backed up or mirrored in conjunction with a **cloud-based database (AWS S3, Azure Blob, Google Cloud Storage, etc.)**. In particular, to reliably store large-capacity 3D model data and repetitive version history, delta versioning, data compression and deduplication, and metadata indexing functions are implemented together.

[0103] The stored data is utilized for various purposes, such as the following.

[0104] First, when remaking or correcting ballet shoes for the same user, they can be quickly reproduced based on existing design information, thereby increasing the precision and efficiency of repetitive production.

[0105] Second, by comparing and analyzing design models with users of similar body types or foot structures, it is utilized for the automation of customized designs or for learning algorithms in recommendation systems.

[0106] Third, it can be utilized as a big data source for training to build machine learning models, such as AI-based foot shape data analysis, elastic design optimization, or post-wear feedback prediction.

[0107] Fourth, it functions as a record basis for verifying production quality and responding to after-sales service (AS), and can serve as a reference for tracking design errors or analyzing the causes of manufacturing defects.

[0108] In addition, the storage unit (1060) is equipped with advanced security and recovery functions. To protect sensitive data associated with the user's biometric information or ignition history, the stored data is encoded using an encryption method of AES-256 or higher, and a TLS / SSL-based security protocol is applied during transmission. A real-time automatic backup function is enabled to periodically create replicas, and a RAID-based or multi-region redundancy structure is supported to enable data recovery even in the event of server failure or system error. Furthermore, user access logs and data modification history are recorded separately and used as evidence for integrity audits.

[0109] [Communication Department (1080)]

[0110] The communication unit (1080) is responsible for transmitting and receiving data between modules within the system or between external devices and servers, and functions as a communication hub connecting the flow of information in the manufacturing process. It supports wired (USB, LAN) or wireless (Wi-Fi, Bluetooth, 5G, etc.) communication methods for interoperability with scanning devices, CAD systems, analysis servers, user interface devices, etc. Various communication protocols such as HTTP, MQTT, and WebSocket can be used, and through real-time synchronization between systems, changes to design data, reflection of feedback, and verification of manufacturing results are performed smoothly. In addition, an error detection and correction algorithm is built in to prevent packet loss, delay, and data inconsistency problems that may occur during communication.

[0111] [Management Server (1070)]

[0112] The management server (1070) is a central control unit that manages the entire system in an integrated manner and performs high-level functions such as user authentication, design history management, fitting result analysis, system resource allocation, and communication status monitoring. This server integrates and manages design history and fitting data for each user to convert them into reusable design assets, and also includes log recording of system performance and abnormal conditions, as well as predictive maintenance functions. When necessary, it can perform design data restoration, fitting history comparison, and automated modified design generation in response to remote work progress or customer service requests. Additionally, the server functions as a central repository capable of continuously updating the latest design algorithms or material databases, and is configured to be scalable to enable parallel interaction with multiple user terminals.

[0113] [Control unit (1090)]

[0114] The control unit (1090) comprehensively manages the entire ballet shoe production system (1000) and is configured to systematically control the operation sequence, execution conditions, and data flow between modules for each process stage, ranging from scanning, analysis, design, production, and fitting. The control unit (1090) is configured to go beyond simple command transmission functions to monitor the status of each module in real time and perform situation-adaptive control, such as path readjustment based on unexpected environmental changes or user input. Additionally, to ensure the entire system is seamlessly linked based on a workflow, it precisely controls the flow of process switching conditions, completion signals, and timing intervals, and applies a queue-based or event-based scheduling structure to prevent synchronization errors.

[0115] Data transfer and module execution timing between each stage can be implemented through Finite State Machine (FSM) or PLC-based sequence logic. In particular, between the scan-analysis-design stages, a conditional branch statement is applied to determine whether to proceed to the next stage after verifying data and checking the intermediate storage status. For example, if the quality of the foot scan data is below a set standard, mesh conversion is temporarily suspended, and a routine is called to induce the user to retake the image. In this way, the control unit (1090) pre-configures an exception handling procedure considering that each stage is interdependent, and sets an automatic recovery path in the event of an error, thereby increasing the stability and availability of the entire system.

[0116] The control unit (1090) also performs an active response function that dynamically adjusts operations by receiving real-time data from sensors and input devices distributed throughout the system. For example, if an abnormal load distribution is detected by a pressure sensor during the process of inserting a toe restoration structure, the control unit (1090) analyzes this and automatically generates a command to adjust the insertion direction, speed, or depth of application. In this way, a situation awareness function can be realized and intelligent feedback control can be performed through an interface with external sensors (pressure sensors, position sensors, tilt sensors, touch inputs, etc.).

[0117] The hardware implementation of the control unit (1090) can be configured in various ways depending on the system complexity and response time requirements. For systems focused on simple calculations and repetitive control, it can be configured based on a small microcontroller (MCU) or an embedded board (Raspberry Pi, Arduino, etc.), and for complex systems requiring high-speed processing and multi-task management, an industrial PLC (Programmable Logic Controller) or a dedicated SoC (System on Chip) can be adopted. If more sophisticated data flow control and remote management functions are required, a server-based software control module controls all modules centrally and interacts with each sub-device through communication protocols such as RESTful API or MQTT.

[0118] In addition, the control unit (1090) incorporates a log recording system and a real-time status monitoring function to visually debug the entire process flow or to allow a manager or user to check the status of a specific step in real time. This function is particularly useful for rapid cause analysis and process recovery execution in the event of a manufacturing error.

[0119] The control unit (1090) goes beyond simple hardware execution commands and connects all components within the system, and operates as the logical central axis of the entire ballet shoe production system (1000), including process flow, exception handling, real-time sensor response, and adaptive control based on user input, thereby enabling stable production of high-performance ballet shoes tailored to the user.

