Custom Shoe Sole Lattice via 3D Fabrication

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Solution Overview

Problem

Current shoe manufacturing methods for sports and outdoor activities are costly for producing small quantities due to the high expense of steel cutting dies and molds, limiting the customization and cost-effectiveness for individualized shoe designs that provide optimal cushioning, shock absorption, and stability.

Innovation Solution

The system digitizes 3D models of feet to create customized shoe soles with structural lattices for enhanced energy absorption, using 3D fabrication and integrating sensors for pressure and movement data, allowing for mass customization and health monitoring.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If steel cutting dies and die-cutting machinery are used to manufacture shoe soles, then large numbers of the same style of tread pattern can be produced cost-effectively, but small quantities of customized shoes become prohibitively expensive

Engineering Contradiction:

Improveproduction volumeVSAvoidmanufacturing cost for small quantities

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent uses 3D scanning to create digital copies of the foot anatomy and uses these digital models as templates for manufacturing customized shoe soles. This copying approach eliminates the need for expensive physical dies and molds for each customization, allowing cost-effective production of small quantities while maintaining high customization levels.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent changes the manufacturing parameters from traditional die-cutting to 3D printing technology. This parameter change enables the system to produce customized shoe soles without requiring expensive steel cutting dies, thereby reducing manufacturing costs for small quantities while maintaining productivity.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If traditional die-cutting methods are used for sole manufacturing, then standardized tread patterns can be efficiently produced, but customization to individual foot anatomy becomes impractical

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidcustomization capability

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The patent introduces dynamic customization capability by using 3D scanning and digital modeling that can adapt to each individual's foot anatomy. The manufacturing process transitions from static, standardized dies to a dynamic system that generates unique sole designs based on scanned foot data, maintaining efficiency through automation while enabling full customization.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent performs preliminary 3D scanning and digital modeling of the foot anatomy before the actual manufacturing process. This preliminary action creates a digital template that guides the 3D printing process, allowing customization to be integrated into the manufacturing workflow rather than added as a separate, time-consuming step.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If 3D fabrication is used to create customized shoe soles with structural lattices, then personalized comfort and energy absorption are achieved, but manufacturing complexity increases

Engineering Contradiction:

Improvecustomization precisionVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical die-cutting and molding systems with 3D printing technology. This substitution simplifies the manufacturing process by using additive manufacturing to directly create complex lattice structures from digital models, eliminating the need for expensive steel dies and complex assembly processes while maintaining high precision customization.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach enables the production of highly functional, customized shoes at a reasonable cost, providing personalized comfort and health monitoring capabilities, including early detection of health issues and timely interventions.

Implementation Method 1

optimizing the structural lattice to maximize energy absorption by the sole

Methodology Applied

Scientific EffectEnergy absorption: Damping

Implementation Method 2

sensors coupled to the sole to detect foot pressure and movement data

Methodology Applied

Scientific EffectPressure detection: Piezoresistive Effect

Data Source

PatentUS12017387B2Systems and methods for mass customization

Publication Date: 2024.06.25 TRAN BAO

AI summary

A method to reproduce an original object includes receiving a 3D model of the original object; forming a reformable master shape from the 3D model by using a computer controlled shape actuator; impressing the reformable master shape into a reformable material to form a custom mold, the reformable material having a material state that is reversible between a solid condition stable force-resisting state and a flowable state by addition of a transition liquid; pouring a material into the custom mold while the reformable material is in the stable force-resisting state and fabricating a copy; adding the transition liquid to the reformable material to change the state of the reformable material from the stable force-resisting state to the flowable state; and reusing the reformable material to form another custom sole once the reformable material is in the flowable state.