Modular Shoe Last Structure for Reusable Custom Upper Shaping
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Solution Overview
Problem
Existing methods for producing shoes do not effectively address the reuse of lasts after they are no longer used, limiting the ability to customize and reutilize them for different users.
Innovation Solution
A last for shaping a shoe upper is created using an aggregate of joinable and separable blocks, allowing for customization and reassembly, which can be produced by joining blocks together based on user-specific foot shape data and disassembled for reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a last is made as a single integrated structure, then it provides structural integrity and stability, but it cannot be reused for different users and creates waste
Solution Approach 1:
The last is divided into multiple separate blocks that can be individually removed and reconfigured. Each block corresponds to a specific portion of the last ( toe, vamp, quarter, heel ), allowing the blocks to be separated, stored, and reused for different shoe sizes and styles, thereby achieving reusability while maintaining structural integrity when assembled
2Adaptability or versatility
If a last is customized for each user, then it provides perfect fit and comfort, but it cannot be reused and increases storage requirements
Solution Approach 1:
By segmenting the last into standardized blocks, the system enables customization through different combinations of the same set of blocks rather than creating entirely new lasts for each user. The blocks can be stored in a compact manner and reconfigured as needed, reducing storage space requirements while maintaining customization capability
Solution Approach 2:
The same set of blocks serves multiple functions by being reconfigured for different users, shoe sizes, and styles. Each block can be used in various positions and combinations, making the block set universally applicable rather than dedicated to a single custom last
3Ease of manufacture
If lasts are discarded after use, then production is simple and straightforward, but material waste increases and sustainability is reduced
Solution Approach 1:
Instead of discarding the entire last after use, the invention recovers the individual blocks by separating them from the used last structure. The blocks are then cleaned, inspected, and reused for creating new lasts for different users, thereby reducing material waste while maintaining ease of manufacture through a straightforward block separation and reuse process
Data Source
AI summary
A last is provided for shaping a shoe upper, such as a custom-made last tailored to a user's foot. Embodiments include a last for shaping a shoe upper including at least an outer peripheral portion comprising an aggregate of a plurality of blocks, the plurality of blocks being joinable together to form a portion of the last and shape the shoe upper, and separable from each other after being joined together. The plurality of blocks includes a first plurality of blocks which are identical to each other. Embodiments also include a method for producing a last for shaping a shoe upper, the method including forming the last by joining a plurality of blocks together to form an aggregate, the plurality of blocks including a first plurality of blocks which are identical to each other.