WO2008070537A2 - Système et procédés de fabrication de chaussures faites sur mesure - Google Patents

Système et procédés de fabrication de chaussures faites sur mesure Download PDF

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Publication number
WO2008070537A2
WO2008070537A2 PCT/US2007/086014 US2007086014W WO2008070537A2 WO 2008070537 A2 WO2008070537 A2 WO 2008070537A2 US 2007086014 W US2007086014 W US 2007086014W WO 2008070537 A2 WO2008070537 A2 WO 2008070537A2
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WIPO (PCT)
Prior art keywords
foot
custom
last
footwear
wearer
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PCT/US2007/086014
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English (en)
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WO2008070537A3 (fr
Inventor
Wei Weng
Liqun Zhu
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Ingenious Targeting Laboratory, Inc.
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Publication of WO2008070537A2 publication Critical patent/WO2008070537A2/fr
Publication of WO2008070537A3 publication Critical patent/WO2008070537A3/fr

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    • 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
    • A43D3/00—Lasts
    • A43D3/02—Lasts for making or repairing shoes
    • A43D3/021—Lasts for making or repairing shoes for orthopaedic footwear
    • 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

  • This invention relates to a system and the methods of making custom footwear. More particularly, this invention relates to a system and the methods applying in an efficient, integrated, front-to-end process in the making of cost- effective footwear with multi-level customization.
  • Mass production industries have been successful for almost a century due to the efficiency and cost-effectiveness associated with its concept.
  • the consumers usually have to struggle to balance their personalized needs with the limitations of the off-the-shelf products. If the mass-produced products could not meet consumers' individualized requirements, either the consumers had to sacrifice their requirements or the providers of the off-the-shelf products would suffer from high inventory cost.
  • Custom-tailored products can address consumers' personalized needs in great details.
  • the rapid progress of computer technologies and Internet has provided powerful tools for various industries in efficiently and economically marking custom products.
  • the healthcare and consumer industries have to switch from traditional mass production to computerized custom production since their clients are humans with diversified biometric characteristics.
  • the footwear industry the footwear mass- producers are experiencing more and more problems developing and fitting the right footwear as the consumers becoming increasingly selective of what they wear.
  • the foot of an individual contains many unique biometric features, which are the fingerprints of the person.
  • Mass-produced footwear is not adequate to address the biological diversity of human feet.
  • the off-the-shelf footwear usually causes pain, fatigue, and sometimes serious foot problems due to lacking of proper fitting to the foot.
  • the conditions and shape of their feet continuously change with age and biological conditions.
  • One of such cases is that the shape and conditions of feet become very different when a female is pregnant.
  • Foot disorders include arthritis, bunion, claw toe, hammer toe, diabetic foot, excessive pronation/supination, flat foot, metatarsalgia, hallux rigidus, heel spur, and plantar fasciitis, just to name a few. Foot disorders usually induce deformities in the foot. The patients with foot disorders suffer the most from ill-fitted footwear, and their foot condition might worsen if they continue to wear improperly fitted footwear. [0005] Custom- tailored footwear can increase the fitting level; hence reduce potential health hazards. Various systems and methods related to the making of custom footwear have emerged over the past decades. In United States patent 5,632,104, customized shoes built to reduce the stress in feet are described.
  • the shoe comprises an upper and a sole portion that define a foot support surface.
  • the foot support surface is curved to fit the natural shape of a heel of the wearer's foot.
  • the foot support surface further gradually slopes under toes of wearer's foot such that when wearer is standing erect, articulate extremities of toes do not nominally touch said foot support surface, thereby allowing toes to plantarflex and dorsiflex.
  • the footwear in the invention is generally related to orthopedic shoes.
  • an impression of the whole foot is first used to make a positive mold.
  • the positive mold is then used directly as the custom last for the making of the custom shoe.
  • the custom last of United States patent 4,662,079 is not optimized and cannot be adjusted.
  • the shape and style of the custom shoe in the United States patent 4,662,079 can not be customized according to wearer's preference since it has the exact shape of the foot.
  • United States patent 6,823,550 methods of making custom orthotics are described. First, the wearer selects orthotics with certain style and appearance according to their needs and taste. Custom inserts are then added into the selected orthotics.
  • the custom orthotics in the United States patent 6,823,550 is related to the customization of a medical device rather than the general footwear.
  • the regarding customization methods don't include the custom making of shoe upper and shoe sole.
  • Similar methods of making custom-tailored medical devices are also described in United States patent 6,463,351.
  • United State patent 6,463,351 the customization process starts from making a model of customer's body part for which a medical structure is to be manufactured, followed by a reverse-engineering process in which the model of the body part is digitized into data points. The data points are then processed for the design and manufacture of the medical device.
  • the customization process in United State patent 6,463,351 is not towards the custom-making of footwear components, as well as the integration of these custom components into final custom footwear.
  • United States patent application US2001/0020222 Al system and method of using Internet for custom footwear manufacturing are described.
  • the shoe last in United State patent application US2001/0020222 Al is generated by a shoe last design unit, which makes the shoe last to match the 3- D shape of the individual foot. Therefore, the last is not re-usable.
