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WO2024224341A1 - Formes d'article chaussant, leurs procédés de fabrication et article chaussant fabriqué à l'aide de ceux-ci - Google Patents

Formes d'article chaussant, leurs procédés de fabrication et article chaussant fabriqué à l'aide de ceux-ci Download PDF

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Publication number
WO2024224341A1
WO2024224341A1 PCT/IB2024/054060 IB2024054060W WO2024224341A1 WO 2024224341 A1 WO2024224341 A1 WO 2024224341A1 IB 2024054060 W IB2024054060 W IB 2024054060W WO 2024224341 A1 WO2024224341 A1 WO 2024224341A1
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WO
WIPO (PCT)
Prior art keywords
last
template
footwear
foot
digital model
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/IB2024/054060
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English (en)
Inventor
Christopher John BOADLE
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
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Filing date
Publication date
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Publication of WO2024224341A1 publication Critical patent/WO2024224341A1/fr
Anticipated expiration legal-status Critical
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Classifications

    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43D—MACHINES, TOOLS, EQUIPMENT OR METHODS FOR MANUFACTURING OR REPAIRING FOOTWEAR
    • A43D1/00—Foot or last measuring devices; Measuring devices for shoe parts
    • A43D1/02—Foot-measuring devices
    • A43D1/025—Foot-measuring devices comprising optical means, e.g. mirrors, photo-electric cells, for measuring or inspecting feet
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43D—MACHINES, TOOLS, EQUIPMENT OR METHODS FOR MANUFACTURING OR REPAIRING FOOTWEAR
    • A43D1/00—Foot or last measuring devices; Measuring devices for shoe parts
    • A43D1/02—Foot-measuring devices
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43D—MACHINES, TOOLS, EQUIPMENT OR METHODS FOR MANUFACTURING OR REPAIRING FOOTWEAR
    • A43D1/00—Foot or last measuring devices; Measuring devices for shoe parts
    • A43D1/08—Measuring devices for shoe parts
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43D—MACHINES, TOOLS, EQUIPMENT OR METHODS FOR MANUFACTURING OR REPAIRING FOOTWEAR
    • A43D3/00—Lasts
    • A43D3/02—Lasts for making or repairing shoes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y50/00—Data acquisition or data processing for additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43D—MACHINES, TOOLS, EQUIPMENT OR METHODS FOR MANUFACTURING OR REPAIRING FOOTWEAR
    • A43D2200/00—Machines or methods characterised by special features
    • A43D2200/60—Computer aided manufacture of footwear, e.g. CAD or CAM

Definitions

  • the present technology relates broadly to the field of footwear lasts, methods of manufacturing thereof, and footwear made using the footwear lasts.
  • Traditional footwear manufacture comprises using a physical model, also know as a “last” around which a footwear material is molded to produce the footwear.
  • the footwear is specifically designed to the shape and dimensions of an individual’s feet.
  • the present technology provides a method for creating bespoke footwear lasts using additive 3D printing and template footwear lasts which are reusable.
  • the method is applicable to both 3D digital models of the footwear lasts, as well as the physical lasts.
  • the method comprises comparing 3D digital models of an individual's foot and a template footwear last suitable for the individual to determine volumetric differences at specific points between the foot and the footwear last.
  • a 3D printer is then used to additively print only the specific volumetric areas that are deficient, on a physical model of the template last, thereby creating a bespoke footwear last that fits the individual's foot shape.
  • the 3D printed additive material can then be removed from the physical model of the template last and recycled after use, minimising material waste, and permitting the template footwear last to be re-used for another individual.
  • embodiments of methods and systems of the present technology adapt a pre-existing footwear last (“template model”) by adding material to make the shape tailored to the foot shape of the individual. After the footwear has been made using the template last, the added material can be removed and the template last can be re-used.
  • template model a pre-existing footwear last
  • the added material can be removed and the template last can be re-used.
  • the use of additive 3D printing for creating bespoke footwear last as described herein presents an environmentally-friendly solution by reducing or minimising material waste, recycling 3D printed material, and using energy-efficient manufacturing techniques.
  • Recycling 3D printed material The 3D printed additive material used to create the bespoke footwear lasts can be recycled after use, further reducing or minimising waste.
  • the present technology reduces the costs and time involved in the manufacture of footwear from bespoke footwear lasts. This renders bespoke footwear accessible to many more people, and for many more functionalities such as health-related reasons (plantar fasciitis, flat feet, high arches, arthritis, and diabetic foot) and performance (athletes, military personnel, etc.).
  • the present technology can provide significant benefits in terms of comfort, support, and overall foot health such as by reducing pressure on specific areas of the foot, and correcting biomechanical imbalances.
  • a method of manufacturing a personalized last for an item of footwear for an individual the method executable by a processor of a computer system, the method comprising: obtaining a 3D digital model of a foot of the individual; obtaining a 3D digital model of a template last for the item of footwear; overlaying the 3D digital model of the template last and the 3D digital model of the foot; identifying a region of the 3D digital model of the template last that requires personalization based on the overlayed 3D digital models of the template last and the foot; causing the manufacture of the personalized last by sending instructions to an additive manufacturing apparatus to print an extended portion, according to the identified region, onto a physical model of the template last corresponding to the obtained 3D digital model of the template last.
