Custom Footwear Design via Segmented Pre-Cut Panels
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Solution Overview
Problem
Existing customization systems for footwear lack the ability to apply customized designs to objects with curved surfaces and do not provide sufficient variability in design options, especially when using printers or similar devices, limiting the customization of footwear portions.
Innovation Solution
A method for customizing footwear that involves a graphical interface system allowing customers to design their footwear, which is then printed or stitched onto pre-cut portions, packaged with a lace for self-assembly, enabling customers to create customized articles of footwear with adjustable laces and various design elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional printing methods are used for customization, then flat two-dimensional surfaces can be customized, but curved surfaces of footwear cannot be properly customized
Solution Approach 1:
The footwear upper is divided into multiple pre-cut portions that can be separately customized and then assembled. This segmentation allows each flat portion to be printed independently using traditional printing methods, while the assembled 3D structure achieves coverage of curved surfaces. The patent describes cutting the upper into separate pieces that are later stitched or bonded together to form the complete footwear.
Solution Approach 2:
The solution transitions from two-dimensional printing on flat surfaces to three-dimensional coverage of curved surfaces by using multiple flat panels that assemble into a 3D structure. The pre-cut portions are printed in 2D and then configured in 3D space to conform to the curved geometry of the footwear, effectively adding a dimensional aspect to the customization process.
2Ease of manufacture
If pre-determined designs are used for footwear customization, then manufacturing is simplified, but customer customization options are limited
Solution Approach 1:
The upper portions are pre-cut into standardized segments with predetermined shapes and attachment features, but the graphical designs are applied after cutting based on customer selections. This preliminary structural preparation simplifies manufacturing while allowing post-processing customization of the visual appearance, combining both benefits.
Solution Approach 2:
Different graphical designs, colors, and patterns can be applied to different pre-cut portions of the footwear upper. This allows high customization variability in the visual appearance while maintaining standardized manufacturing processes for the structural components. Each portion can be independently customized without affecting the manufacturing of other portions.
3Productivity
If automated production methods are used, then productivity increases, but customization of individual footwear portions is reduced
Solution Approach 1:
The footwear upper is segmented into multiple pre-cut portions that can be independently produced using automated cutting machines, then separately customized with graphical designs, and finally assembled. This segmentation enables parallel processing of multiple components, maintaining high productivity while allowing individual customization of each portion.
Solution Approach 2:
The standardized pre-cut portions serve multiple functions: they are structural components of the footwear, canvases for graphical customization, and modular units that can be assembled in different configurations. This multi-functionality allows automated production of universal components that can be adapted to various customization requirements.
Data Source
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AI summary
A method of customizing an article of footwear that is configured for self assembly is disclosed. The method includes steps of applying customized designs to pre-cut portions, and packaging the pre-cut portions with a lace and a set of instructions into a kit of parts. The kit of parts can be taken home and assembled by the customer.