[0120] [Display section (1100)]

[0121] The display unit (1100) performs the function of visually outputting information such as foot shape scan results, mesh structure, elastic structure design, correction history, and manufacturing progress status to intuitively provide it to users and administrators. It is configured in the form of a touchscreen-based GUI or a monitor-based dashboard, and an interface is provided to allow direct operation of real-time feedback input, design modification, and virtual wear simulation. In addition, elasticity value distribution maps, pressure response maps, and visual representations of toe restoration structures are output in the form of 3D models or color maps, and administrators can judge manufacturing quality or decide whether to make corrections based on this. In particular, the display unit (1100) plays a role in transparently explaining user-customized designs and reflecting feedback, and acts as one of the factors determining the quality of the user experience.

[0122] The ballet shoe production system (1000) can be linked with a wired / wireless communication network (1110), a smartphone (1120) (1120), a remote PC (1130), etc. for real-time data exchange and remote control between the user and the system.

[0123] The wired / wireless communication network (1110) is a basic infrastructure for transmitting and receiving data between the system and external devices, and reliably transmits design data, fitting results, and manufacturing instruction information through a local network or the internet. Wired LAN or wireless Wi-Fi, Bluetooth, LTE / 5G communication methods are applied, enabling real-time synchronization and remote control between systems.

[0124] The smartphone (1120) (1120) is used as part of the user interface to perform tasks such as booking foot scans, checking fitting schedules, checking the production status of ballet shoes, and inputting wearing feedback. Additionally, it is linked with a cloud server to check the user's design history or feedback data and performs the role of transmitting it to the system.

[0125] The remote PC (1130) is used as a management terminal that allows an administrator to access the system to modify design files, issue correction instructions, and monitor the progress status of each process step in real time. It is suitable for processing high-capacity CAD files, reviewing simulation results, comparing multi-user data, etc., and enables centralized control of the overall operational status of the system.

[0126] FIG. 7 discloses a flowchart for implementing a method of making customized ballet shoes based on the ballet shoe making system (1000) according to the present invention illustrated in FIG. 1.

[0127] Although the following description focuses on the method of producing custom ballet shoes, the description of the components at each stage will be described in a way that avoids duplication with the ballet shoe production system (1000), and the function of the ballet shoe production system (1000) will be described while describing the method of producing custom ballet shoes rather than the ballet shoe production system (1000).

[0128] Referring to FIG. 7, a flowchart is illustrated for providing ballet shoes optimized for the wearer's foot structure by scanning the user's foot in three dimensions (3D), converting the scanned data into a mesh form as shown in FIG. 3 to analyze the spacing of each part of the foot, and applying appropriate elasticity to each part according to the analyzed spacing information. The method for making customized ballet shoes according to the present invention is implemented by including the following steps.

[0129] (s01) Foot shape scanning step :

[0130] This is a step for securing basic data to produce custom ballet shoes based on the user's actual foot, which involves precisely capturing the shape of the user's entire foot using a three-dimensional (3D) scanning device. In this step, the external shape of various parts of the foot, such as the toes, instep, ball of the foot, sole, and heel, is collected as high-resolution three-dimensional images. By capturing multi-angle information that includes not only the front but also the side and back, it is possible to accurately reflect the overall curvature, protrusions, and height differences of the foot.

[0131] The scanning method may adopt at least one of various technologies, such as structured light, laser, and photogrammetry, and the scan results are stored as 3D shape data in digital format. This data is subsequently used as input for mesh conversion and analysis processes and serves as the basis for precise ballet shoe design that reflects the user's individual foot structure.

[0132] (s02) Mesh transformation step :

[0133] This is a step of converting the 3D shape data obtained in the above foot shape scanning step into a mesh structure that can be processed by a computer. The scan data is generally composed of a continuous curved surface or a point cloud, and in this step, the foot shape is converted into a digitized three-dimensional model by dividing it into a polyhedral grid structure consisting of polygonal patterns such as triangles or squares.

[0134] The mesh structure generated in this process represents the shape of the user's foot as a grid or grid at regular intervals, and allows for the numerical representation of the location of each point, surface curvature, and concave and convex shapes. The converted mesh can be saved in formats such as STL, OBJ, and PLY, and the resolution (polygon density) can be adjusted according to the purpose of analysis.

[0135] The transformed mesh data is divided into major regions, such as the toes, ball of the foot, instep, and heel, based on anatomical criteria for the subsequent analysis step. This division process is performed to distinguish major regions, such as the instep, toes, ball of the foot, and heel, on the mesh based on the anatomical structure of the user's foot. Criteria utilized for division include the distribution of spatial coordinates, abrupt changes in surface curvature, differences in contour density, and changes in surface elevation and tangential direction. For example, at the boundary where the instep and ball of the foot meet, abrupt changes in curvature or a narrowing of mesh spacing occur, and these characteristics serve as criteria for the division algorithm to compartmentalize the region.

[0136] Segmentation can be performed automatically based on predefined anatomical reference points and the spatial characteristics of the corresponding mesh. In the automatic segmentation method, anatomical reference data such as the total length and width of the foot, toe positions, and the protrusion position of the malleolus are pre-input into the algorithm. By analyzing the mesh's coordinate values ​​and changes in curvature according to these criteria, each region is mechanically identified and boundaries are established. In this process, points where curvature changes abruptly or contours converge are considered boundaries, and machine learning-based classification models or rule-based clustering algorithms may be used.

[0137] Meanwhile, in cases where accurate segmentation is difficult with automatic analysis alone, a semi-automatic method may be used in parallel, in which the user directly views the 3D mesh model on the screen to specify reference points or manually adjust boundaries. In this case, the user can set the segmentation area by clicking or dragging the mouse, or check and correct the segmentation boundaries suggested by the system, thereby allowing for a more precise reflection of the structural characteristics of each dancer's foot.

[0138] Ultimately, each part is partitioned into independent identification areas on the mesh, allowing elastic values ​​to be analyzed and applied for each part in a subsequent step.

[0139] (s03) Mesh alignment step :

[0140] After converting the scanned foot shape data into a mesh structure, the step involves correcting alignment errors or poor connections between the polygonal grids to reconstruct it into a consistent 3D shape.