  • the obtaining the 3D digital model of the template last comprises selecting a given 3D digital model of the template last from a plurality of differently sized template lasts.
  • the selection of the given 3D digital model of the template last from the plurality may be based on a foot size of the user.
  • the selected 3D digital model of the template last may be under-sized.
  • the physical model of the template last is reusable and the extended portion is configured to be removably printed onto the physical model of the template last.
  • the same physical template last can be used multiple times for the same individual with different footwear, or for different individuals.
  • the method further comprises removing the extended portion from the physical model of the template last.
  • the physical model of the template last is thus reusable and can be used multiple times for the same individual or for different individuals.
  • the method further comprises causing a robotic arm to retrieve the physical model of the template last from a library of the plurality of the template lasts.
  • the overlaying comprises aligning the 3D digital model of the template last and the 3D digital model of the foot of the individual according to one or more predetermined anchor points on both of the 3D digital model of the template last and the 3D digital model of the foot.
  • the identifying the region comprises: determining a portion of the 3D digital model of the foot that extends beyond the 3D digital model of the template last when the 3D digital models of the foot and the template last are overlayed.
  • the method further comprises: adjusting the identified region to take into account one or more of: a desired fit of the footwear; a desired comfort of the footwear; a type of the footwear; and user preferences.
  • the method further comprises: adjusting the identified region to smooth a profile of the determined region.
  • the method further comprises: obtaining one or both of the 3D digital model of the template last and the 3D digital model of the foot from a database or from a data capture apparatus for capturing the 3D digital model of the foot.
  • the data capture apparatus may comprise a 3D scanner, a photogrammetry-based scanning system using a camera of a portable device such as a smart phone or a tablet.
  • the method may further comprise scanning the foot using a 3D scanner or importing a previously scanned 3D model of the foot.
  • selecting the 3D digital model of the template last from a plurality of differently sized template lasts may comprise retrieving the 3D digital model of the template last from a database.
  • the identifying the region includes defining the region by: a location relative to the 3D digital model of a template last.
  • causing the manufacture comprises determining a printing location, on the physical model of the template last, for printing the extended portion based on the defined location of the identified region.
  • the method further comprises: obtaining a 3D digital model of an orthotic mold of the footwear, and causing the additive manufacturing apparatus to print, onto the physical model of the template last, the orthotic mold.
  • the method further comprises: causing a post-processing assembly to smooth and/or polish the personalized last.
  • the method comprises smoothing at least a portion of the printed extended portion. This may provide a seamless integration with the physical model of the template last.
  • the method further comprises: causing the application of a surface pattern, a surface texture and/or a surface colour onto the personalized last.
  • the method further comprises: causing a curing of the extended portion.
  • the method further comprises: obtaining input of a material to be used for the extended portion and determining at least one operation parameter of the additive manufacturing apparatus based on the selected material.
  • the material to be used for the extended portion may comprise one or more of a recyclable, biodegradable and eco-friendly material.
  • the method further comprises: causing the manufacture of the footwear based on the manufactured personalized last.
  • the method further comprises receiving user feedback regarding one or more of a fit, comfort and performance of the footwear manufactured from the personalized last, and updating one or more of the region, the extended portion and the personalized last.
  • the user feedback may be used as training data by a machine learning algorithm to improve the fit, comfort and/or performance of the footwear manufactured by the personalized last.
  • the method further comprises causing display of one or more of the overlaid 3D digital model of the template last and the 3D digital model of the foot, the identified region, the extended portion, the personalized last and the item of footwear manufactured from the personalized last.
  • the display may be on a screen.
  • the display may be through a virtual reality device or an augmented reality device.
  • the processor may be further configured to receive user interaction with the displayed image(s). The received user interaction may be used to update any of the overlaid 3D digital model of the template last and the 3D digital model of the foot, the identified region, the extended portion, the personalized last and the item of footwear manufactured from the personalized last.
  • a virtual reality or an augmented reality environment can be used to image and modify a digital twin of any of the overlaid 3D digital model of the template last and the 3D digital model of the foot, the identified region, the extended portion, the personalized last and the item of footwear manufactured from the personalized last.
  • the digital twin may be used to simulate and monitor performance and wear of the footwear and/or user foot biomechanics over time.
  • a system of manufacturing a personalized last for an item of footwear for an individual comprising: an additive manufacturing apparatus; and a processor of a computer system, communicatively coupled to the additive manufacturing apparatus, and configured to execute a method comprising: obtaining a 3D digital model of a template last for the item of footwear; obtaining a 3D digital model of a foot of the individual; overlaying the 3D digital model of the template last and the 3D digital model of the foot; identifying a region of the 3D digital model of a template last that requires personalization based on the overlayed 3D digital models of the template last and the foot; and causing the manufacture of the personalized last by sending instructions to the additive manufacturing apparatus to print onto a physical model of the template last, an extended portion according to the identified region of the 3D digital model of the foot.
  • the obtaining the 3D digital model of the template last comprises selecting from a plurality of 3D digital models of the template last having different sizes, such as based on a foot size of individual.
  • the additive manufacturing apparatus comprises a moveable robotic arm for printing the extended portion.
  • the additive manufacturing apparatus comprises a powder bed fusion apparatus, a photopolymerization apparatus or a material extrusion apparatus.
