Textile Reinforcement Mapping for Custom Shoe Compression
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Solution Overview
Problem
Existing elastomeric textiles in athletic footwear provide uniform compression and spring rates, lacking customization for varying levels of support and resiliency across the foot.
Innovation Solution
A system utilizing cameras and a controller to measure deformation in athletic shoes, generating a strain map, and applying elastomer reinforcements via 3D printing to create customized shoe components with varying spring rates and resilience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If elastomeric textiles are produced in a single uniform layer, then the manufacturing process is simple, but the compression and spring rate are uniform across the entire textile, lacking customization
Solution Approach 1:
The patent applies local quality by creating regions of varying reinforcement within the elastomeric textile. Different areas receive different amounts of reinforcement material (e.g., thermoplastic polyurethane) deposited through additive manufacturing, resulting in localized variations in spring rate and compression characteristics. This allows specific high-wear or high-stress areas to have enhanced properties while other areas maintain the base elastomeric properties.
Solution Approach 2:
The patent combines elastomeric textile base material with reinforcement materials (such as thermoplastic polyurethane) to create a composite structure. The reinforcement materials are deposited in varying quantities and patterns onto the elastomeric substrate, creating a multi-material composite that provides both the elasticity of the elastomer and the structural support of the reinforcement, with customizable spatial distribution.
2Adaptability or versatility
If uniform reinforcement is applied across the textile substrate, then the manufacturing process is simple and fast, but the resulting article provides undifferentiated compression across the foot
Solution Approach 1:
The patent employs dynamic control of the additive manufacturing process to vary reinforcement deposition in real-time across different locations on the textile substrate. The system dynamically adjusts material extrusion rates, head movement speeds, and deposition patterns based on pre-programmed designs or real-time sensor feedback, enabling customized reinforcement patterns without significantly extending manufacturing time through efficient process control.
3Adaptability or versatility
If varying levels of reinforcement are applied to the textile substrate, then customized compression and resilience are achieved, but the additive manufacturing process becomes more complex
Solution Approach 1:
The patent applies preliminary action by pre-programming the reinforcement patterns and parameters before the additive manufacturing process begins. Design software allows users to specify desired compression levels, spring rates, and reinforcement distributions for different areas of the textile substrate. These parameters are stored as digital models that guide the additive manufacturing system, eliminating the need for complex real-time adjustments during manufacturing and reducing operational complexity.
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
Customized shoe components provide tailored compression and resilience, enhancing athletic performance by adapting to individual foot movements.
Implementation Method 1
The additive manufacturing device is configured to apply a reinforcement to a textile substrate to variably reinforce the textile substrate according to the strain map
Implementation Method 2
The elastomeric textiles conform to the athlete's foot. The elastomeric textiles further gently squeeze the athlete's foot to provide support to the foot. When the foot flexes, the elastomeric textiles flex with the foot.
Data Source
AI summary
A system to produce a textile component of an article includes an additive manufacturing device in selective communication with a processor and memory. The processor and memory are configured to determine a strain value in a region of a textile component of a reference article based on images of the reference article from a camera in selective communication with the processor and memory and to generate a strain map based on the strain value. The additive manufacturing device is configured to apply a reinforcement to a textile substrate of a custom article to variably reinforce the textile substrate according to the strain map and to form the textile component of the custom article.