[0141] To resolve issues such as positional inconsistencies between multiple frames, discontinuities in boundary surfaces, and duplicate points that may occur during the scanning process, an alignment algorithm is applied based on the boundary lines, vertex coordinates, and face orientations of each polygonal element. In this step, correction is performed to ensure that even if the same area is duplicated or misaligned across multiple scan images, it is aligned into a single integrated mesh form.

[0142] The alignment process is generally performed automatically using point cloud alignment techniques (e.g., ICP, RANSAC, etc.), and ultimately, mesh data with a uniform and continuous grid structure is generated.

[0143] (s04) Noise removal step :

[0144] This is a step to improve data quality by removing unnecessary noise or error points included in the mesh data.

[0145] Due to various external factors such as the illuminance and reflectance of the scanning environment, as well as the resolution and sensitivity of the sensor, the acquired 3D mesh data may contain abnormal elements that do not accurately reflect the shape of the foot. For example, if the lighting is excessively strong or weak, the surface of the scanned area may be perceived as excessively bright or dark, resulting in missing or incorrectly connected point clouds. Additionally, if the sensor fails to properly detect parts of the foot surface due to changes in reflectance, the mesh may be generated with protrusions that differ from the actual shape.

[0146] In addition, if the scanned subject moved or the posture was inconsistent, point data of specific parts may overlap or twist and be represented as a distorted shape, which may result in unrealistic gaps, abnormal overlap between meshes, or unnecessary external protrusions (spikes) on the outside of the foot.

[0147] In the noise removal stage, various quantitative criteria are utilized to automatically detect and remove anomalies or irregular shapes present in the scanned 3D mesh data. First, statistical-based anomaly detection techniques can be applied; for example, in the average distance-based method, the average distance formed by each point or vertex with adjacent points is calculated, and points where this value deviates significantly from statistical criteria are considered anomalies. In the neighbor density-based method, if a specific point has fewer neighbors than the minimum number required to be maintained within a certain radius, that point is identified as external noise and treated as a target for removal.

[0148] In addition, by analyzing the local continuity and curvature gradient of the mesh, it is possible to automatically detect areas where abrupt changes in direction or discontinuities occur in the natural surface flow. For example, if the curvature of a surface changes abruptly compared to adjacent faces, or if the direction of normal vectors between polygons is abnormally bent, the face may be considered to be distorted by external noise or scan errors. By combining these criteria, the algorithm automatically detects spike-shaped protrusions, holes, non-manifold faces, etc., and designates them as areas to be removed.

[0149] After the abnormal regions are removed in this manner, gaps or defects on the mesh can be processed in one or a combination of two ways: interpolation and remeshing.

[0150] Interpolation is a method that collects geometric information from adjacent polygonal faces of a missing area and uses this information to smoothly connect the missing area. The information utilized includes the gradient, curvature, and normal vector direction of adjacent faces; through this, new vertices and faces of the missing area are generated while maintaining the continuous flow of the existing surface. Interpolation prioritizes the smooth connection of surfaces and is suitable for cases where surface smoothness or visual consistency must be maintained.

[0151] The reconstruction method is a procedure that generates a new mesh structure for missing regions. Rather than simply extending or connecting existing faces, it involves completely redesigning the area to fill it with polygonal cells. This method is used when more structurally precise processing than interpolation is required and is advantageous for ensuring topological continuity and geometric stability when the mesh topology is incomplete or non-manifold. The reconstructed faces are connected to the surrounding mesh and adjusted to maintain the geometric consistency of the overall structure.

[0152] These two methods are applied selectively depending on the degree of data damage, the size of the missing area, and the structural characteristics of the surrounding mesh; in some cases, interpolation and reconstruction are applied together to achieve a more natural and continuous mesh restoration.

[0153] Mesh data refined through this process can more accurately reflect the actual foot structure of users and is utilized as a reliable input for subsequent elastic analysis and structural design stages.

[0154] Generally, filtering algorithms (e.g., Gaussian smoothing, Laplacian filter, statistical outlier removal, etc.) are applied to remove unnecessary elements while maintaining the continuity and smoothness of the data, and manual correction may also be performed if necessary.

[0155] Figure 2 shows the final result of converting the 3D shape data obtained in the foot shape scanning step into a 3D mesh structure through mesh matching and noise removal.

[0156] (s05) Part division step :

[0157] This step involves identifying key areas based on the anatomical structure of the foot using refined mesh data and dividing them into regions. In this stage, geometric features such as mesh coordinate information, curvature variations, surface density distribution, and surface contours are utilized to classify the entire mesh into the toes, ball of the foot, instep, sole, and heel.

[0158] Specifically, due to the anatomical formation of a joint between the toes and the ball of the foot, the mesh exhibits a characteristic of abrupt changes in curvature. This change in curvature is represented by sections where the tangent direction of the mesh surface changes rapidly, or by points where normal vectors between adjacent faces form large angles. Therefore, this region serves as a primary criterion for automatic boundary determination during region segmentation.

[0159] Furthermore, the instep and sole exhibit a distinct difference in height (z-axis coordinate value) and possess opposing characteristics in the overall orientation of their curves. While the instep is convex upward, the sole is concave downward; consequently, distinct boundaries appear in these areas due to differences in consistency regarding gradients and surface direction, as well as changes in curvature.

[0160] The ballet shoe manufacturing system (1000) according to the present invention automatically estimates the boundary lines of each part by analyzing geometric differences, coordinate distribution, rate of change of curvature, surface density, etc. The estimated boundary lines allow mesh data to be divided according to certain criteria so that each part can be distinguished by an independent label or identification ID.

[0161] Meanwhile, if the automatic segmentation algorithm fails to accurately identify complex foot structures or non-standard shapes, a semi-automatic correction method may be used in conjunction, allowing the user to manually specify reference points on the mesh model screen or directly adjust incorrect boundaries. In this case, the user sets segmentation criteria by clicking or dragging points such as the toe reference point, ankle position, or maximum width of the ball of the foot, and the system performs more precise segmentation by reflecting these settings.

[0162] Finally, each part is stored with an independent ID or label assigned, and is utilized as a unit area for physical property analysis and elastic design in subsequent stages.