  • the additive manufacturing apparatus is a 3D printer using fused deposition modeling (FDM), stereolithography (SLA), or selective laser sintering (SLS) technology.
  • FDM fused deposition modeling
  • SLA stereolithography
  • SLS selective laser sintering
  • system further comprises a post-processing assembly for one or more of smoothing the personalized model, polishing the personalized model, applying a surface pattern on the personalized model, applying a surface texture on the personalized model, applying a surface colour on the personalized model.
  • system further comprises the physical last based on the 3D digital model of the template last, and wherein the physical last is made from a material which is one or more of: recycled, recyclable, reusable, durable, and biodegradable.
  • system further comprises a plurality of physical models of the template last, the plurality of physical models of the template last comprising different sizes.
  • system further comprises material for printing the extended portion, the material being one or more of: recycled, recyclable, reusable, and biodegradable.
  • the system further comprises a data capture apparatus for capturing the 3D digital model of the foot.
  • the data capture apparatus may comprise a 3D scanner or a photogrammetry-based scanning system using a smartphone or tablet camera.
  • the system further comprises a fabrication unit housing the additive manufacturing apparatus which is communicatively coupled to the processor.
  • the fabrication unit may comprise a portable micro-factory creating a localized supply chain sourcing materials and components from local suppliers.
  • the system further comprises a recycling system.
  • the recycling system may comprise a storage unit for one or more of: removed extended portions, template lasts and footwear.
  • the system further comprises a quality control module configured to monitor the template lasts, the personalized models and the footwear produced therefrom and to identify any defects or anomalies.
  • the system further comprises a virtual reality device or an augmented reality device communicatively coupled to the processor.
  • the virtual reality device and/or the augmented reality device may be configured to display one or all of a digital twin of the personalized template last, the overlayed 3D digital model of the food and the 3D digital model of the template last, and the item of footwear manufactured therefrom.
  • a system of manufacturing a personalized last for an item of footwear for an individual comprising: a processor of a computer system configured to determine an extended portion for adapting a template last of the footwear to make it personalized to a foot of the individual; an additive manufacturing apparatus, communicatively coupled to the processor, for printing the determined extended portion onto the template last of the footwear to generate the personalized model.
  • the additive manufacturing apparatus comprises a moveable robotic arm for printing the extended portion.
  • system further comprises a data capture apparatus for capturing a 3D digital model of the foot and providing it to the processor.
  • a method of generating a personalized last for an item of footwear for an individual the method executable by a processor of a computer system, the method comprising: obtaining a 3D digital model of a template last for the item of footwear; obtaining a 3D digital model of a foot of the individual; overlaying the 3D digital model of the template last and the 3D digital model of the foot; identifying a region of the 3D digital model of the foot that extends beyond the 3D digital model of the template last; incorporating the identified region onto the 3D digital model of a template last, and determining the 3D digital model of the template last with the identified region incorporated thereon as a 3D model of a personalized model for the item of footwear; and saving the 3D model of a personalized model for the item of footwear in a database.
  • a network for manufacturing personalized lasts for items of footwear comprising: at least one computer system for determining personalized lasts for items of footwear as described above, a plurality of fabrication units in different locations, each fabrication unit comprising a system for manufacturing as described above.
  • a method for designing a personalized last of footwear for an individual comprising: obtaining a personalized last according to any of the herein described methods, obtaining feedback from a user on a performance of footwear manufactured from the personalized last, and modifying the personalized last based on the user feedback.
  • footwear any garment to be worn on a foot or feet of an individual.
  • Non-limiting examples include: shoes, boots, sandals, slippers, sports shoes, ski boots, snowboarding boots, dance shoes, and the like.
  • Footwear as defined herein does not encompass orthotics alone but may encompass footwear incorporating an orthotic or an orthotic mold.
  • a computer system may refer, but is not limited to, an “electronic device”, an “operation system”, a “system”, a “computer-based system”, a “controller unit”, a “control device” and/or any combination thereof appropriate to the relevant task at hand.
  • computer-readable medium and “memory” are intended to include media of any nature and kind whatsoever, non-limiting examples of which include RAM, ROM, disks (CD- ROMs, DVDs, floppy disks, hard disk drives, etc.), USB keys, flash memory cards, solid statedrives, and tape drives.
  • a “database” is any structured collection of data, irrespective of its particular structure, the database management software, or the computer hardware on which the data is stored, implemented, or otherwise rendered available for use.
  • a database may reside on the same hardware as the process that stores or makes use of the information stored in the database or it may reside on separate hardware, such as a dedicated server or plurality of servers.
  • Embodiments of the present technology each have at least one of the above-mentioned object and/or aspects, but do not necessarily have all of them. It should be understood that some aspects of the present technology that have resulted from attempting to attain the above- mentioned object may not satisfy this object and/or may satisfy other objects not specifically recited herein.
