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RESEARCH ARTICLE

Custom Shoe Sole Design and Modeling Toward 3D

Printing

Ali Zolfagharian , Mohammad Lakhi , Sadegh Ranjbar , Mahdi Bodaghi 4
2
3
1
1 School of Engineering, Deakin University, Geelong, Australia
2 Department of Mechanical Engineering, University of Birjand, Birjand, Iran
3 Department of Mechanical Engineering, Birjand University of Technology, Birjand, Iran
4 Department of Engineering, School of Science and Technology, Nottingham Trent University, Nottingham NG11 8NS, UK

Abstract: This study introduces a design procedure for improving an individual’s footwear comfort with body weight index
and activity requirements by customized three-dimensional (3D)-printed shoe midsole lattice structure. This method guides
the selection of customized 3D-printed fabrications incorporating both physical and geometrical properties that meet user
demands. The analysis of the lattice effects on minimizing the stress on plantar pressure was performed by initially creating
various shoe midsole lattice structures designed. An appropriate common 3D printable material was selected along with
validating its viscoelastic properties using finite element analysis. The lattice structure designs were analyzed under various
loading conditions to investigate the suitability of the method in fabricating a customized 3D-printed shoe midsole based on
the individual’s specifications using a single material with minimum cost, time, and material use.

Keywords: Customization; Shoe; Sole; 3D printing; 4D printing; Viscoelastic, Polyurethane

*Correspondence to: Ali Zolfagharian, School of Engineering, Deakin University, Geelong, Australia; a.zolfagharian@deakin.edu.au
Received: June 1, 2021; Accepted: June 25, 2021; Published Online: July 23, 2021

Citation: Zolfagharian A, Lakhi M, Ranjbar S, et al., 2021, Custom Shoe Sole Design and Modeling Towards 3D Printing. Int J Bioprint,
7(4):396. http://doi.org/10.18063/ijb.v7i4.396

1. Introduction and high productivity needs of individuals in the market.
However, the development of footwear 3D printing
The use of additive manufacturing and three-dimensional is driven by trends in digital production and desire for
(3D) printers is very popular these days [1-3] , and they personalized experience. Considering midsoles, they
have various applications in various industries, including are typically constructed throughout the shoe as a solid
aerospace , automotive , soft robotics , construction , component with the same level of support. The designers
[6]
[7]
[5]
[4]
food printing , and tissue engineering [9,10] . One of these may optimize cushioning properties throughout the
[8]
is the custom manufacturing of products. 3D printing whole shoe by adjusting various sections of a midsole,
opens the way to novel footwear items by integrating new producing better performance footwear. The present study
materials and digital production. At present, the technology shows an approach to improve the efficiency of shoes in
now makes it easier to produce high-performance sports different uses through the optimal geometry design of a
shoes and customized sandals using 3D printed shoe 3D printing material tailoring different purposes.
components. This enables shoe manufacturers to join the Due to unhealthy lifestyle, like high fat diet and
market rapidly by exploring new designs and offering lack of enough exercises due to working from home, a
more personalization options. Despite these benefits, the higher number of people are nowadays prone to various
use of 3D printing in footwear remains limited, as the types of diseases, which lead to obesity, which in turn
technology currently is yet to enable mass customization increases body mass index (BMI). People with high BMI
incorporating high-level nonlinear materials behavior frequently suffers from the problems of foot ulceration
and geometrical designs to accommodate the intensive due to excessive walking or standing for a long time.

© 2021 Zolfagharian, et al. This is an Open Access article distributed under the terms of the Creative Commons Attribution License, permitting distribution
and reproduction in any medium, provided the original work is cited.
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