First proposals

Ideation

In my search for how to design insoles, I came across the SoleMorph project, which already applies specialized manufacturing standards. This was one of my main concerns, as I have not studied any specialty related to human body physiology. Therefore, I started researching and found that the project adapts to the individual needs of each person in an open source way (Sing in Gensole beta program).

SoleMorph is a project developed at the MIT Media Lab that explores the manufacturing of custom insoles and shoe soles using adaptable geometry and digital fabrication technologies like 3D printing.

Solemorph

Parametric design: It uses generative algorithms to adapt the sole geometry based on the user's pressure and biomechanics. Metamaterial structures: Instead of relying on soft or rigid materials, it uses internal patterns that vary in stiffness and cushioning across different areas of the foot. Digital fabrication: Typically using 3D printing in TPU or other flexible materials, allowing for extreme customization. Adaptive response: Depending on the user's pressure, the sole can change its mechanical behavior in real-time.

Scanning my feet

I scanned my foot using the machine HandySCAN 3D|SILVER. This technology is not yet available in our FabLab, but a team came to give us a demonstration, and I asked them to help me with the scan, as it is rare to have the opportunity to use such a specialized product.

Sketches

I wanted to create some sketch proposals to experiment with how a parametric design would look on the shoes.

• In Proposal A, I started with a defined pattern, but I realized it wasn’t bold enough.
• In Proposal B, I aimed for a more organic interwoven pattern while maintaining the vertical direction from Proposal A.
• In Proposal C, I incorporated what I had learned about parametric design using the Voronoi tool. This approach introduced a different perspective from my initial ideas, which is why I decided to explore it further.
• In Proposal D, I applied the same design principles from Proposals A and B but arranged them horizontally.

For the next stage, I will focus on the proposals that best represent the organic variability of unique visual elements—just like unique bodies. With that in mind, I have chosen to move forward with Proposals B, C, and D.

Design & Fabrication

To create the parametric design in Grasshopper Rhinoceros, I found a tutorial from 3DBeast that was incredibly helpful as a starting point for my designs. This tutorial allowed me to experiment and realize that by adjusting the edges in Rhino, I could manipulate both the geometry and the parametric design more freely. I applied this insight to my final design, where the curves closely follow the structure of these edges, creating a more cohesive and dynamic form.

I focused on two different shoe lasts, both adapted to my foot. However, design number 2 follows the natural shape of my foot more closely, which is why its tip is sharper. In contrast, design number 1 is more abstract in its shapes but still adapted to my foot.

Proposal B – This design is the one that most closely resembles the tutorial. I really liked it, but I would like to explore it further.

• This proposal uses last 1.

Proposal C – I really enjoyed working on this design. Here, I made a variation to increase the shoe’s width as an experiment.

• This proposal uses last 1, but I widened it to experiment with how it would look.

Proposal D – I found this design more interesting because the sole elements are closer together, which could potentially provide better weight support.

• In this proposal, I used last 2.

Prototypes

For my prototypes, my instructor, Nuria, helped me refine my focus on both design proposals and testing. As a result, I created three scaled prototypes (PLA) to decide on the final design and also printed three full-scale (1:1) shoe sections to test the fit and comfort with my foot.

Although my plan is to 3D print the shoe along with the insole, the latter will feature a small parametric pattern to ensure better support and durability.

3D Pirint

Slicing and preparation in Ultimaker Cura for printing the parts on the Ender 3 Pro.

Proposal B – In this design, I realized that the holes in the insole need to be very small or that it should not have a solid layer, as the pattern gets imprinted on the skin after standing for a while.

That said, I really liked how the final printed design turned out.

Proposal C – This design, with larger holes but a thinner structure, causes the insole to deform over time. Additionally, the holes leave marks on the skin after standing for a while.

Proposal D – I really liked this design; I believe it reflects the most experimentation on my part. However, I encountered the same issue with the pattern leaving marks on the skin.

Despite this, I’ve chosen this proposal for my final project. I will integrate the insole I created with Gensole and add a solid layer to ensure direct contact with the foot without leaving imprints on the skin.

Mentoring notes

TROY - Conduct research on the different foot positions during various daily activities. Analyze variable density maps on the sole and focus on generative design, foot physiology, and ergonomics.

ANASTASIA

• Amazing presentation in the way you talk about find a personalized solution, with the scans. i would read more about the topic, about troy's research: Wired Footwearology

CECILIA

• Amazing presentation in the way you talk about find a personalized solution, with the scans. i would read more about the topic, about troy's research.

CLAUDIA

• Look at Fusedfootwearfor aesthetic research! Search for the right filaments to print those, the properties of the materials are quite imortant at this stage. Look into flexible filmanets like PolyFlex TPU95 or TPE // have a look at the past fabricademy projects about shoes - annie ferlatte / sara alvarez // https://www.footwearology.com/course/grasshopper-for-footwear

Half-fabrication files

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1. Test file: 3d modelling test ↩