  • Figure 1 depicts a schematic diagram of a system for manufacturing a footwear last, in accordance with non-limiting embodiments of the present technology
  • Figure 2 depicts a schematic diagram of a computing environment of the system of Figure 1, in accordance with non-limiting embodiments of the present technology
  • Figure 3 depicts a flowchart of a method of manufacturing a footwear last, in accordance with non-limiting embodiments of the present technology
  • Figure 4 depicts a 3D digital model of a template last for an item of footwear for a left foot and a right foot of an individual, in accordance with non-limiting embodiments of the present technology
  • Figure 5 depicts a 3D digital model of the left foot and the right foot of the individual, in accordance with non-limiting embodiments of the present technology
  • Figure 6 depicts the 3D digital model of the left foot and the right foot of Figure 5 overlayed with the 3D digital models of the template lasts for the left foot and the right foot of Figure 4, in accordance with non-limiting embodiments of the present technology
  • Figure 7 depicts regions of the 3D digital model of the template lasts of the left foot and the right foot that require personalization based on the overlayed 3D digital models of the template last and the feet of Figure 5, in accordance with non-limiting embodiments of the present technology;
  • Figure 8 depicts the region of the right foot of Figure 7 after processing and smoothing, in accordance with non-limiting embodiments of the present technology
  • Figure 9 depicts the personalized last comprising the processed and smoothed region of Figure 8 applied to the template last, in accordance with non-limiting embodiments of the present technology
  • Figure 10 depicts a pathway of 3D printing on the physical model of the template last of the footwear, in accordance with non-limiting embodiments of the present technology
  • Figure 11 depicts an example micro-factory in which a system for manufacturing the personalized last is disposed, in accordance with non-limiting embodiments of the present technology
  • Figure 12 depicts another example micro-factory in which a system for manufacturing the personalized last is disposed, in accordance with non-limiting embodiments of the present technology
  • Figure 13 depicts yet another example micro-factory in which a system for manufacturing the personalized last is disposed, in accordance with non-limiting embodiments of the present technology
  • Figure 14 depicts a transportation of the micro-factory of Figure 13 in accordance with non-limiting embodiments of the present technology
  • Figure 15 depicts a network of micro-factories, in accordance with non-limiting embodiments of the present technology
  • Figure 16 depicts a schematic of a method of manufacturing a footwear last, in accordance with non-limiting embodiments of the present technology
  • Figure 17 depicts a reusability of the personalized footwear last, in accordance with nonlimiting embodiments of the present technology.
  • Figure 18 depicts a user interaction in the method of manufacturing a footwear last, in accordance with non-limiting embodiments of the present technology.
  • footwear lasts also referred to as footwear models
  • the present technology uses a 3D digital model of a template last 10 (also referred to as template model) ( Figure 4) of the footwear, and a 3D digital model of a foot 20 of the individual ( Figure 5), to determine a personalized last 30 for the item of footwear ( Figure 9).
  • the personalized last 30 can be manufactured by simply augmenting the template last 10 with material on one or more regions that require personalisation for the shape of the template last 10 to correspond to the individual’s foot.
  • FIG. 1 there is depicted a schematic diagram of a system 100 suitable for determining the personalized last 30, in accordance with certain non-limiting embodiments of the present technology.
  • the system 100 as depicted is merely an illustrative implementation of the present technology.
  • the description thereof that follows is intended to be only a description of illustrative examples of the present technology. This description is not intended to define the scope or set forth the bounds of the present technology.
  • modifications to the system 100 may also be set forth below. This is done merely as an aid to understanding, and, again, not to define the scope or set forth the bounds of the present technology.
  • the system 100 of Figure 1 comprises a computer system 110.
  • the computer system 110 may be configured, by pre-stored program instructions, to determine the personalized last 30 of the footwear for the individual, and/or to cause the manufacture of the personalized last.
  • the computer system 110 may be configured to receive data pertaining to the foot of the individual and/or data pertaining to the template last of the footwear on which the personalized last 30 will be determined. According to some non-limiting embodiments of the present technology, the computer system 110 may receive the data via local input/output interface (such as USB, as an example, not separately depicted). In other non-limiting embodiments of the present technology, the computer system 110 may be configured to receive the data over a communication network 125, to which the computer system 110 is communicatively coupled.
  • local input/output interface such as USB, as an example, not separately depicted
  • the communication network 125 is the Internet and/or an Intranet. Multiple embodiments of the communication network may be envisioned and will become apparent to the person skilled in the art of the present technology. Further, how a communication link between the computer system 110 and the communication network 125 is implemented will depend, inter alia, on how the computer system 110 is implemented, and may include, but is not limited to, a wire-based communication link and a wireless communication link (such as a Wi-Fi communication network link, a 3G/4G/5G communication network link, and the like).
  • the computer system 110 can be configured for receiving the data from a vast range of devices. Some of such devices can be used for capturing and/or processing data pertaining to the foot or feet of the individual. More specifically, in certain non-limiting embodiments of the present technology, the data received from such devices may comprise the 3D digital model 20 of the foot, indicating a surface of the foot.
  • the computer system 110 may have at least one interface device 120 for providing an input or an output to a user of the system 100, the interface device 120 being in communication with the input/output interface 180.
  • the interface device is a screen 122.
  • the interface device 120 may be a monitor, a speaker, a printer, or any other device for providing an output in any form such as an image form, a written form, a printed form, a verbal form, a 3D model form, or the like.
  • the interface device 120 also comprises a keyboard 124 and a mouse 126 for receiving input from the user of the system 100.
  • Other interface devices 120 for providing an input to the computer system 110 can include, without limitation, a USB port, a microphone, a camera, or the like.
  • the computer system 110 may be connected to other users, such as through their respective clinics, through a server (not depicted).
  • the computer system 110 may also be connected to stock management or client software which could be updated.
