3D Printed Mesh Midsole for Impact Distribution
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Solution Overview
Problem
Conventional footwear often lacks adequate cushioning and support, leading to discomfort, fatigue, and increased risk of injuries such as blisters, muscle, tendon, and ligament damage, as well as bone stress fractures, due to inadequate distribution of impact forces during daily activities.
Innovation Solution
A three-dimensional mesh sole for footwear is designed with interconnected unit cells and nodes, featuring a unique bottom surface structure that minimizes weight, enhances flexibility, and facilitates attachment of an outsole, utilizing additive manufacturing techniques like continuous liquid interface production to create a customizable and durable midsole.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional footwear materials and structures are used, then manufacturing simplicity is maintained, but cushioning and impact force distribution are inadequate
Solution Approach 1:
The sole is divided into multiple unit cells arranged in a three-dimensional mesh pattern, with each unit cell containing struts and nodes that can independently deform to absorb impact forces. This segmentation allows the sole to provide superior cushioning while maintaining manufacturability through repetitive geometric patterns.
Solution Approach 2:
The sole structure incorporates platforms of varying sizes at different locations to optimize impact force distribution. Larger platforms are positioned in high-impact areas such as the heel region, while smaller platforms are used in lower-impact areas, providing localized cushioning optimization throughout the sole.
2Weight of moving object
If traditional solid midsole construction is used, then structural strength is sufficient, but weight is excessive and flexibility is reduced
Solution Approach 1:
The midsole is constructed as a three-dimensional mesh with interconnected unit cells containing void spaces, creating a porous structure that significantly reduces weight compared to solid construction. Despite the porosity, the strategic arrangement of struts and nodes maintains sufficient structural strength to support the foot and distribute loads.
Solution Approach 2:
The sole combines multiple geometric elements (unit cells, struts, nodes, platforms) into a composite structure that achieves optimal balance between weight and strength. The three-dimensional mesh pattern creates a lightweight framework that nonetheless provides robust mechanical support and impact absorption.
3Stability of the object's composition
If nodes are connected at the bottom surface, then structural stability is improved, but flexibility and outsole attachment are compromised
Solution Approach 1:
The connection between adjacent nodes is selectively removed at the bottom surface, extracting the stabilizing function from that specific location while preserving it in the three-dimensional mesh structure above. This allows the bottom surface to remain flexible for outsole attachment while the overall structure maintains stability through its interconnected unit cells and platforms.
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
The solution provides improved cushioning, support, and traction by distributing impact forces effectively, reducing fatigue and the risk of injuries while allowing for lightweight and customizable footwear with enhanced flexibility and attachment efficiency.
Implementation Method 1
The sole includes a three-dimensional mesh including: a plurality of interconnected unit cells, each interconnected unit cell including a plurality of struts defining a three-dimensional shape and a plurality of nodes at which one or more struts are connected
Implementation Method 2
utilizing additive manufacturing techniques like continuous liquid interface production to create a customizable and durable midsole
Implementation Method 3
each of the plurality of nodes defining the bottom surface includes a platform, the platform including: a top platform surface, a bottom platform surface, a side surface connecting the top platform surface and the bottom platform surface
Data Source
AI summary
Soles for articles of footwear with a three-dimensional mesh having a bottom surface defined at least partially by a plurality of nodes having a platform with a top platform surface connected to a bottom platform surface with a side surface a plurality of struts for the three-dimensional mesh directly connected to the top platform surface. In some embodiments, the side surface of two directly adjacent nodes defining the bottom surface are not connected to each other at the bottom surface. In some embodiments, the bottom platform surface of two or more adjacent nodes can merge to form a continuous integrally formed surface at the bottom surface of the three-dimensional mesh.