Customized Footwear Arch Support via 3D Scanning and Printing

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Solution Overview

Problem

Standard footwear cannot provide an optimal fit for every individual due to variations in foot anatomy, leading to potential injuries and discomfort, and custom-made shoes are costly and time-consuming.

Innovation Solution

A system that uses a 3D scanner to capture foot dimensions, compares them with pre-determined shoe dimensions, and 3D prints customized arch supports, which are then attached to an insole and inserted into the shoe, allowing for quick customization of footwear in a retail setting.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If custom-made shoes are produced to provide optimal fit for each individual, then footwear fit and support are improved, but manufacturing cost and production time increase significantly

Engineering Contradiction:

Improvefootwear fitVSAvoidproduction time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The shoe customization process is divided into separate segments: standard shoe production and custom arch support fabrication. The arch support is manufactured independently using 3D scanning and printing, then integrated into the standard shoe. This segmentation allows the shoe upper and sole to be produced using efficient standardized processes while only the critical fit portion requires custom manufacturing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The customer's foot is scanned and the arch support design is generated before the shoe assembly is finalized. The 3D model of the foot is created in advance, allowing the arch support to be manufactured while the customer waits in the store, rather than requiring extended lead time for complete shoe customization.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If custom-made shoes are produced to provide optimal fit for each individual, then footwear fit and support are improved, but manufacturing cost increases

Engineering Contradiction:

Improvefootwear fitVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The shoe is segmented into standard components (upper, sole) and custom components (arch support). By separating the customization to only the arch support portion, the majority of the shoe can be produced through efficient standardized manufacturing, reducing overall cost while still providing custom fit benefits.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The arch support uses cost-effective materials and a simplified manufacturing process (3D printing) compared to traditional custom shoe making. The focus is on producing an affordable custom component rather than an expensive complete custom shoe.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Productivity

If standard footwear is produced for mass production, then manufacturing efficiency and cost are improved, but fit and support for individual feet deteriorate

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidfootwear fit

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The arch support provides localized customization to match the specific contours and requirements of the customer's foot anatomy. While the rest of the shoe maintains standard mass-produced quality, the arch support area is precisely tailored to the individual's needs, delivering optimal fit where it matters most.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The system uses automated 3D scanning and computer-generated design to create the arch support configuration based on the customer's foot measurements, reducing manual customization work while maintaining high precision fit.

Inventive Principle:

Principle #25Self-service

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

Enables the creation of customized footwear that provides optimal support and fit without the high cost and wait time associated with custom-made shoes, allowing customers to purchase off-the-shelf shoes that are tailored to their specific foot shape.

Implementation Method 1

scanning a foot of a customer who has selected a shoe for purchase

Methodology Applied

Scientific Effect3D scanning: Photogrammetry

Implementation Method 2

printing the arch support with a 3D printer

Methodology Applied

Scientific Effect3D printing: 3D Printing

Data Source

PatentUS10452054B2Methods and systems for retail customizable footwear components

Publication Date: 2019.10.22 REEBOK INTERNATIONAL LIMITED

AI summary

A method of making an arch support for an article of footwear at a kiosk includes scanning a foot of a customer who has selected a shoe for purchase, determining dimensions of the customer's foot based on the scan, comparing the dimensions of the customer's foot with pre-determined dimensions of a last used to make the selected shoe, defining a shape characterized by the difference between the dimensions of the customer's foot and the dimensions of the last, and printing the arch support with a 3D printer. The arch support has the shape characterized by the difference between the dimensions of the customer's foot and the dimensions of the last.