  • the system 100 comprises a data capture apparatus 130 for capturing the 3D digital model 20 of the foot.
  • the data capture apparatus 130 may comprise any suitable device for capturing an image of the foot and deriving the 3D digital model 20 therefrom, such as an imaging device.
  • the data capture apparatus 130 is a mobile device such as a tablet or smartphone, or the like.
  • the imaging device may comprise a 3D body part scanner configured to image the foot, or an impression of the foot.
  • the imaging device comprises VolumentalTM Mobile 3D Scanner or VoxelcareTM 3D Laser Planter Foot Scanner Compact.
  • the image data may be converted to the 3D digital model 20 of the foot by the data capture apparatus 130 or by the computer system 110.
  • the image data associated with the foot may be structured as a binary file or an ASCII file, may be discretized in various ways (e.g., point clouds, polygonal meshes, pixels, voxels, implicitly defined geometric shapes), and may be formatted in a vast range of file formats (e.g., STL, OBJ, PLY, DICOM, and various software-specific, proprietary formats). Any image data file format is included within the scope of the present technology.
  • the system 100 may also comprise an additive manufacturing apparatus 140 for manufacturing the foot last.
  • the additive manufacturing apparatus may comprise a 3D printer of any suitable technology type such as one or more of: HP jet fusionTM, selective laser sintering, polyjet, fused deposition of material (FDM), and stereolithography technologies.
  • the additive manufacturing apparatus 140 may be a standard commercially available 3D printer or can be a specialised printer designed specifically for producing footwear lasts.
  • the 3D printer can be of one of the types of HP Jet Fusion available from HP INC. of 1501 Page Mill Road, Palo Alto, CA, 94304, United States of America. It should be expressly understood that the 3D printer can be implemented as any other suitable equipment.
  • the 3D printer comprises a print bed, a print head or nozzle, and a control system that directs the movement of the print head to create the desired shape.
  • the print head may be connected to a robotic arm and controlled by the control system of the 3D printer to be moveable in a plurality of different directions, orientations and distances to print complex and intricate shapes. This setup enables the printer to reach difficult-to-access areas and print objects with greater precision and accuracy.
  • the robotic arm may have 3, 4, 5 or 6 axes of movement. In one example, the robotic arm is Agilus 10 R900 by KUKATM.
  • the additive manufacturing apparatus 140 uses materials which are one or more of: recycled, recyclable, reusable, and biodegradable.
  • the material is a thermoplastic elastomer, such as one or more of polyethylene, polyurethane, poly lactic acid (PL A), polyethylene terephthalate (PET) and thermoplastic polyurethane (TPU).
  • the PLA may be derived from renewable resources such as com start and sugar cane and is a biodegradable and compostable polymer.
  • the TPU is recyclable and biodegradable polymer.
  • the additive material is a different material to that used for the template lasts.
  • the system 100 may further comprise a recycling system (not shown) that allows for the recycling of the additive material after use.
  • the recycling system can be a closed-loop system that recycles the material within the additive manufacturing apparatus or can be a separate system that recycles the material externally.
  • the recycling system is configured to exploit this difference to separate the additive material printed onto the template last from the template model itself.
  • the recycling system comprises apparatus suitable for applying heat, cooling, peeling, or solubilizing the additive material from the template last.
  • the thermo-resistance properties of the template last and the additive material may be different such that heating or cooling the template last with the additive material thereon would separate the additive material from the template last, thereby permitting the template last to be re-used.
  • the additive material removed from the template last may also be re-used or otherwise recycled.
  • the system 100 further comprises footwear manufacturing apparatus 150 for manufacturing the item of footwear from the footwear last printed by the additive manufacturing apparatus.
  • the footwear manufacturing apparatus 150 may comprise the same or another additive manufacturing apparatus 140.
  • the footwear manufacturing apparatus 150 may comprise, without limitation, one or more of: cutting apparatus, skiving apparatus, lasting apparatus, sewing machines, sole attaching apparatus, finishing apparatus, heat-setting apparatus, heat-setting apparatus, embossing apparatus, laser-cutting apparatus, injection molding apparatus.
  • the system 100 comprises a plurality of template lasts 10.
  • the template lasts 10 may each have different sizes and shapes to accommodate for different sizes of feet for an individual.
  • the template lasts 10 may be made of different materials.
  • the template lasts 10 may also have different styles for making different types of footwear therefrom (boots, shoes, sandals, etc.).
  • the system 100 comprises apparatus for making the template lasts 10.
  • the micro-factory 102 is a compact, self-contained unit that includes all the necessary components and equipment to manufacture the personalized lasts 30 and footwear on-demand.
  • the micro-factory 102 comprises a mobile unit, such as a bus or truck for example housing at least some, or all, components of the system 100.
  • the mobile nature of the micro-factory allows for the production of personalized footwear at various locations, such as retail stores, events, or even remote areas with limited access to traditional manufacturing facilities.
  • the computer system 110 and the additive manufacturing apparatus 140 may be housed in the mobile unit.
  • the micro-factory may have a footprint area of 16 metre squared, 15 metre squared, 14 metre squared, or 13 metre squared.
  • the micro-factory may store a plurality of the physical lasts, such as in a library form.
  • the micro-factory comprises at least the computer system 110, the additive manufacturing apparatus 140.
