3D Printed Shoe Sole with Independent Cushion Elements
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Solution Overview
Problem
Existing sole structures for athletic footwear often require multiple, separately manufactured parts that are assembled manually, leading to increased manufacturing time, labor costs, and reduced customization options.
Innovation Solution
A sole structure for footwear featuring a midsole shell and cushion elements integrally formed using 3D printing, where the midsole shell defines a cavity to retain independently movable cushion elements, allowing for customizable cushioning characteristics based on wearer preferences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate parts are manually assembled to form the sole structure, then customization options and cushioning characteristics can be adjusted, but manufacturing time and labor costs increase
Solution Approach 1:
The patent merges multiple separate components (midsole shell, cushion elements, outsole) into a single integrally formed structure through 3D printing. The midsole structure is created as one unified piece with all cushion elements embedded during the printing process, eliminating manual assembly steps while maintaining the ability to customize cushioning characteristics through digital design parameters.
Solution Approach 2:
The invention utilizes parameter changes in the 3D printing process to achieve customization. By modifying digital design parameters such as cushion element density, distribution, size, and material properties during the printing process, different cushioning characteristics can be achieved without changing the physical assembly process, thus maintaining productivity while enabling adaptability.
2Adaptability or versatility
If multiple separate parts are manually assembled to form the sole structure, then cushioning characteristics can be customized, but labor costs increase
Solution Approach 1:
The patent combines multiple manufacturing operations into a single 3D printing process. The midsole shell, cushion elements, and their assembly are all created in one continuous printing operation, eliminating the need for separate manufacturing and assembly steps that would require labor, thereby reducing labor costs while maintaining customization capability through digital design.
Solution Approach 2:
The 3D printing process is self-service in nature, where the digital model automatically guides the creation of the entire midsole structure with all its cushioning elements. The system self-assembles the complex internal structure without human intervention during manufacturing, reducing dependence on manual labor while preserving the ability to customize cushioning characteristics through software parameters.
3Adaptability or versatility
If traditional multi-component sole structures are used, then manufacturing flexibility exists, but device complexity increases
Solution Approach 1:
The patent merges multiple components into a single integrated midsole structure printed in one operation. The complex internal arrangement of cushion elements within the midsole shell is created as one unified piece, reducing the number of separate parts and interfaces while maintaining manufacturing flexibility through digital design and rapid prototyping capabilities of 3D printing.
Data Source
AI summary
A sole structure for a shoe and a method of manufacturing the sole structure with additive manufacturing is provided. A midsole structure is integrally formed with a midsole shell having an upper platform and lower platform integrally formed to define a cavity therebetween. A plurality of cushion elements is retained in the cavity. Each of the plurality of cushion elements is movable independently in the cavity. The midsole shell and the cushion elements formed together in a three-dimensional printing process.