  • United State patent application US2001/0020222 Al only the system and method of custom-making of shoe upper were described while the custom-making of other footwear components such as insole and sole were not included.
  • the most similar template is identified later according to the footwear order containing a customer's information such as foot geometry. Then the selected last template is further machined into the customized last for the customer.
  • the manufacturing process of custom shoe last is divided into two consecutive steps: the manufacturing of pre-finished last templates, and the further machining on the last templates into final custom lasts. In this case, special precision equipment and additional time are still required to machine every last template into individualized custom last.
  • an electronic database containing custom lasts is constructed first. In the electronic last database, all the lasts have been fine- tuned in multiple biometric dimensions of human foot, and these lasts are fully functional.
  • custom lasts As to the foot without abnormalities in shape, generally no further modification is required on the custom lasts before they are used in making custom footwear.
  • the custom last in the database can also be further modified to accommodate foot abnormalities or disorders, such as hammer toe, bunion, etc. Therefore, the custom-making of shoe upper using custom lasts is a more efficient process in the present invention.
  • A. Luximon, R. S. Goonetilleke and K. L. Tsui Foot landmarking for footwear customization, Ergonomics, 2003, V 46, No. 4, pp 364-383. In this paper, the authors address that a shoe with a shape more similar to the foot could achieve higher comfortable level. This is because that the shoe was more able to maintain the foot in its neutral posture.
  • the authors also address that customized footwear is expensive to produce due to a variety of complex constraints that have to be imposed in the footwear customization process, such as the design and fabrication of custom shoe-lasts, the manufacturing of customer moulds for outsoles, and the design and manufacturing of custom dies for the cutting of the upper patterns.
  • the authors propose a method of land-marking the 2-D projected contour of consumers' foot so that the best match of the mass-produced shoes could be identified.
  • the authors of the publication did not come up with an effective method of making custom footwear in an effective and efficient way.
  • the custom fit between the footwear and the foot is achieved by matching the 3-D features of the custom lasts and the 3-D biometric features of the foot.
  • the fitting level is calculated and adjusted in multiple 3-D dimensions.
  • the customization process of this invention is more comprehensive than the 2-D land-marking method proposed in the above publication.
  • This invention relates to a system and the methods of making custom footwear.
  • a multi-level customization process is employed in the system of the invention.
  • shoe last is customized according to the biometric features of the foot.
  • the components of the footwear are fine-tuned through a set of interactive measurements for the wearer' needs, while the appearance of the footwear is custom-designed according to the taste of the wearer.
  • Major components of the custom footwear include: a custom upper that best-fits the shape of wearer's foot; a multi-layered custom insole with its surface conforming to the plantar surface of the foot; and a custom sole that sandwiching a heel pad with custom height.
  • the methods for custom-making of the footwear include: custom last database construction, reverse-engineering for the 3-D foot model, measurement and analysis for foot features, expert system-guided automatic last look-up for the best- fit last, modification and tune-up on the best- fit last, custom- making of shoe upper using the custom last, custom-making of multi-layered insole according to the plantar surface geometry of the foot, making of custom sole, and the integration of custom upper, insole and sole into final custom footwear.
  • the custom footwear is made through the following process. First, a custom last database is constructed, which stores the geometric features of custom-designed lasts along multiple dimensions. In the last database, one last table corresponds to a footwear style. A reverse- engineering process is used to acquire a 3-D computer model of the foot.
  • the 3- D model of the foot is further measured and analyzed to extract the 3- dimensional features of the foot.
  • the foot measurement process not only the foot geometries along last dimensions are measured, but also the 3-D shape and locations of any foot abnormalities are recorded.
  • Automatic last look-up is then carried out according to the extracted foot features, which iterate the last table of the desired style.
  • fitting indices of all lasts are computed by fitting algorithms derived from a set of rules from an expert system. The fitting indices show the fitting levels between the last features and those of the foot. A best-fit last is chosen from the last database after sorting all the fitting indices of the lasts.
  • the 3-D shape of the best-fit last may further be tuned up and optimized to accommodate any deformities or irregularities of the wearer's foot. In certain cases, fully customized last would be manufactured if the look-up process is not able to select a best-fit last.
  • Custom upper of the footwear is then made using the finalized custom last.
  • a thermal-plastic forming mould is made by Computer Numerical Controlled (CNC) machining process referring to the 3-D shape of the plantar surface of the foot.
  • CNC Computer Numerical Controlled
  • a multi-layered plate comprising a layer of shell material, a layer of cushioning material, and a layer of lining material, is then thermal-plastically-formed and trimmed into the custom insole.
  • a custom sole is made by trimming the outlines of the midsole and outsole according to the contour of the bottom of the custom last, and by sandwiching a custom-made heel-pad between the midsole and outsole. Finally, the custom upper, insole, and sole are integrated into the custom footwear, with the colors, materials and other accessories of the footwear customized according to the wearer's preferences.
  • FIGURE 1 shows the overall workflow for the making of the custom footwear of the invention
  • FIGURE 2 shows an example of the reverse-engineering process for acquiring a 3-D computer model of a foot.
  • An optical scanning method is employed where a handheld optical scanner is used to scan the foot.