  • the micro-factory may further include one or more of: 3D scanning equipment for capturing foot data, storage units (for raw 3D printing materials, template lasts and finished products), post-processing tools such as for smoothing, cleaning or polishing the manufactured footwear, and packaging equipment.
  • the inventory management system is integrated with the central computer system 110, allowing for real-time tracking of stock levels and automatic reordering of materials when necessary.
  • the micro-factory may also include a waste management system that separates and recycles any unused or discarded materials to minimize environmental impact.
  • the additive manufacturing apparatus 140 may include multiple 3D printers to increase production capacity and efficiency.
  • the additive manufacturing apparatus 140 is placed in close proximity to the material storage units to minimize material handling and transportation.
  • Post-processing and packaging equipment are located near an output area to streamline the finishing and shipping processes.
  • the computer system 110 may be positioned in a central location, allowing for easy access and control of the various components.
  • the micro-factory is equipped with the necessary power supply, ventilation, and environmental control systems to ensure optimal operating conditions for the equipment and operators.
  • the mobile unit may be fitted with high-capacity batteries and generators to provide a reliable power source, even in remote locations.
  • the ventilation system is configured to maintain a clean and temperature-controlled environment, which is important for the proper functioning of the 3D printers and other sensitive equipment. Sensors may be included to monitor humidity, air quality, and contaminants such as dust.
  • the micro-factory is connected to the internet via satellite or mobile broadband, enabling seamless communication with remote servers and databases. This connection allows the micro-factory to receive 3D foot scan data, design files, and production instructions from the central computer system 110.
  • the micro-factory can also send real-time production data, quality control reports, and inventory updates back to a central processor for monitoring and analysis.
  • the micro-factory incorporates one or more of: (a) an automated material handling system that accurately dispenses the required amount of raw materials for each production job, reducing waste and minimizing human error; (b) an integrated quality control system that uses computer vision and machine learning algorithms to inspect the manufactured footwear for any defects or deviations from the design specifications. This system ensures that only high-quality products are delivered to the customers; (c) a user-friendly interface that allows operators to easily monitor and control the production process, access relevant information, and communicate with the central system.
  • the micro-factory may be equipped with a range of post-processing tools and equipment, such as one or more of: Automated cleaning systems that remove any residual support materials or debris from the 3D printed parts; polishing and buffing machines that smooth out any surface imperfections and give the footwear a professional finish; packaging equipment for packaging the footwear such as for delivery to the customer.
  • post-processing tools and equipment such as one or more of: Automated cleaning systems that remove any residual support materials or debris from the 3D printed parts; polishing and buffing machines that smooth out any surface imperfections and give the footwear a professional finish; packaging equipment for packaging the footwear such as for delivery to the customer.
  • the micro-factory approach offers several advantages and use cases, such as: on-site production at events or retail stores, allowing customers to receive their personalized footwear within a short timeframe; providing access to personalized footwear in remote or underserved areas where traditional manufacturing and distribution channels may be limited; and enabling rapid prototyping and testing of new footwear designs, as the micro-factory can quickly produce small batches of customized shoes for evaluation and feedback.
  • micro-factories are deployed in different locations, forming a network of interconnected units that share data, resources, and best practices. This network is centrally managed and optimized to meet the demands of various markets and customers (Figure 15).
  • FIG. 2 there is depicted a schematic diagram of a computing environment 240 suitable for use with some implementations of the computer system 110 of Figure 1.
  • the computing environment 240 comprises various hardware components including one or more single or multi-core processors collectively represented by the processor 250, a solid-state drive 260, a random-access memory 270 and an input/output interface 280.
  • Communication between the various components of the computing environment 240 may be enabled by one or more internal and/or external buses 290 (e.g., a PCI bus, universal serial bus, IEEE 1394 “Firewire” bus, SCSI bus, Serial-ATA bus, ARINC bus, etc.), to which the various hardware components are electronically coupled.
  • internal and/or external buses 290 e.g., a PCI bus, universal serial bus, IEEE 1394 “Firewire” bus, SCSI bus, Serial-ATA bus, ARINC bus, etc.
  • the input/output interface 280 allows enabling networking capabilities such as wire or wireless access.
  • the input/output interface 280 comprises a networking interface such as, but not limited to, a network port, a network socket, a network interface controller and the like. Multiple examples of how the networking interface may be implemented will become apparent to the person skilled in the art of the present technology.
  • the input/output interface 580 may implement specific physical layer and data link layer standard such as EthernetTM, Fibre Channel, Wi-FiTM or Token RingTM.
  • the specific physical layer and the data link layer may provide a base for a full network protocol stack, allowing communication among small groups of computers on the same local area network (LAN) and large-scale network communications through routable protocols, such as IP.
  • the solid-state drive 260 stores program instructions suitable for being loaded into the random -access memory 270 and executed by the processor 250, according to certain aspects and embodiments of the present technology.
  • the program instructions may be part of a library or an application.
  • the computing environment 240 is implemented in a generic computer system, which is a conventional computer (that is, an “off the shelf’ generic computer system).
  • the generic computer system may be a desktop computer/personal computer, but may also be any other type of electronic device such as, but not limited to, a laptop, a mobile device, a smart phone, a tablet device, or a server.
  • a laptop a mobile device
  • a smart phone a tablet device
  • server a server
  • the system 100 may be geographically split and comprise a network of communicatively coupled computer systems, data capturing apparatus 130, additive manufacturing apparatus 140 and footwear manufacturing apparatus 150.
