Abstract. Anatomical insoles and additions have a corrective action on the footwear user. They are intended to reduce and adequately distribute plantar pressure among support points, thus minimising the stress these points can undergo. Such customised components have traditionally been manufactured by subtractive techniques, i.e. by milling a sheet of material. Latest advances in additive manufacturing (AM) techniques and, in particular, the popularisation of 3D printing by fused deposition modelling (FDM), have opened new ways for the production of anatomical insoles. These technologies allow additional functionalities to be added, as for instance the use of materials with antimicrobial properties, or, at a structural level, zonal control in 3D design to increase cushioning capacity. The latter cannot be achieved by traditional manufacturing techniques, in that the inside of the element is not accessible. However, there are no CAD tools available for the design and production of insoles, which are specifically oriented to take advantage of the benefits that AM can bring about. This paper describes a new methodology intended for the functionalisation of anatomical insoles through a systematic approach. On the one hand, internal structures are automatically obtained by parametric design; on the other hand, the 3D geometry of the insole or addition is adequately processed so that it can be printed by FDM, thus circumventing the constraints of this production technique. Industry. 2018Industry. , 95: 38-53. doi:10.1016Industry. /j.compind.2017 Keywords This is a previous version of the article published in Computers in 3D Printing of Functional Anatomical InsolesAbstract. Anatomical insoles and additions have a corrective action on the footwear user. They are intended to reduce and adequately distribute plantar pressure among support points, thus minimising the stress these points can undergo. Such customised components have traditionally been manufactured by subtractive techniques, i.e. by milling a sheet of material. Latest advances in additive manufacturing (AM) techniques and, in particular, the popularisation of 3D printing by fused deposition modelling (FDM), have opened new ways for the production of anatomical insoles. These technologies allow additional functionalities to be added, as for instance the use of materials with antimicrobial properties, or, at a structural level, zonal control in 3D design to increase cushioning capacity. The latter cannot be achieved by traditional manufacturing techniques, in that the inside of the element is not accessible. However, there are no CAD tools available for the design and production of insoles, which are specifically oriented to take advantage of the benefits that AM can bring about. This paper describes a new methodology intended for the functionalisation of anatomical insoles through a systematic approach. On the one hand, internal structures are automatically obtained by parametric design; on the other hand, the 3D geometry of the insole or addition is adeq...
Abstract. Shoe soles are extremely complex to design and manufacture due to their organically shaped but technically precise nature and their manufacturing constraints. Consequently, there is a need for the increased design process flexibility offered by the use of specific CAD methodologies and techniques, to facilitate the work of expert designers and permit effective construction of the three-dimensional elements comprising the complete structure. Recent advances in additive manufacturing systems have extended the possibilities of shoe sole design. These systems can be used to create the final mould and to incorporate dynamic elements that are of particular value in sports footwear. In this article, we present a new methodology for the design and validation of shoe soles. The methodology assists designers in the design concept process and in transfer of the design to manufacturing. The model incorporates both a structural and a functional approach. To this end, a set of specific tools have been developed that can be used to quantify design quality. For example, the model calculates the coefficient of friction, or slip resistance, necessary to comply with international standards concerning safety footwear.Keywords: shoe sole design, additive manufacturing, rapid prototyping, parametric design, shoe slip resistance. Highlights This paper presents a new methodological techniqueto design complex footwear soles. It shows how to specific CAD/CAE tools can improve footwear sole 2D/3D design shorting time and validating final model for manufacturing. It also shows how to additive manufacturing can be used in footwear industry for shoe sole mould production. A full practical case of shoe sole design is presented.
The last is the basic industrial component in footwear manufacturing, from which product development starts. Correct last grading ensures the best fit for the intended group of users of the footwear model to be produced. The size marked on the last should respect the specific intervals defined in the different international sizing systems, like the European, UK, US or Mondopoint systems, which are all described in international standards. New approaches in the field of CAD/CAM have emerged over recent years towards the automation of this process. However, these are partial approaches that neither address the grading process according to the different standards nor consider the various parts of the shoe that are not affected by size increments. This paper presents a new accurate and efficient technique for the automation of the shoe last grading process based on the conjugate gradient method. Through this method, it is possible to obtain a graded shoe last that conforms to the international standards in force relative to shoe sizing and allows for the shoe parts that are not affected by size increments. This technique is based on the target measures of length and perimeter of the last to be graded, and aims to minimise the quadratic difference between these values and those obtained from the graded last. This method has been evaluated through a battery of tests performed on a geometrically heterogeneous group of shoe lasts. The results obtained were accurate and the execution time was fast enough to be used for mass production.Keywords Footwear manufacturing Grading Shoe last Conjugate gradient ISO Standards Highlights This paper presents an accurate and efficient technique for shoe last grading based on the conjugate gradient method. This paper describes a grading algorithm based on the minimisation of the error obtained from comparing measures between shoe lasts. This grading technique conforms to ISO standards relative to sizing systems and allows for footwear parts that are not affected by the grading process. This paper presents a detailed battery of experiments by which the goodness and accuracy of this method were evaluated.
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