  • a rigid and transparent plate is used to support the foot at its plantar surface so that the plantar surface of the foot can be scanned;
  • FIGURE 3 is an example of the 3-D computer model of a foot in Surface Triangulation List (STL) format.
  • the CAD model is converted from the 3-D point clouds that are reconstructed from the optical scanning process;
  • FIGURE 4 shows the Cartesian coordinate system used to define the position of the foot. The coordinate system is used as the reference for the measurement and extraction of the foot features;
  • FIGURE 5 shows examples of the key features of a foot, as well as the method of extracting these features from the 3-D computer model of the foot.
  • the features displayed include: foot length, forefoot width, rear-foot width, ball girth, waist girth, instep girth, and heel girth;
  • FIGURE 6 is a computer model of the plantar surface of the foot, which is generated from the 3-D model of the foot.
  • the plantar surface model of the foot includes the whole arch of the foot.
  • This computer model is used to make a plantar surface mold by CNC machining. The mold is later used to in the thermal-plastic forming process for the custom insole.
  • FIGURE 7 shows an example of a multi-layered custom insole (in exploded view).
  • the insole is composed of a top layer made of breathable lining material and cushioning material, and a middle shell layer made from thermal cork, and a bottom heel pad layer (optional) made of cushioning material.
  • the custom insole is made through a thermal forming process.
  • a heel pad with customized height and cushioning effect may be attached at the bottom of the custom insole.
  • the insole can be further customized according to any special needs (such as certain foot disorders). In this example, a hole is cut off from the insole where the wearer has a corn.
  • FIGURE 8 shows an example of multi-layered custom sole (in exploded view).
  • the sole is composed of a midsole (top), a rigid heel pad with customized height (middle), and an outsole with bottom texture customized according to the gait pattern of the wearer (bottom).
  • the midsole and outsole sandwiches the heel pad.
  • the contour of the sole is trimmed according to the outline of the bottom of the custom last.
  • Figure 1 shows the integrated process and overall workflow for the making of the custom footwear of the invention.
  • a custom last database is constructed beforehand as the reference of the footwear-making process.
  • the lasts with the same style form a data table (last table).
  • the custom lasts are featured with more geometric dimensions than the conventional lasts for off-the-shelf footwear, while in each dimension the last size are divided into finer scales.
  • the footwear-making process starts with a reverse-engineering process for obtaining the 3-D geometric model of the wearer's foot.
  • the 3-D foot model is further processed to provide information for making the custom upper as well as the custom insole.
  • the major task is to determine the custom last that best- fits the biometric features of the wearer' s foot, so that any occurrence of localized pressure concentration between the upper and the foot can be prevented (See, A. Luximon, R. S. Goonetilleke and K. L. Tsui, Foot landmarking for footwear customization, Ergonomics, 2003, V 46, No. 4, pp 364-383).
  • the custom upper made from the best-fit last should also be able to constrain the foot in a proper space so that the foot would not slide in the shoe while the wearer walks.
  • the 3-D foot model is measured and analyzed in multiple dimensions for a multi-dimensional foot feature vector.
  • the number of the foot features that are measured may vary according to the foot condition.
  • the 3-D shape and location of any foot abnormalities such as hammer toe, bunion, etc.
  • the measurement and analysis of the 3-D foot model is carried out using professional Computer- Aided Design (CAD) software.
  • CAD Computer- Aided Design
  • the 3-D foot model from the reverse-engineering process is also processed to generate a 3-D geometric model containing the plantar surface of the foot (with foot arch) (See Figure 7).
  • This 3-D model of the plantar surface is used to manufacture the mold for the custom insole through a CNC machining process.
  • a multi-layered plate is thermal -plastically formed into the shape of the foot plantar surface using the insole mold. The deformed plate is trimmed into the custom insole.
  • the foot features are obtained from the 3-D foot model, they may be adjusted according to the wearer's wearing need, such as sock thickness and the wearer's preference for shoe tightness. Given the wearer's preference for the style of the footwear, the foot features are then used as the inputs of a last lookup process for the best-fit last in the custom last database.
  • the last look-up process is fully automatic and is guided by a set of fitting algorithms derived from the rules of an expert system.
  • the expert system contains knowledge bases and rules used to judge the fitting between a last of the desired style and the foot. As the searching result, the best- fit last is fetched from physical last storage for later use.
  • the best-fit last may need further tune -up or optimization if a small portion of the fitting indices of the last are beyond a set tolerance, or any foot deformities have to be accommodated. If the last look-up process was not able to find a best- fit last after searching the last table, a fully customized last would be made. The finalized custom last is used for making the custom shoe upper.
  • the manufacturing process goes through a set of secondary processes as another level of customization.
  • the secondary process starts from a set of interactive measurements for the wearer' s special needs and tastes for the custom footwear.
  • the parameters measured include, but not limited to: softness of the insole cushioning layer, height of the heel pad in the sole, preferences of colors and materials, preferences for monograms and logos, and any special requirements on the upper, insole, and/or sole.
  • the secondary manufacturing processes are carried out. They are: The manufacturing of shoe upper using the finalized custom last, the custom-making of shoe sole, the making of custom-insole, the integration of the custom upper, custom sole, and custom insole into final custom footwear.
  • Last is one of the key components in footwear manufacturing.