[0163] (s06) Mesh Spacing Analysis Step :

[0164] This is a step of identifying the physical characteristics of a specific area by analyzing the spacing and density (distribution) of points or surfaces constituting the mesh for each segmented foot area.

[0165] In the mesh spacing analysis step, the physical characteristics of each part can be quantitatively identified by analyzing the spatial spacing and structural density between the triangular or square cells constituting the mesh. Specifically, the spatial characteristics and load distribution characteristics of the corresponding part are inferred by calculating the average distance between the centroids of each cell, the cell area distribution, the angular difference formed at the boundary lines between adjacent cells, and the alignment direction of the cells.

[0166] For example, the forefoot and hindfoot regions of the sole, where weight is particularly concentrated, generally tend to exhibit narrow mesh spacing and high cell density. In these areas, the surface is subtly pressed or compressed during scanning, causing the mesh to form more densely, which suggests that the corresponding area is subjected to heavy load. Conversely, areas subjected to relatively less load, such as the instep or the upper surface of the toes, have wider mesh cell spacing and gentler changes in inclination between cells, resulting in a smooth, continuous curve.

[0167] This analysis can be performed based not only on the distance between cells but also on quantitative figures such as the variance between cell centers, the standard deviation relative to the average cell area, and local curvature, thereby enabling the evaluation of pressure concentration, elasticity requirements, and the need for support structures in each area.

[0168] Consequently, the spacing and density information obtained at this stage is utilized as reference values ​​for the subsequent elasticity value calculation and structural design stages, and serves as a design guideline for realizing functional ballet shoes specialized for the user's feet.

[0169] The analysis results from the mesh spacing analysis stage are utilized as reference values ​​for calculating elasticity values ​​and structural design in subsequent stages, and provide foundational data for the production of customized ballet shoes that reflect the user's foot structure and load distribution characteristics.

[0170] (s07) Elasticity value calculation step :

[0171] The elasticity value calculation step is a step in which the elastic characteristics required by a specific part are quantified and determined based on data such as mesh spacing, cell density, and curvature changes for each part derived from the preceding mesh spacing analysis step.

[0172] In this stage, various indicators obtained through the preceding analysis—such as mesh spacing, curvature distribution, cell density, and slope variations for each foot area—are comprehensively considered to calculate appropriate elasticity values ​​based on the physical characteristics required for each part. The elasticity values ​​calculated are derived as numerical values ​​that comprehensively reflect the magnitude of the load the area must support, the frequency of repetitive compression and expansion during movement, the degree of shock absorption, as well as the user's body weight and exercise intensity.

[0173] In particular, the forefoot and hindfoot, where loads are concentrated, possess structural characteristics in which a significant portion of body weight is transferred during gait or pointe movements. Mesh analysis reveals that these areas tend to exhibit narrow intercellular spacing, high surface density, and abrupt gradients compared to the surroundings. These characteristics indicate a functional requirement for these regions to withstand heavy loads while simultaneously absorbing shock and recovering rapidly. Accordingly, materials with a high modulus of elasticity (e.g., high-elasticity TPE, EVA, PU, ​​etc.) are required for these areas, and structural designs with excellent rebound elasticity and recovery rate can be applied.

[0174] On the other hand, areas subjected to relatively less external pressure, such as the instep or the upper surface of the toes, feature a shape with wide mesh spacing and a gradually changing curvature, suggesting that these areas require greater emphasis on flexible movement, lightweight design, and breathability rather than support. Soft materials with low compression resistance are suitable for these areas, and the elastic design is also focused on ensuring comfort and flexibility rather than shock absorption.

[0175] The elastic values ​​that can be applied to reflect the functional requirements of each of these parts are as listed in [Table 1] below.

[0176] region function Required characteristics Applied elasticity value (Shore A hardness) Applicable elastic modulus (N / mm²) forefoot Weight concentration, rebound force High elasticity, durability 50-70 Shore A 1.5-3.0 N / mm² heel (hindfoot) Shock absorption Resilience, shock absorption 40-60 Shore A 1.0-2.0 N / mm² midfoot Arch support Medium strength elasticity 35-55 Shore A 0.8-1.5 N / mm² instep of a foot Flexibility, breathability Low elasticity, softness 20-40 Shore A 0.3-0.7 N / mm² Upper side of the toe Accepting movement Very low elasticity 15-35 Shore A 0.2-0.5 N / mm²

[0178] The elasticity value applied in this invention can be expressed in various quantitative indicators, such as the required compressive repulsion force per specific unit area (N / mm²), the Shore hardness value of the material, tensile strength, or the recovery rate over time, and is ultimately calculated to satisfy both functionality and user experience in a balanced manner for each part.

[0179] The elasticity value can be expressed in physical units (such as N / mm² or Shore hardness), and if necessary, it may be automatically calculated based on a formula by referencing computer simulations or human biomechanical data, or calculated by referring to a predefined standard table. This calculated result is utilized as an input value for the elastic structure design in the next stage, the elastic application design stage.

[0180] (s08) Elasticity Application Design Phase :

[0181] The elastic application design step is a step of specifically designing the most suitable elastic structure for each part of the ballet shoe based on the elastic values ​​for each part calculated in the above step (s07). This design process is performed to satisfy the elastic strength, response characteristics, and durability required by each part based on the calculated numerical data, and serves to convert quantified material property information into a structure that can be actually applied.

[0182] Design criteria include various factors that determine the physical properties of the elastic structure to be applied to the foot. Specifically, these include the type of elastic material to be applied (e.g., EVA, TPE, PU, ​​silicone, etc.), the thickness of the material (in mm), the shape or cross-sectional structure (e.g., flat, grid, porous), the material arrangement density (number of elastic inserts per unit area or spacing), and the arrangement direction (alignment direction considering the direction of force or flow of movement). These factors are combined and designed based on the user's foot anatomical structure, body weight, body type, gait habits, and ballet movement characteristics.

