Adjustable Footwear Last Structure for Multi-Size Production
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Solution Overview
Problem
The high cost and inefficiency of manufacturing footwear due to the need for multiple lasts for different sizes, especially in large-scale production, customized products, and small runs, as well as the challenges of storing, selling, or recycling used lasts.
Innovation Solution
Development of size-adjustable footwear lasts that can be modified longitudinally and in girth dimension, utilizing interchangeable parts in a portable kit, allowing for fewer physical lasts to be needed and enabling customization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple physical lasts are produced for different shoe sizes, then footwear manufacturing can accommodate all size requirements, but tooling costs and production costs increase significantly
Solution Approach 1:
The last is divided into modular components including interchangeable forefoot parts, heel parts, and adjustment mechanisms that can be reconfigured to create different shoe sizes from a single base last, eliminating the need to manufacture separate lasts for each size
Solution Approach 2:
A single last design serves multiple functions by accommodating various shoe sizes through interchangeable components and adjustment mechanisms, allowing one last to replace multiple size-specific lasts
2Adaptability or versatility
If multiple physical lasts are manufactured for a full size run, then all shoe sizes can be produced, but storage costs and inventory management complexity increase
Solution Approach 1:
The last system uses segmented, interchangeable components that can be assembled in different configurations to produce various shoe sizes, reducing the total number of physical lasts needed from multiple complete lasts to a single base last with interchangeable parts
3Adaptability or versatility
If traditional lasts are used for customized footwear, then specific size requirements can be met, but production efficiency decreases and costs increase
Solution Approach 1:
The last incorporates dynamic adjustment mechanisms and interchangeable components that can be quickly reconfigured to match custom foot measurements, enabling efficient production of customized footwear without requiring specialized tooling or time-consuming processes
Data Source
AI summary
Footwear lasts have size adjustment capabilities. As some more specific examples, footwear lasts may be adjustable in the longitudinal direction and/or in the girth dimension. In this manner, fewer physical lasts may be needed for making a full size run of footwear products. Additionally or alternatively, aspects of this adjustable last technology may be used for making customized footwear products, for making small runs of footwear products, and/or for adjusting sizes of existing footwear products.