  • the size of foot differs from person to person.
  • shoe lasts are divided into groups and categorized according to age, gender, foot length, girth, and other distinguishable parameters.
  • the index system for a last set comprises the discrete information including customer group (e.g., boys, girls, men, ladies, etc.), foot size (foot length, forefoot width, and rear foot width), and foot girth (ball, waist, and instep).
  • customer group e.g., boys, girls, men, ladies, etc.
  • foot size foot length, forefoot width, and rear foot width
  • foot girth ball, waist, and instep
  • each last is uniquely labeled and contains a unique feature vector.
  • Note some fully customized lasts are exact copies of the surface shape of the feet; hence no indexing system is available for this type of fully customized lasts.
  • custom last database is constructed to store the key geometric features of custom-designed lasts.
  • the database is composed of multiple data tables. Each table corresponds to a footwear style, and is composed of a set of electronic lasts of the style.
  • more dimensions are used to define the geometry of the custom last than those used to define conventional non-custom lasts.
  • finer scales are used in all these dimensions.
  • the dimensions used to describe the last geometry, as well as the scaling of these dimensions, are collected according to the gathered foot statistics from a test population.
  • the custom last database is constructed referring to the US standard foot-last reference tables for mass production footwear industries, as the follows.
  • i is the /th dimension in foot (or last) dimensions; "L” stands for the feature vector a last in a last table for off-the-shelf footwear, and “F” stands for the feature vector a foot in the test population.
  • the averages of the errors were calculated in every dimension. Shifts are corrected first by modifying the last dimensions so that the errors have zero means. Afterwards, another set of errors is calculated by comparing the modified last feature vector and the foot feature vector. The standard deviations of the new errors are calculated. Any dimension with error standard deviation larger than a threshold is further divided into finer- scales, or added as a new dimension for the custom last.
  • a finer- scaled last with higher dimensions can be derived from a original last with label Students-5B, as Students-(5.2)(5.0)(5.3)(B.l)(B.3)(B.2), which corresponds to lady' last with main length index 5, and length sub-scale 2, forefoot width sub-scale 0, rear foot width subscale 3; main girth index B, and ball girth sub-scale 1, waist girth sub-scale 3, and instep girth sub-scale 2.
  • the custom last database is constructed by combining the fine-tuned foot-last reference tables.
  • Any last table of the database can be targeted after the wearer picked a specific style, and searched automatically to find the last that best- fits the biometric features of the wearer's foot.
  • a tolerance value is set in this last lookup process to constrain the allowed geometric difference between a last and the foot. In most cases, the tolerance can be met provided the wearer's foot is in normal condition.
  • the second solution is to manufacture a fully customized last if numbers of fitting indices are way beyond tolerance. Usually this case occurs when the foot has significant abnormalities over a large volume or area.
  • the geometric features of the fully customized last can be added into the last table for future reference.
  • the 3-D foot model is the reference for the fully custom last.
  • the fully custom last is manufactured using a technique similar to Rapid Prototyping & Manufacturing (RPM).
  • RPM Rapid Prototyping & Manufacturing
  • the shoe is custom-made to exactly match the 3-D shape of a foot.
  • the shoe upper is made through a series of foot molding process.
  • the foot mold used as the shoe last has the exact 3-D shape of the foot.
  • the reverse engineering process for acquiring the 3-D foot shape is not necessary.
  • drawbacks associated with the method First, the clearance between the footwear and the foot cannot be adjusted or optimized since the foot mold is of the exact shape of the foot. In most cases, such exact matching between the shoe upper and the foot does not yield the highest fitting.
  • the shape and style of this kind of custom footwear cannot be adjusted since the last is set to foot shape.
  • the molding process is labor-intensive, costly and time-consuming.
  • optical scanning method is used in the reverse-engineering process for acquiring the 3-D computer model of the foot.
  • a laser strip travels through the foot surface.
  • a camera captures the curved laser strip as it travels along the foot surface so that the images can be processed to reconstruct the shape of the foot as discrete 3-D points.
  • the scanner reconstructs the 3-D point clouds according to optical triangulation method.
  • the acquired 3-D point-clouds on foot surface can be converted into a 3-D digital model in certain computer file format, so that the 3-D digital model can be imported into proper CAD software for further process.
  • Any optical scanner can be employed in the reverse-engineering process.
  • a portable, hand-held scanner is used.
  • the scanning covers the whole surface of the foot, including the upper surface of the foot and the plantar surface of the foot containing foot arch.
  • the scanning covers a part of the lower leg.
  • an apparatus In order to scan the plantar surface of foot effectively and accurately, an apparatus is designed to elevate the foot from ground, and support the foot at its plantar surface. In the scanning of foot plantar surface, the foot is pressed against a rigid and transparent plate made of glass or plasti-glass. The thickness of the plate is small so that laser beam can pass through the plate with negligible refraction.
  • the reverse-engineering process is as the follows. The wearer places his/her foot on the transparent plate of the foot-support apparatus, and adjusts the posture and position of the body and the foot until no stress is felt in the foot and the leg. As shown in Figures 1, an operator holds the hand-held laser scanner and makes multiple sweeps. The sweeps are made along different directions until the laser strip travels through the whole foot surface.