[0183] For example, since the forefoot area of ​​the sole is subjected to repeated strong loads and impacts during jump landings or pointe movements, a high-elasticity material (e.g., PU foam or TPE blend material) with excellent shock absorption and rebound elasticity can be selected for this area and applied with a sufficient thickness of about 10 to 15 mm. In addition, considering the contact area with the ground, a hexagonal or porous cell structure may be formed internally to maximize pressure distribution, or a unidirectionally arranged grid pattern may be introduced to reinforce rebound force.

[0184] On the other hand, since the heel (rearfoot) serves as the primary point of shock absorption for the ground and needs to reduce vibration and alleviate fatigue, a multi-layer structure emphasizing shock reduction functionality can be designed in this area. For example, a two- or three-layer laminated structure can be formed by placing a medium-elastic material on the upper side to soften contact with the sole of the foot, and adding a high-elastic layer on the lower side to effectively absorb external shocks. Depending on the case, a gel-based insert may be included, or a curved structure to disperse shock absorption force may be added.

[0185] This structure is configured to reflect the biomechanical functions that each part must perform and the degree of burden during actual movement, and is optimized based on the elasticity values ​​quantified in step (s07) and the physical property information of the corresponding part. The design data is digitized through a CAD-based modeling environment or simulation tool and linked to subsequent manufacturing processes to be applied to the actual production of ballet shoes.

[0186] The design method can be implemented by utilizing CAD tools or by directly mapping elastic values ​​to physical properties on a mesh, and may also include irregular structural forms tailored to the characteristics of each part (e.g., grid structures, structures containing air layers, etc.). Through such customized design, ballet shoes can be realized as functional products that respond precisely to the user's movement characteristics and load distribution.

[0187] (s09) Elastic material application step :

[0188] The elastic material application step is a step of selecting a material to implement the structure in the actual ballet shoe based on the elastic structure information for each part designed in the above step (s08) and physically applying it.

[0189] In this step, a material that matches the designed shape structure and physical conditions is matched and applied according to the required elastic range for each part as presented in [Table 1] examples of elastic values ​​by part. For example, if Shore A hardness of 20 and an elastic modulus of 2.5 N / mm² are required for the forefoot part in step (s08), a TPE blend or a high-elasticity PU-based material with similar properties is selected and applied to the location.

[0190] The application method can be implemented in various ways depending on the design form and manufacturing process method. For example, in a 3D printing-based direct molding method, an elastomer can be additively manufactured with the same shape as the structure defined in the CAD model, and in the case of using a thermoforming or multi-injection molding method, each elastomer can be implemented by injection molding or compression molding according to a specified mold.

[0191] In addition, depending on the structural design, it is possible to insert the elastic material to a certain depth, laminate it on a base layer, or integrate it into the inner lining structure of the ballet shoe. Representative examples of implementation include absorbent pads, grid-type cushioning layers, gel cushions, and air pockets, and each element is positioned to correspond to its designed location and shape.

[0192] In addition, as one of the methods for implementing an elastic structure, a woven structure in which the weft (810) and warp (820) intersect as shown in FIG. 8 can be applied. This method applies the basic compositional principles of a fabric to the inside or outside of a ballet shoe, and by forming at least one of the weft (810, horizontal thread) and warp (820, vertical thread) with an elastic material, flexibility and resilience are imparted to the entire structure.

[0193] In one embodiment, a flexible material such as high-elasticity silicone rubber or TPE is used for the weft (810), and nylon or polyester fibers with stable support are used for the warp (820). By cross-weaving heterogeneous materials in this way, the fibers actively stretch or contract according to the movement of the user's foot, and can induce an elastic response tailored to each part of the foot. This structure has the advantage of ensuring both a snug fit and a rebound sensation when worn, as well as ensuring breathability and durability, by integrating an elastic material into the inner lining or insole layer.

[0194] In another embodiment, by imparting individual elastic properties to each weft (810a, 810b, … 810n) or warp (820a, 820b, … 820n) in a woven structure as shown in FIG. 8, a differentiated elastic response can be achieved for each part. For example, silicone rubber or a TPE elastomer with high rebound elasticity can be applied to the weft (e.g., 810a, … 810d) corresponding to the forefoot area to effectively support the load and provide resilience, while the weft (e.g., 810e, … 810n) corresponding to the instep or toe area can be composed of a material with relatively low elasticity or flexibility to enhance the fit and freedom of movement.

[0195] This method allows for the adjustment of the combination and arrangement of elastic materials at the thread level within the same woven structure, thereby enabling the realization of a precise, customized elastic distribution that dynamically responds to the curvature and movement of the foot according to the arrangement order of fiber cross-sections, the distance between threads, and the direction of stress. Additionally, by setting the cross-sectional shape (e.g., circular, elliptical, ribbon-shaped, etc.) or surface friction coefficient of each weft thread (810) differently, functional responses such as stress absorption, anti-slip, or control of recovery speed for specific areas can be added. This multi-layered structure induces high-level biomechanical responses, particularly in localized areas of the insole (93) or lining, and can significantly improve the overall wearing experience while maintaining breathability and lightness.

[0196] In another embodiment, as shown in FIG. 9, first to third elastic means (94a, 94b, 94c) having different elasticities are sequentially arranged in the front part of the ballet shoe (90). This configuration is intended to provide an elastic structure that responds stepwise according to the magnitude and distribution of the load during movements such as pointe movements, where body weight is concentrated and supported on the toes.

[0197] The first elastic means (94a) is positioned closest to the toes and is formed of a highly elastic material having high compressive strength and rapid recovery force, serving to absorb direct impact on the toes and provide a rebound force. The second elastic means (94b) is located behind it and is composed of a material having a medium elastic modulus, gradually absorbing energy during the transitional phase where the impact is dispersed, thereby alleviating user fatigue and inducing a stable posture change. The third elastic means (94c) is formed of a relatively soft material, maintaining flexibility throughout the entire front part while reducing pressure on the instep and facilitating natural movement.

