3D-Printed Footwear Structure With Integrated Cushioning and Support

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Solution Overview

Problem

Existing footwear fails to effectively integrate cushioning and support, leading to increased soreness and fatigue during everyday activities due to inadequate impact force management.

Innovation Solution

The sole and upper portions of footwear are integrally formed as a single piece using additive manufacturing, incorporating a midsole with interconnected unit cells, outer and inner skins, and a core structure with struts to provide seamless integration of structural and aesthetic features.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional footwear construction methods are used with separate upper and sole portions, then manufacturing flexibility and material selection are improved, but integration of cushioning and support functions deteriorates

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidintegration of cushioning and support functions

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent merges the upper portion and sole portion into a single integrally formed footwear article through additive manufacturing. This integration ensures that cushioning and support functions are seamlessly combined without relying on separate components, directly resolving the contradiction between manufacturing flexibility and functional integration.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single-piece footwear structure performs multiple functions simultaneously - providing cushioning, support, structural integrity, and aesthetic features - all within one integrated component. This multi-functionality eliminates the need for separate upper and sole portions while maintaining manufacturing flexibility through additive manufacturing processes.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If multiple separate components are used to provide cushioning and support, then material selection and customization are improved, but structural complexity and assembly requirements deteriorate

Engineering Contradiction:

Improvematerial selection and customizationVSAvoidstructural complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines multiple functional components (upper, sole, cushioning elements, support structures) into a single integrated article. This merging reduces structural complexity and eliminates assembly requirements while maintaining the adaptability to select different materials and customize designs through additive manufacturing parameters.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The additive manufacturing process allows customization of material properties, structural parameters, and geometric features through digital model adjustments. This enables material selection and customization without increasing structural complexity, as all features are defined by manufacturing parameters rather than separate physical components.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If traditional assembly methods are used to construct footwear, then manufacturing flexibility and material variety are improved, but production time and labor requirements deteriorate

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidproduction time

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The complete footwear structure is designed and manufactured in its final integrated form during the additive manufacturing process, eliminating subsequent assembly steps. This preliminary action of creating the complete structure in one operation directly reduces production time and labor requirements while maintaining manufacturing flexibility.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

By merging all footwear components into a single article manufactured through additive manufacturing, the patent eliminates multiple assembly operations. This integration significantly reduces production time and labor requirements compared to traditional methods of assembling separate upper and sole portions.

Inventive Principle:

Principle #5Merging (Combining)

4Adaptability or versatility

If separate upper and sole portions are used, then aesthetic customization and design freedom are improved, but structural integration and durability deteriorate

Engineering Contradiction:

Improveaesthetic customizationVSAvoidstructural integration

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The patent integrates the upper and sole portions into a single structurally unified article while maintaining aesthetic customization capabilities. The additive manufacturing process allows for customized designs and aesthetic features to be incorporated directly into the integrated structure, ensuring both structural integration and design freedom without compromising durability.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS20260020640A1Additively manufactured footwear

Publication Date: 2026.01.22 ADIDAS AG

AI summary

Additively manufactured articles of footwear comprising a sole portion and an upper portion 3D printed as a single piece. In some embodiments, the article of footwear can comprise an outer skin comprising a plurality of continuous beams extending adjacent to each other and defining at least part of an outer contour of the upper portion, at least part of an outer contour of the sole portion, or both. In some embodiments, the article of footwear can comprise an inner skin comprising a network of beams defining at least part of an inner contour of the upper portion. In some embodiments, the article of footwear can comprise a core structure that connects beams of the outer skin to beams of the inner skin.