  • the reconstructed point clouds corresponding to the foot surface are displayed in real time on a computer screen.
  • the whole scanning process would comprise of N sweeps, with N determined by the completeness and quality of the reconstructed 3-D points of the foot surface.
  • a series of operations are performed on the reconstructed point clouds. These operations may include de-noising, removal of redundant points, check for completeness, interpolation to raw surface, and gap filling.
  • the raw surfaces generated from the point clouds are then converted into a 3-D computer model, which can be in any 3-D surface format such as STL, DXF, VRML, and IGES, etc.
  • Figure 3 shows an exported foot geometric model in Surface Triangulation List (STL) format.
  • the obtained 3-D computer model of the foot is used in both extracting key foot features for the searching and optimization of custom last, , and C ⁇ C machining of the plantar surface mold for the thermal-plastic forming of the custom insole.
  • a foot of a person has fingerprinting biometric features which uniquely representing the person.
  • both the 3-D surfaces of the last and the surface of the foot has to be abstracted into a set of quantitative features.
  • the dimensions along which the features are extracted should be adequate in representing the geometric characteristics of the foot and the last.
  • the dimensions that play important roles in determining the fitting between a foot and a shoe should also be included for feature extraction.
  • the 3-D foot model acquired by the reverse-engineering process is measured and analyzed to extract the key features of the foot.
  • the foot features are extracted along the dimensions that are used to describe a custom last of the wearer-picked style.
  • special foot features are extracted from the 3-D foot model in representing any local deformations of the foot, such as hammer toe, bunion, heel spur, etc.
  • the CAD software should have the capability of handling complex 3-D surfaces.
  • the 3-D surface model of the foot can be further converted into any other CAD model format to facilitate the measurement process.
  • a 3-D Cartesian coordinate system is bound onto of the foot model, as shown in Figure 4. Therefore, a set of cross- sections can be constructed with the reference of this coordinate system. In these cross-sections, the following geometric information of the foot is contained: the line on which the foot length is measured; the lines along which the fore-foot width and rear-foot width are measured; the planes on which the ball girth, the waist girth, and the instep girth are measured, and more.
  • the measurements of length and width are performed on the corresponding cross-sections by measuring the distance between two end-planes which containing the fore-most and rear-most points of the cross-section.
  • feature curves containing the girth information are constructed first on the corresponding cross-sections. The length of a feature curve is then measured or calculated as the girth feature.
  • a feature vector comprising of all the foot features is formed.
  • the foot features are placed into the feature vector with certain order that corresponds to the data fields in the targeted last table.
  • the feature vector extracted from the 3-D foot model is applied as the input in the search process for a best-fit last in the custom last database.
  • the automatic last look-up process is to compare the feature vector of the foot and that of a custom last with the desired style. It is guided by the rules from an software-based expert system.
  • the expert system contains expert knowledge for the optimum fitting between a foot and a last of the exact style. For all the styles derived from a base style, an expert system is and configured to guide the corresponding last look-up process.
  • the rules of the expert system are derived from the statistical analysis on a test population. The expert system suggests a range for the difference between any foot feature and the corresponding last feature.
  • an optimum difference between a foot feature and the corresponding last feature is automatically determined within the range imposed by the expert system.
  • This optimum difference is controlled by a set of rules in the expert system, such as the preferred sock thickness and the preferred shoe tightness of the wearer, etc.
  • a last- foot difference vector is formed by the expert system.
  • a desired last feature vector is then formed by adding the difference vector onto the foot feature vector.
  • the last look-up process is carried out to automatically search for a custom last with feature vector closest to the desired last feature vector.
  • the look-up process is performed as the follows. [0041] A computer software first picks a last table from the custom last database, which corresponds to the chosen style. A set of fitting indices are calculated for any last in this last table, as the following:
  • i is the z ' th last in the targeted last table
  • j is thejth dimension in the feature vector of a last
  • S stands for the fitting index
  • S 11 being the fitting index of last i along feature dimension j
  • S 1 being the overall fitting index of last i over all feature dimensions
  • w stands for the weight associated with the jth dimension of the feature vector of the last
  • DL stands for the feature vector of the desired last
  • L stands for the feature vector of a last in the targeted last table.
  • An upper threshold is set as the minimum requirement for any fitting index S 11 . Once the software finishes searching the targeted last table, the last with the highest fitting index S 1 is selected as the custom last providing all the fitting indices S 11 are below the threshold.
  • a last would be selected by the software for further modification into the custom last:
  • the primary feature dimensions of the last satisfies the primary requirements imposed by the desired last feature vector.
  • the secondary feature dimensions of the last are modified physically to meet the secondary requirements imposed by the desired last.
  • the primary feature dimension is the length of the last.
  • the secondary feature dimensions may include one or more of the following: forefoot width, rear-foot width, toe part height, ball girth, instep girth, waist girth, and heel girth, etc.
  • Such modification on the selected last is reversible. The last is restored into its original shape after the custom footwear is made.
  • the last- lookup software would not select any last from the targeted last table. Instead, a fully customized last would be made for the foot.
  • the fully customized last is first manufactured as a replica of the 3-D model of the foot. Then it is patched, smoothed, and finished into its final shape.