[0198] This multi-layered structure provides a more precise response to weight transfer than a single elastomer and is advantageous for fine balance control and improved fit. Each elastic element can be realized by applying different material properties (such as EVA, PU, ​​or silicone-based composites) or by adjusting factors such as shore hardness, compression ratio, or thickness within the same material. Each layer of the multi-layered structure can be integrally molded using a lamination method or manufactured in the form of an insertable pad or reinforcement layer, allowing for custom configuration according to the user's foot structure or intended use.

[0199] In another embodiment according to the present invention, precise elasticity control tailored to the functional requirements of each part is possible by adjusting the fiber weaving density, cross angle, elastic yarn arrangement ratio, etc.

[0200] The weaving density of the fiber can control the compressive resistance and support strength of the structure by adjusting the number of yarn crossovers per unit area; higher density ensures higher support and lower elongation, while lower density ensures flexibility and breathability.

[0201] The intersection angle is a factor that can control the elastic response in a specific direction through the geometric arrangement of the intersection point where the weft (810) and warp (820) meet. For example, a 45-degree diagonal intersection structure is advantageous for multi-directional stretching, whereas a vertical and horizontal structure provides excellent support in one direction.

[0202] In addition, rather than distributing the elastic yarns uniformly throughout, the compressive repulsion, recovery force, and flexibility can be precisely adjusted for each section by inserting them at a high localized rate in areas where the load is concentrated or by arranging them repeatedly in a zigzag pattern.

[0203] The elastic material applied in this invention is selected from various rubber elastomers or foam materials such as EVA (Ethylene Vinyl Acetate), TPE (thermoplastic elastomer), PU (polyurethane), and silicone rubber, and, depending on the case, may be configured in the form of a heterogeneous composite structure combining multiple materials or a multi-layer laminated structure. The elastic values ​​and design shapes for each part are converted into a single integrated mapping structure, and processed so that the material type and application location can be automatically linked within the system.

[0204] In addition, according to the present invention In the elastic material application stage As illustrated in FIG. 9, the ballet shoe (90) can be configured to accommodate various internal structures to improve functional performance, and accordingly, a plurality of internal components are included.

[0205] The ballet shoe produced by the ballet shoe manufacturing method according to the present invention features a reinforcing cover (92) or a protective shell applicable together with a toe elastic structure (91). This reinforcing cover (92) is positioned on the inner or outer side of the front part of the ballet shoe to provide a physical protective function so that the toe elastic structure (91) is not damaged by external impact or wear.

[0206] Additionally, the reinforcing cover (92) can be formed into a curved shape considering the bending direction and load application direction of the toe area, and also performs the role of stably maintaining the shape of the elastic structure of the toe and supporting it so that deformation occurs uniformly when compressed. As a material, lightweight reinforced plastic, composite rubber, or compression-molded TPE can be used.

[0207] Meanwhile, the ballet shoe according to the present invention may be configured to include an insole (93) or a customized footbed structure (93). This component (93) is a structure that supports the entire sole of the user's foot, improving comfort and assisting in shock absorption and balance maintenance during ballet movements.

[0208] The insole (93) is generally formed from a foam material (EVA, latex, etc.), a gel cushion, or a woven elastic material, and can be molded to fit the shape of the user's foot as needed or custom-made based on 3D scan data. In particular, it works together with the first to third elastic means (94a, 94b, 94c) to regulate pressure distribution and disperse the response to load.

[0209] Accordingly, the ballet shoe illustrated in FIG. 9, produced by the ballet production method according to the present invention, is configured to provide support and balance restoration optimized for the user's foot structure and ballet movement characteristics through the interaction of the toe elastic structure (91), reinforcing cover (92), and insole (93).

[0210] The applied elastic material does not merely provide physical properties; it repeatedly performs compression and recovery responses in accordance with the load distribution across different body parts during ballet movements, thereby substantially contributing to improved user comfort, balance maintenance, and reduced fatigue.

[0211] Furthermore, ballet shoes with the application of elastic materials represent the preliminary stage of the finished product, where the designed structure and function are realized in actual form; they are subsequently completed in a state where they can be worn directly by the user through processes such as shell finishing, fitting review, or adjustments.

[0212] (s10) Toe elastic structure design stage :

[0213] The toe elastic structure design stage involves designing a roly-poly-like elastic support structure to be applied to the front part of the ballet shoe, taking into account situations where body weight is concentrated on the toes, particularly in ballet movements such as the pointe.

[0214] This structure is designed to control the shift and tilting of the center of gravity that occurs the moment the toes touch the ground, thereby helping the user's posture naturally return to the vertical axis direction without the center axis shifting to one side. In the pointe position, the entire body weight is concentrated on the narrow area of ​​the toes, so even a slight tilt of the toes to the left or right, or forward or backward, can cause the posture to collapse or the center of gravity to waver.

[0215] The elastic structure designed to prevent this must possess a restoring force that allows it to temporarily compress in response to load on the toes and return to its original shape when the load is released; this restoration direction is designed to act toward the vertical axis center. Specifically, the optimal structural form is derived by considering the radius of curvature of the toes, the user's weight distribution range (e.g., forefoot or lateral center point), and the maximum allowable angle of foot tilt during ballet movements.

[0216] For example, hemispherical or domed shapes may be applied to enhance central restoring force; since these provide equal restoring force in all directions when a central load is applied, lateral sway can be minimized. If necessary, an asymmetric elastic hardness distribution may be applied to the lower part of the structure, or an internal sloped structure or rib pattern that guides the direction of restoration may be formed to further enhance restoring stability.

[0217] Additionally, as illustrated in FIG. 10, the toe elastic structure (91) is positioned at a location directly corresponding to the user's toe (102) and is designed to sufficiently cover the area where the toe load is concentrated. FIG. 10(a) is a drawing illustrating the form in which the toe elastic structure (91) is inserted in the direction of the toe, and the structure is formed in a shape that wraps along the front and bottom surfaces of the toe, and is configured so that compression and restoration can occur according to the movement of the user's toe.

