Sketching Process
Analyzing modular footwear solutions and mechanism led to sketching possible designs for easy assembly and recycling.
The Aim: an adhesive-free mechanism to connect shoe components for simple replacement.
Take Aways
During the sketching process, I explored a multitude of possible mechanical solutions. From simple traditional mechanisms such as slots, buttons, snap hooks and groves; to more speculative design solutions like UV curing biomaterials and soft robotics. From this process, I came to the conclusion that creating a simple mechanical solution would be most beneficial for the user experience and 3D printed technologies.
Rapid Prototyping
Started turning my sketches into low-fidelity prototypes using cardboard and scrap parts.
CAD Prototyping
After these low-fidelity models, I began 3D modeling in Solidworks, I created an update model from my original sketches, with a primary twisting mechanism located near the toe box (medial plantar). Heel is secured by hooks and groves.
This model was flawed for several reasons. It was very difficult to align the locking mechanism into place without seeing the guide recess.
Back To The Drawing Board
Conducted a second round of sketching and prototyping.
Plug Connections
The solution consists of 22 plugs positioned along the underside of the insole. These plugs create a strong connection and allow for easy application, which is important when considering the user experience. The plugs are pressed into place from the topside of the insole and aligned into a recess in the outsole.
Shoe Last
I discovered a 3D model of a shoe last based on the silhouette of an Adidas Ultraboost and scaled it accordingly to fit the proportions of the foot 3D scans taken from my time at Fleet Feet. The model was then sent to the CNC machine and produced with a high-density foam.
Testing Filaflex Foamy Filament
For the insole cushion of the final model, I chose FilaFlex Foamy Filament for its superior cushioning properties. I conducted compression tests with different print settings to find the best infill density and flow rate, evaluating how these factors affected the material's compressibility and resilience.