  • a variety of methods are available in making a replica of the 3-D foot model, such as 3-D CNC machining. In the preferred embodiments of the invention, a method similar to Rapid Prototyping & Manufacturing (RPM) is employed in replicate the 3-D foot model into a physical template for the fully customized last.
  • RPM Rapid Prototyping & Manufacturing
  • the finalized custom last is used for the making of custom shoe upper.
  • the upper style is determined by the last style.
  • a set of constraints is further imposed in the upper-making process. These constraints are imposed by certain geometric characteristics of the wearer' s foot that are involved in the motion of the foot but are not involved in defining the 3-D shape of the foot. These geometric characteristics are measured directly from the 3-D foot model. These constraints need to be met in the upper making process to ensure that the custom upper would not interfere with any motion of the foot. For example, one of such constraints is that the upper should not interfere with the foot movement about the ankle joint.
  • Multi-layered custom insole is a key component of the custom footwear in the preferred embodiments of the invention.
  • the custom insole is to provide elastic support to the foot arch to prevent arch fatigue from long-term expansion (standing) or cyclic expansion and contraction (walking), and to re-distribute the body load from the high pressure areas (especially the heel and metatarsal areas) onto the whole plantar surface.
  • the custom insole is also to provide custom cushioning and shock-absorption to the plantar surface of the foot.
  • the custom insole can be customized to accommodate any health problems associated with the foot plantar surface.
  • the arch support is achieved by integrating an elastic shell layer (the middle layer in Figure 7).
  • the shell layer sets the surface shape of the custom insole to conform to the plantar surface of the foot. It acts as non-linear distributed springs that support the arch of the foot. Therefore, body load can be distributed by the insole shell over the whole plantar surface. The pressure concentration on the heel and metatarsal area can be reduced, and the arch can be protected from long-term or cyclic deformation.
  • the shell layer is made of any thermal-plastic material that is elastic in room temperature and deforms plastically after being heated . In the preferred embodiments, the shell layer is made of thermal cork.
  • the thermal plastic forming process of the shell layer is as the following: A thermal-plastic forming mold is manufactured by CNC machining according to the generated plantar surface model of the foot (as shown in Figure 6).
  • the mold can be made from easy-to-machine and cheap materials such as wood or plaster.
  • a plate of shell material is heated until it can deform freely .
  • the heated shell plate is put against the mould surface and pressed by a vacuum pump until it deforms to match the exact surface of the mold. Then the shell plate is cooled down to room temperature, and trimmed to remove unnecessary materials according to the 2-D contour of the plantar surface model of the foot.
  • a layer of cushioning material and a layer of lining material are glued on top of the shell material before the thermal-plastic forming process. After the thermal-plastic forming process, these layers have the same surface shape and are trimmed together with the shell layer.
  • the cushioning layer is used for shock absorption. It also helps to distribute the high pressure at the heel and metatarsal areas onto the plantar surface of the foot by increasing the contact area between the foot and the insole. The thickness and the softness (Duro value) of the cushioning layer are customized according to the preferences of the wearer.
  • the lining layer is made of soft porous material, such as calfskin or lamp skin. The lining material is used to further increase the contact area between the foot and the insole, as well as make the custom insole breathable
  • a cushioning heel pad can be attached onto the insole bottom at the heel area (see Figure 7).
  • the insole heel pad is integrated into the custom insole to provide additional cushioning and shock absorption for the heel since the heel takes the most of the body load while standing or walking.
  • the insole heel pad also helps to adjust the position of the foot to let the foot set in a stress-free position along the foot length direction.
  • the insole heel pad is also made with custom softness and thickness according to the wearer's preferences.
  • FIG. 7 shows an example of the multi-layered custom insole of the invention.
  • a custom sole comprises of a midsole, a rigid heel pad, and an outsole.
  • the midsole and outsole sandwiches the heel pad, as shown in Figure 8.
  • the 2-D outlines of these sole components are trimmed according to the 2-D contour of the bottom of the custom last.
  • the rigid heel pad elevates the heel of the wearer, so that the clearance between the foot plantar surface and the top of the outsole tapes down from the heel to the toe.
  • the height of the sole heel pad is customized according to the wearer's preference. Interactive measurements are carried out for the optimum height of the sole heel pad, as the following: The wearer is requested to step on two 5 mm-thick pads, with the pads beneath the heels.
  • the custom footwear of the invention is made by a bi-level customization process.
  • the first level of customization relates to the customization of the footwear according to the wearer's biometric characteristics, as described in the previous sections.
  • the second level of customization relates to further customization of the footwear based on the subjective needs and tastes of the wearer. These personal needs and tastes may include the health-care requirements, the colors and materials of the footwear, and any footwear accessories such as personal monograms and logos, etc.
  • the wearer has selected his/her preferred style from diversified shoe styles before the last look-up process.
  • the wearer may design the appearance of the footwear with the selected style, or make further modifications on any footwear component of the selected style. Collections of colors, materials, shapes or types of footwear components of the style, are provided to the wearer so that he/she can build his/her own footwear with his/her preferred appearance. For example, a color template of 36 colors are provided to the wearer so that the wearer can select his/her preferred color for any patch of the custom footwear.