[0218] FIG. 10(b) is a front view drawing illustrating a state in which the load of the user's foot (102) acts substantially on the toe elastic structure (91), showing the principle that the entire toe area rests on the center of the structure and that the restoring force of the structure automatically acts in a vertical direction when a deviation of the center of gravity occurs. In particular, as shown in FIG. 10(b), the elastic structure (91) supports the entire underside of the user's toes and is designed to respond with a uniform repulsive force to movements in which the toes tilt or deviate to the side.

[0219] Through this design, the elastic structure itself restores balance even to slight deviations in the center of gravity at the toes when performing pointe movements, helping the user maintain their posture without disruption. The elastic structure can be formed from a single material or designed as a multi-layered structure combining multiple materials, with each layer designed to share roles such as shock absorption, rebound force, and resilience. This structure performs not only the function of absorbing load on the toes but also assisting in posture maintenance.

[0220] Through this design, the elastic structure itself restores balance even with slight deviations in the center of gravity at the toes when performing pointe movements, helping the user maintain their posture without disrupting it.

[0221] The elastic structure may be formed from a single material or designed as a multi-layered structure combining multiple materials, with each layer designed to share roles such as shock absorption, rebound force, and resilience. This structure performs not only to absorb toe load but also assists in maintaining posture.

[0222] (s11) Step of applying elastic structure to the toes:

[0223] The step of applying the elastic toe structure is to physically place the designed roly-poly-shaped elastic support structure inside the front part of the ballet shoe, that is, in the area where the toe is accommodated.

[0224] In this stage, design and placement are carried out to precisely correspond to the shape of the front space inside the ballet shoe, so that the previously designed toe elastic support structure is applied to exactly align with the wearer's center of pressure.

[0225] First, the design coordinates are corrected so that the center point of the elastic body is accurately aligned based on the position and direction where the user's toes touch and the central axis of the pressure distribution. This can be achieved by calculating the center of load on 3D mesh data or by determining the position based on actual pressure data obtained through repeated wear tests.

[0226] The elastic body can be applied as an insert inside the ballet shoe or molded integrally with the ballet shoe.

[0227] In the case of the insert type, the elastic structure is formed through a separate mold and then fixed to the inner front part of the ballet shoe by bonding, press-fitting, or slot joining; at this time, precise machining is required to maintain the degree of adhesion with the inner surface and the positional error within ±1mm.

[0228] When molded as a single integrated structure, the elastic structure is simultaneously molded within the mold along with the outer or inner shell of the ballet shoe, ensuring not only alignment with the center of gravity but also a snug fit at the toes and structural integrity. This method has the advantage of preventing the elastic structure from detaching or deforming even during repetitive pointe movements, and can provide long-lasting retention.

[0229] This precise application enables the resilience to act exactly in the designed direction, and when worn, the elastic structure operates to control movement along the center of the toes and maintain postural stability.

[0230] The elastic structure can be formed from highly resilient materials such as EVA, TPE, and silicone, and a special texture may be applied to the bottom of the structure in contact with the ground to enhance anti-slip properties and rebound force. The alignment and joining methods must be carefully considered to ensure that the structure effectively performs the functions of maintaining balance and restoring posture in front of the foot.

[0231] (s12) Production Information Integration Phase :

[0232] The production information integration stage is the step of generating the final digital model for the actual production of ballet shoes by consolidating the data for each component designed in the preceding stages (elasticity values ​​by part, structural shape, material information, etc.) into a single integrated design file.

[0233] In this stage, individually generated data, such as elastic structure design information calculated for each part, material type and property values, application location coordinates, thickness and density distribution information, and toe support structure design information, are integrated in a common coordinate system. In the case of mesh data-based design, an attribute-assigned 3D model (e.g., STL + material map) is formed by combining the mesh and attribute values ​​for each part, and in a CAD or CAE environment, an assembly model with defined parts and property values ​​is completed.

[0234] During the integration process, collision and interlocking checks are performed to ensure there is no interference between the components, and finally, the output is converted into a format that can be processed on actual manufacturing equipment (e.g., STEP, IGES, AMF, etc.).

[0235] The generated final model is configured to include or be linked with process data such as layer-by-layer output, molding sequence information, and material distribution conditions in accordance with actual manufacturing methods such as printing, molding, and sewing in subsequent manufacturing stages.

[0236] (s13) Ballet shoe production stages :

[0237] The ballet shoe production stage is the stage of completing the actual ballet shoe into a physical product form by processing and assembling it based on the final model data generated in the aforementioned production information integration stage.

[0238] The manufacturing method can be implemented in various ways depending on the designed structure and materials used, and, for example, the following methods can be applied in combination:

[0239] - 3D Printing Method: This method involves layer-printing polymer or elastic composite materials using a nozzle or photopolymerization method, enabling the precise realization of complex internal structures and elastic distributions in different regions. In particular, it is suitable for designs containing internal lattice structures, porous structures, or multiple material distributions, and allows for different material or density settings to be applied to specific areas through precise digital control. While the production speed may be relatively slow, it is advantageous for producing customized single parts.

[0240] - Thermoforming: This is a method in which thermoplastic polymer films or sheets, such as EVA or TPU, are heated above a certain temperature to soften them, then pressed against a pre-fabricated mold and molded into a designed shape by applying pressure. It is primarily suitable for exterior structures or simple curved designs and enables high-speed mass production. The detail of the exterior and surface precision are determined by the degree of adhesion to the mold.

[0241] - Compression Molding: This is a molding method in which thermoplastic or thermosetting elastic materials are injected into a fixed mold and then compressed under high temperature and pressure conditions. Since it allows for the realization of multi-layered structures or complex cross-sections in a single process, it is suitable for areas requiring both structural support and shock absorption, such as the soles or internal cushioning layers of ballet shoes. Mold precision and pressure balance significantly influence the molding quality.

[0242] - Overmolding: This is a method of forming a single composite structure by sequentially injecting two or more materials with different elastic values ​​with a time delay. By overlapping and bonding the second material before the first hardens, materials with different functions for different parts are combined into a single structure. For example, it is possible to realize a dual-rigidity structure where the outer layer is rigid and the interior is flexible.