  • 3D digital models of the foot 20 may be obtained from any location and the personalized footwear last and footwear manufactured at any location.
  • FIG. 3 there is depicted a schematic diagram of a method 300 for manufacturing a personalized last for an item of footwear for an individual, in accordance with certain non-limiting embodiments of the present technology.
  • STEP 302 Obtaining a 3D digital model of a template model
  • the method 300 comprises, at step 302, the processor obtaining the 3D digital model of the template last 10 for the item of footwear (Figure 4).
  • the 3D digital model of the template last 10 may be obtained from a database, such as the random access memory 270 of the computer system 110.
  • the database may store a plurality of 3D digital models of template last of footwear.
  • the database may be updated with changes and/or additions to the template lasts.
  • the template lasts may be for different sizes of footwear, different styles of footwear, for the left feet, for the right feet, etc.
  • the obtaining the 3D digital model of the template last 10 may be responsive to receiving input of a request.
  • the input may include the individual’s footwear size or dimensions
  • the step of obtaining the 3D digital model of the template last 10 may comprise selecting the 3D digital model of the template last 10 from a plurality of 3D digital models of the template last 10 based on the foot size or dimensions provided.
  • the dimensions may include a length of the foot, a width of the foot, an arch height of the foot, etc.
  • Other inputs and selection criteria are also within the scope of the present technology.
  • the selecting the 3D digital last template may comprise under-sizing, that is to say, selecting a template last that is slightly smaller than the individual’s foot.
  • STEP 304 Obtaining a 3D digital model of a foot of the individual
  • Step 304 the processor obtains the 3D digital model 20 of a foot of the individual ( Figure 5). Step 304 may be performed before Step 302, as illustrated in Figure 3, or after Step 302.
  • the processor can obtain the 3D digital model 20 of the foot.
  • the 3D digital model 20 of the foot is obtained from the data capture apparatus 130.
  • the 3D digital model 20 of the foot is generated, based on image data of the foot, by a finite element analysis (FEA) software and stored in a format receivable by the processor.
  • FEA finite element analysis
  • the order of steps 302 and 304 are not limited.
  • the 3D digital models 10, 20 may comprise a plurality of mesh elements representative of a surface of the foot.
  • a shape of a given mesh element of the plurality of mesh elements is not limited, and the given mesh element can be, for example, a triangular mesh element.
  • the plurality of mesh elements may include quadrilateral mesh elements, convex polygonal mesh elements, or even concave polygonal mesh elements, as an example, without departing from the scope of the present technology.
  • the processor overlays the 3D digital model 20 of the foot and the 3D digital model 10 of the template last ( Figure 6).
  • the overlaying may be performed by aligning respective anchor points on the 3D digital models of the template last 10 and the foot 20.
  • the anchor points (not shown) may be predefined and based on anatomical landmarks of the foot, such as heel, toe and ball of the foot. Any other anchor points are also within the scope of the present technology, such as those defined by coordinates within a 3D coordinate system of both the 3D digital models of the template last 10 and the foot 20.
  • the method 300 may further comprise the processor identifying anchor points on one or both of the 3 D digital models of the template last 10 and the foot 20 before aligning the respective anchor points to overlay the models.
  • STEP 308 Identifying a region that requires personalization
  • the processor identifies a region 40 of the 3D digital model of the template last 10 that requires personalisation based on the overlayed 3D digital models of the template last 10 and the foot 20.
  • the identifying the region 40 comprises determining one or more portions of the 3D digital model of the foot 20 that extends beyond the 3D digital model 10 of the template last when the 3D digital models of the foot 20 and the template last 10 are overlayed. In other words, the identifying the region 40 comprises determining areas of the foot which have parameters outside of the footwear last. These portions are an indication that the foot has a larger dimension than the footwear that would be made from the template last.
  • the identified region 40 is a 3D shape having a dimension (e.g. height) which will directly impact the enlargement needed of the footwear model, and hence the footwear to accommodate the individual’s foot.
  • the identified region 40 may be adjusted.
  • the identified region 40 may be enlarged, in one or more dimensions, according to a predetermined multiplier.
  • the predetermined multiplier may be determined according to a function of the footwear that will be made from the personalized last, a position on the foot, etc. For example, if the identified region is due to a bunion and the footwear to be manufactured is a sport shoe, the identified region 40 may be made deeper to allow more room during running. It can therefore be said that the predetermined factor takes into account a desired fit and/or desired comfort of the footwear.
  • the identified region 40 may be modulated through user input.
  • the method 300 may further comprise adjusting the identified or the isolated region to smooth a profile of the identified and/or isolated region 40. The smoothing may take into account a profile of the footwear last at the location of the region 40.
  • the method 300 may further comprise generating additional regions based on other personalisation adjustments needed to the item of footwear, such as for example orthotic insoles, and the like.
  • the processor isolates from the 3D digital model of the foot 20, the identified region 40.
  • the isolated identified region 40 may then be stored by the processor such as in a database.
  • Step 310 is optional.
  • the adjustments to the region 40 described in step 308 may equally be performed on the isolated identified region 40 instead of, or in addition to, the adjustments made in step 308.
  • the identified region 40 includes a location of the region 40 relative to the 3D digital model of the template last 10.