  • a material template composed of different upper material (leather or non-animal materials), insole materials (cushioning and lining materials), and outsole materials (leather, rubber, etc.), are also provided to the wearer so that the wearer can select the preferred materials for the custom footwear.
  • Footwear accessories for cosmetic or personal use can be integrated into the custom footwear, such as monograms and logos.
  • Personalized marks such as characters or favorite drawings, can also be integrated into the custom footwear according to the wearer's opinion.

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  • Life Sciences & Earth Sciences (AREA)
  • Biophysics (AREA)
  • Footwear And Its Accessory, Manufacturing Method And Apparatuses (AREA)

Abstract

Cette invention concerne un système et des procédés de fabrication de chaussures faites sur mesure. Un processus de fabrication sur mesure à plusieurs niveaux est employé dans le système de l'invention. Premièrement, on fabrique sur mesure une forme pour chaussures en fonction des caractéristiques biométriques du pied. Deuxièmement, on ajuste précisément les composants des chaussures, par l'intermédiaire d'une série de mesures interactives, aux besoins de celui qui les portera (le client), tandis que l'on conçoit sur mesure l'aspect des chaussures en fonction des goûts du client. Les principaux composants des chaussures faites sur mesure comprennent : une empeigne faite sur mesure, qui correspond le mieux à la forme du pied du client; une semelle intérieure multicouche faite sur mesure, dont la surface se conforme à la surface plantaire du pied; et une semelle faite sur mesure, prenant en sandwich une talonnette à hauteur sur mesure. Les procédés de fabrication sur mesure des chaussures comprennent : la construction d'une base de données de formes sur mesure, l'ingénierie inverse pour le modèle de pied en 3D, la mesure et l'analyse pour les caractéristiques du pied, la consultation de formes automatique guidée par un système expert pour la forme qui correspond le mieux, la modification et la mise au point sur la forme qui correspond le mieux, la fabrication sur mesure de l'empeigne de la chaussure en utilisant la forme sur mesure, la fabrication sur mesure d'une semelle intérieure multicouche en fonction de la géométrie de la surface plantaire du pied, la fabrication d'une semelle faite sur mesure, et l'intégration de l'empeigne, de la semelle intérieure et de la semelle faites sur mesure dans les chaussures sur mesure finales. Dans le mode de réalisation préféré, les chaussures faites sur mesure sont fabriquées par l'intermédiaire du processus suivant. Premièrement, on construit une base de données de formes sur mesure, qui stocke les caractéristiques géométriques de formes conçues sur mesure le long de multiples dimensions. Dans la base de données des formes, un tableau de formes correspond à un style de chaussures. On utilise un processus d'ingénierie inverse pour acquérir un modèle informatique en 3D du pied. Le modèle en 3D du pied est davantage mesuré et analysé afin d'extraire les caractéristiques en 3D du pied. Lors du processus de mesure du pied, non seulement on mesure les géométries du pied le long des dimensions de la forme, mais aussi on enregistre la forme en 3D et les emplacements de toutes les anomalies du pied. On réalise ensuite une consultation de formes automatique en fonction des caractéristiques de pied extraites, qui répètent le tableau de formes du style souhaité. Dans ce processus, des indices d'ajustage de toutes les formes sont calculés par des algorithmes d'ajustage dérivés d'un ensemble de règles provenant d'un système expert. Les indices d'ajustage montrent les niveaux d'ajustage entre les caractéristiques de formes et celles du pied. Une forme qui correspond le mieux est choisie dans la base de données des formes après tri de tous les indices d'ajustage des formes. La silhouette en 3D de la forme qui correspond le mieux peut être encore plus mise au point et optimisée afin de contenir n'importe quelles difformités ou irrégularités du pied du client. Dans certains cas, on fabriquera une forme entièrement sur mesure si le processus de consultation ne permet pas de sélectionner une forme qui correspond le mieux. On fabrique ensuite l'empeigne des chaussures faite sur mesure en utilisant la forme sur mesure finalisée. Pour la semelle intérieure, un moule de formage thermoplastique est fabriqué par le processus d'usinage à commande numérique par ordinateur (CNC, 'Computer Numerical Controlled') en se référant à la silhouette en 3D de la surface plantaire du pied. Une plaque multicouche, comprenant une couche de matiè
PCT/US2007/086014 2006-12-01 2007-11-30 Système et procédés de fabrication de chaussures faites sur mesure WO2008070537A2 (fr)

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EP2203082A1 (fr) * 2007-10-23 2010-07-07 Nike International Ltd. Articles et leurs méthodes de fabrication
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WO2012037660A1 (fr) * 2010-09-22 2012-03-29 Incubateur Technologique Inovum Inc. Procédé et système pour fournir au moins une chaussure personnalisée à un utilisateur
BE1019296A3 (nl) * 2010-04-19 2012-05-08 Faes Herman Joannes M Werkwijze voor het maken van orthopedische, maat-en binnenschoenen en leest gebruikt in deze werkwijze.