[0243] - Sewing and Assembly Method: This method involves separately manufacturing components such as the outer shell, inner insole (93), and toe elastic structure of the ballet shoe, and then assembling them by sewing, bonding, or fitting. It is similar to traditional ballet shoe manufacturing methods, offers a high degree of freedom in selecting materials for each component, and allows for increased fitting precision through manual work if necessary. In cases involving complex designs, an automatic sewing machine or assembly jig can be utilized.

[0244] During the manufacturing process, positional alignment, material bonding strength, internal structural retention, and finishing precision are inspected; if necessary, manual work can be performed in parallel or customized correction devices can be utilized to enhance the quality of the finished product.

[0245] The final ballet shoes undergo functional verification through fitting tests, durability tests, and evaluations of resilience under repeated compression, after which they are completed in a product state suitable for delivery to the user.

[0246] (s14) Fitting and calibration steps:

[0247] The fitting and adjustment stage involves having the finished ballet shoes worn by an actual user to check the fit and movement response, and to fine-tune the structure or material placement of specific parts if necessary.

[0248] In this stage, information regarding pressure, imbalance, foreign body sensation, and the degree of elastic response after wearing, based on feedback from the user, is collected; in particular, it is checked whether the center of gravity is unstable or if excessive pressure is concentrated on specific areas during pointe or ballet movements.

[0249] Based on the results of the inspection, correction work may be performed, such as finely adjusting the thickness of the elastic material, repositioning the toe support structure, or changing the curvature of the outer seam or insole (93). This process returns to the (s07) elastic value calculation step and sequentially performs the (s14) fitting and correction step to readjust according to feedback, or is performed by a micro-forming method using manual or thermal processing tools, and functions as a final adjustment step to ensure a customized finish for each user.

[0251] Although the present invention has been described with reference to preferred embodiments, those skilled in the art will understand that various modifications and changes can be made to the invention without departing from the spirit and scope of the invention as described in the following claims. Explanation of the symbols

[0252] 1000: Ballet Shoe Production System 1010 : Scan section 1020 : Conversion unit 1021 : Mesh transformation module (1021) 1022 : Mesh alignment module 1023 : Noise Removal Module 1030 : Analysis Department 1031 : Part Division Module 1032 : Interval analysis module (1032) 1033 : Elasticity value calculation module (1033) 1040 : Design Department 1041 : Elastic structure design module (1041) 1042 : Material Application Module 1043 : Toe Restoration Structure Design Module 1044 : Toe Restoration Structure Application Module 1050 : Production Department 1051 : Production Information Integrated Module 1052 : Ballet Shoe Production Module 1053: Fitting and Calibration Module 1060 : Storage unit 1070 : Management Server (1070) 1080 : Communications Department 1090 : Control unit 1100 : Display section 1110 : Wired and wireless communication network 1120 : Smartphone(1120) 1130 : Remote PC 810(810a, 810b, … 810n) : Weft 820(820a, 820b, … 820n) : Warp thread 91: Toe elastic structure 92 : Reinforcement cover 93 : Instructor

Claims

Claim 1 A method for manufacturing custom ballet shoes suitable for a user's foot structure, comprising: a first step of scanning the user's foot to obtain three-dimensional shape data; a second step of aligning the shape data by converting it into a mesh structure; a third step of analyzing the mesh data by dividing the anatomical parts of the foot; a fourth step of calculating elastic values ​​based on the analysis results; a fifth step of designing a toe elastic structure configured to induce restoring force while in contact with all of the user's toes, wherein different elastic values ​​are applied to the weft and warp threads of woven elastic yarns for each part of the ballet shoe based on the calculated elastic values ​​for each part, and an elastic means placed in the front part of the ballet shoe is designed to have a material with higher compressive strength and high elasticity as it approaches the toes, and an elastic structure is placed therein; a sixth step of applying a material corresponding to the designed structure; and a seventh step of integrating the ballet shoe manufacturing information to create a ballet shoe model and manufacturing the ballet shoe. Claim 2 A method for producing ballet shoes according to claim 1, wherein the first step is characterized by multi-dimensionally photographing the shape of the foot using a structured light scanner or photogrammetry-based equipment and acquiring point cloud data. Claim 3 A method for producing ballet shoes according to claim 1, wherein the second step is characterized by performing position alignment between point clouds obtained at multiple viewpoints, removing outliers or abnormal regions, and interpolating or remeshing missing regions. Claim 4 A method for making ballet shoes according to claim 1, wherein the third step is characterized by calculating mesh spacing, cell density, rate of change in curvature, center deviation, etc., based on each part such as the toes, instep, ball of the foot, sole, and heel, and determining the need for physical support or pressure concentration of the corresponding part. Claim 5 A method for making ballet shoes according to claim 1, wherein the fourth step is characterized by calculating an elastic value including at least one of a plurality of parts such as the toes, the instep, the ball of the foot, and the heel. Claim 6 A method for making ballet shoes according to claim 1, further comprising an 8th step of analyzing the ignition pressure, presence or absence of pain, or imbalance in a specific area using feedback data received from a user after the 7th step, and reflecting this in design correction. Claim 7 A method for producing ballet shoes according to claim 6, wherein the data generated in steps 1 through 8 above is stored together with user identification information and is utilized for re-production or automatic design recommendations for the same user or other users with similar conditions. Claim 8 A method for making ballet shoes according to claim 1, wherein the fifth step is characterized by setting the cross-sectional shape of the weft or the surface friction coefficient differently for each part of the ballet shoe according to the elastic value calculated in the fourth step. Claim 9 A method for making ballet shoes according to claim 1, wherein the fifth step is characterized by setting the fiber weaving density, cross angle, or elastic yarn arrangement ratio according to the elastic value calculated in the fourth step. Claim 10 A method for making a ballet shoe according to claim 1, wherein the fifth step is configured such that at least two of the first to third elastic means (94a, 94b, 94c) having different elasticities are sequentially arranged in the front part of the ballet shoe.

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