  • the location may comprise a coordinate of the region 40.
  • STEP 312 Causing the manufacture of the personalized last
  • the processor causes the manufacture of the personalized last 30 by sending instructions to an additive manufacturing apparatus, such as the additive manufacturing apparatus 140, to print onto a physical model of the template last 50, an extended portion 60 according to the isolated region 40 ( Figure 16).
  • the method 300 comprises determining a printing location of the extended portion 60 based on the location of the region 40 relative to the 3D digital model of the template last.
  • the extended portion may include one or more additional regions for orthotic or other purposes.
  • the printing of the extended portion 60 is performed layer-by- layer. The printing may be performed by a 3D printer having a robotic head with three or more degrees of freedom.
  • the method 300 may further comprises additional manufacturing steps, such as one or more of: smoothing and/or polishing the personalized last 30 (or a region of the personalized model including the extended portion 60), causing the application of a surface pattern, a surface texture and/or a surface colour onto the personalized last 30, and causing a curing of the extended portion 60.
  • the method 300 may comprise obtaining input of a material to be used for the extended portion 60 and determining at least one operation parameter of the additive manufacturing apparatus 140 based on the input material.
  • the extended portion 60 may comprise a material which is one or more of: recycled, recyclable, reusable, and biodegradable.
  • the extended portion is made of one or more of polylactic acid, polyethylene terephthalate or thermoplastic polyurethane.
  • the physical model of the template model 50 is made from a material which is one or more of: recycled, recyclable, reusable, durable, and biodegradable.
  • the template last 50 is made of one or more of polylactic acid, polyethylene terephthalate or thermoplastic polyurethane.
  • the processor may be configured to update the 3D digital model of the template last 10 with the region 40 incorporated therein.
  • the updated 3D digital model of the template last 10 with the region 40 incorporated therein may also be stored by the processor, such as in a memory of the computing environment 240.
  • the processor may be configured to cause display, such as on the screen 122 of the system 100, the updated 3D digital model of the template last 10 with the region 40 incorporated therein, and/or the region 40.
  • the method 300 may further comprise manufacturing the footwear using the manufactured personalized last 30, using for example the footwear manufacturing apparatus 150.
  • the method 300 may further comprise removing the extended portion 60 from the template last 50 and recycling one or both of the extended portion 60 and the template last 50 ( Figure 17).
  • updates about the design and manufacturing process of the personalized last 30 may be provided to the individual.
  • the updates may be provided through a user portal.
  • the user portal may also be used for users to browse footwear options, customize and place orders.
  • users may be provided the personalized last 30 and arrange the footwear fabrication themselves. If the physical personalized last 30 is provided to the user, instructions may be provided regarding removal of the extended portion from the personalized last 30 in order to permit reuse.
  • user feedback may be obtained about one or more of fit, comfort and performance of footwear manufactured using the personalized last 30.
  • changes may be made to the personalized last 30 to improve fit, comfort and/or performance such as by adapting one or more of the template last 10, a configuration of the extended portion 60 and a location of the extended portion 60.
  • the updated personalized last 30 may be stored, such as in the memory 270.
  • the method 300 may further comprise generating a unique identifier for the personalized last 30 for the individual, and storing the unique identifier with the personalized last 30.
  • the personalized last 30 may be used to manufacture the item of footwear. Any one or more of the overlaid 3D digital model of the template last and the 3D digital model of the foot, the identified region, the extended portion, the personalized last and the item of footwear manufactured from the personalized last may be used to create a digital twin. Such digital twins may be viewed and interacted with in a virtual reality or an augmented reality environment ( Figure 18). Modifications to the models may be made based on the user interaction. The digital twin may be used to simulate and monitor performance and wear of the footwear and/or user foot biomechanics over time. The simulation may be performed before the item of footwear is manufactured.

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  • Life Sciences & Earth Sciences (AREA)
  • Biophysics (AREA)
  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Footwear And Its Accessory, Manufacturing Method And Apparatuses (AREA)

Abstract

La présente invention concerne un procédé de fabrication d'un modèle d'article chaussant personnalisé comprenant l'obtention d'un modèle numérique 3D d'une forme de gabarit; l'obtention d'un modèle de pied numérique 3D; la superposition de la forme de gabarit numérique 3D et des modèles de pied; l'identification d'une région du modèle de gabarit numérique 3D qui nécessite une personnalisation sur la base des modèles numériques 3D superposés; l'envoi d'instructions à un appareil de fabrication additive pour imprimer sur un modèle physique du modèle de gabarit, une partie étendue selon la région identifiée du modèle de pied numérique 3D du pied. L'invention concerne également un système comprenant : un processeur d'un système informatique configuré pour déterminer la partie étendue pour adapter la forme de gabarit pour le rendre personnalisé à un pied de l'individu; un appareil de fabrication additive pour imprimer la partie étendue déterminée sur la forme de gabarit de l'article chassant pour générer le modèle personnalisé.
PCT/IB2024/054060 2023-04-25 2024-04-25 Formes d'article chaussant, leurs procédés de fabrication et article chaussant fabriqué à l'aide de ceux-ci Pending WO2024224341A1 (fr)

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US20180317610A1 (en) * 2017-05-02 2018-11-08 ELSE CORP S.r.I. Shoe-last modification method and system based on application of additive patches

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