3D Printed Footwear Lattice Structures for Customization

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Solution Overview

Problem

Current footwear manufacturing methods involve mass production of uniform components, which limits customization and integration of different properties within a single shoe, resulting in lower quality and reduced user-specific customization options.

Innovation Solution

A method for producing 3D printed shoes using a CAD system connected to a 3D printer, involving the creation of a shoe last model, additive manufacturing design tools, and specific design features such as organic lattices, perforations, and cosmetic features to enhance customization and integration of components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If mass production methods with uniform components are used, then productivity is improved, but customization capability deteriorates

Engineering Contradiction:

Improvemass production efficiencyVSAvoidcustomization capability

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The footwear is divided into multiple components (upper, lower, midsole, outsole, insole) that can be independently designed and manufactured through additive manufacturing, allowing each component to be customized while maintaining efficient production workflows

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the footwear are assigned different properties and materials - for example, varying lattice structures in different areas of the midsole to provide localized cushioning, support, or flexibility characteristics tailored to specific functional requirements

Inventive Principle:

Principle #3Local quality

2Ease of manufacture

If uniform components with standard sizes are used, then ease of manufacture is improved, but integration of different properties deteriorates

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidintegration of different properties

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

Multiple components with different properties (structural support, cushioning, ventilation, cosmetic features) are merged into a single integrated footwear structure through additive manufacturing, allowing diverse functionalities to be combined while maintaining manufacturing efficiency

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The footwear utilizes composite structures combining different materials and properties within single components, such as integrating lattice structures with solid regions, or combining breathable and water-resistant materials in the upper

Inventive Principle:

Principle #40Composite materials

3Productivity

If complex supply chains are used, then productivity is improved, but quality deteriorates

Engineering Contradiction:

Improveproduction outputVSAvoidfootwear quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

Multiple manufacturing operations that would traditionally be performed across different facilities in a complex supply chain are merged into a single additive manufacturing process, enabling precise control over component properties and interfaces while maintaining high production output

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS12232574B23D printed footwear with improved cosmetics, comfort and ventilation

Publication Date: 2025.02.25 AMES MAXWELL G

AI summary

The present invention is directed towards customized 3D printed footwear articles and methods for designing and manufacturing 3D printed footwear having improved cosmetics, comfort and ventilation. The improved footwear articles and methods provide greater integration and/or customization of different components. The method used to manufacture the 3D printed footwear can be conceptualized, prototyped, designed both physically and digitally and then finally designed with specific additive manufacturing processes in mind. Upon completion of printing, the components are cleaned and then in any combination, the components are bonded and coated, or coated and bonded to each other.