Main Project Aesthetics: Plans and Alternatives

Hello everyone, I am designing a 3D printed shoe for performance running. My goal is to be able to print all of the components of the shoe, with the exception of the insole, laces, and outsole, which are all generally easy to acquire or make. I am a runner, and the running shoe industry typically has prices that are through the roof for shoes that do not last very long, and are not easily recycled due to the foam used.

For the midsole, I am going to design a silhouette of a performance shoe’s midsole, based on a current popular running shoe model. I will then submit it to the Idea Forge for fabrication. I will request a gyroid infill for slicing, and the number of shells will depend on the aesthetic that I aim for.

I plan to use a TPU filament for the midsole due to its natural rebound abilities, and the infill is something that I will have to test before printing the full part. Some elite shoes have a durometer rating of about C32, which converts to A66, so I can use a durometer to test the viability of my print as a surrogate foam.

In the event that the midsole fails, I will have to do some intense research on the best possible material and infill pattern, and make decisions on how to proceed from there. The midsole is really the primary innovation of this design, and so it is the one I am really counting on to work well.

For the upper, I plan to print a thin mesh designed as a flattened geometry, with increased support in high impact and corrosion places. This is generally better than a print that is already in a shoe’s geometry because  I will also include on this geometry an extra tab to use adhesive or sew to attach the upper to the rest of the shoe. Failure of the upper is less concerning to me than a failure in the midsole. If I am unable to get the correct geometry of the shoe’s upper, I can use one of my running shoes, take of the midsole, and utilize that shoe’s upper on my new midsole. While this will heavily impact the design aesthetic of the shoe, my primary goal in this project is to make a functional midsole for a performance running shoe.

The goal design aesthetic of this project is a combination of organic and futuristic styles. These will both be achieved in the midsole if all goes to plan. a gyroid infill has a naturalistic appearance, and its presence in the shoe gives a sense of something new, unusual, or futuristic. In the event that the infill does not go as planned, I will have to add shelled walls to the midsole. The upper will also help the futuristic design of the part if it all comes together well. Outside of the appearance alone, 3D printing filament can usually be recycled, or can be composed of recycled material. This is something that would be greatly needed in the shoe industry, which is known for causing inordinate waste by using foam.

Thank you for reading!

Sources:

Saucony Endorphin Pro 3

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