EP2589311A1 (fr) * 2011-11-04 2013-05-08 Spannrit Schuhkomponenten GmbH Procédé et dispositif de fabrication et d'adaptation de semelles orthopédiques adaptées de manière individuelle
ITMI20112162A1 (it) * 2011-11-28 2013-05-29 Bruno Marelli Metodo di fabbricazione di calzature
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EP2779898A4 (fr) * 2011-11-17 2015-08-19 Techmed 3D Inc Procédé et système pour former un modèle virtuel d'un sujet humain
US20160081435A1 (en) * 2014-09-23 2016-03-24 William H. Marks Footwear recommendations from foot scan data
CN105708049A (zh) * 2009-04-30 2016-06-29 耐克创新有限合伙公司 物品和制造物品的方法
WO2017025779A1 (fr) * 2015-08-13 2017-02-16 Trya S.R.L. Procédé pour sélectionner une chaussure par comparaison des mesures d'un pied aux mesures de formes à chaussure
CN106510097A (zh) * 2016-11-14 2017-03-22 吴志龙 制作定制鞋的方法
WO2017144663A1 (fr) * 2016-02-24 2017-08-31 Ecco Sko A/S Système et procédé de commande d'une machine de fabrication de pièces de chaussure
ITUB20161214A1 (it) * 2016-03-01 2017-09-01 Annarita Borrelli METODO PER LA REALIZZAZIONE Dl CALZATURE SU MISURA
CN108402601A (zh) * 2018-03-15 2018-08-17 李富志 一种营销鞋类的自选搭配制作方法
CN108772992A (zh) * 2018-05-18 2018-11-09 东莞市兴茂橡塑科技有限公司 脚模的制作方法、装置及成品鞋的包裹性判定方法
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WO2020201505A1 (fr) * 2019-04-04 2020-10-08 Onefid Gmbh Dispositif pour fabriquer une semelle intérieure configurée individuellement pour une chaussure
DE102019108822A1 (de) * 2019-04-04 2020-10-08 Onefid Gmbh Vorrichtung zur Fertigung eines individuell konfigurierten Leistens
CN112989669A (zh) * 2021-04-01 2021-06-18 南通大学 一种针对糖尿病足垫的个性化设计方法
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CN113360477A (zh) * 2021-06-21 2021-09-07 四川大学 一种大规模定制女式皮鞋的分类方法
EP3916346A1 (fr) * 2020-05-27 2021-12-01 Medere Srl Procédé de production d'orthèses personnalisées
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CN115067627A (zh) * 2021-10-21 2022-09-20 安世亚太科技股份有限公司 一种定制鞋楦自动生成系统及方法、设备、存储介质、云平台
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WO2009036939A3 (fr) * 2007-09-18 2009-05-07 Magari S R L Procédé pour calculer la géométrie d'une forme pour chaussure sur mesure
WO2009036939A2 (fr) * 2007-09-18 2009-03-26 Magari S.R.L. Procédé pour calculer la géométrie d'une forme pour chaussure sur mesure
EP2564711A1 (fr) * 2007-10-23 2013-03-06 Nike International Ltd. Articles et procédés de fabrication d'articles
EP2203082A1 (fr) * 2007-10-23 2010-07-07 Nike International Ltd. Articles et leurs méthodes de fabrication
EP2203082B1 (fr) * 2007-10-23 2016-03-30 NIKE Innovate C.V. Articles et leurs méthodes de fabrication
CN105708049A (zh) * 2009-04-30 2016-06-29 耐克创新有限合伙公司 物品和制造物品的方法
CN101658347B (zh) * 2009-09-24 2011-11-30 浙江大学 一种脚型动态形状获取方法
BE1019296A3 (nl) * 2010-04-19 2012-05-08 Faes Herman Joannes M Werkwijze voor het maken van orthopedische, maat-en binnenschoenen en leest gebruikt in deze werkwijze.
WO2012037660A1 (fr) * 2010-09-22 2012-03-29 Incubateur Technologique Inovum Inc. Procédé et système pour fournir au moins une chaussure personnalisée à un utilisateur
EP2589311A1 (fr) * 2011-11-04 2013-05-08 Spannrit Schuhkomponenten GmbH Procédé et dispositif de fabrication et d'adaptation de semelles orthopédiques adaptées de manière individuelle
US9691176B2 (en) 2011-11-17 2017-06-27 Techmed 3D Inc. Method and system for forming a virtual model of a human subject
EP2779898A4 (fr) * 2011-11-17 2015-08-19 Techmed 3D Inc Procédé et système pour former un modèle virtuel d'un sujet humain
ITMI20112162A1 (it) * 2011-11-28 2013-05-29 Bruno Marelli Metodo di fabbricazione di calzature
WO2014068160A1 (fr) * 2012-10-29 2014-05-08 Francisco Ripoll Juan Semelle pour chaussure unifiée et procédé de fabrication de semelles
ES2482465A1 (es) * 2012-12-10 2014-08-01 Francisco RIPOLL JUAN Sistema huella-barro para plantilla de calzado
US20160000188A1 (en) * 2013-03-14 2016-01-07 Jason R. Hanft Protective patient footwear design and manufacturing system and methods
US20180343981A1 (en) * 2013-03-14 2018-12-06 Modern Protective Footwear, Llc Protective Patient Footwear System and Methods
EP2973079A4 (fr) * 2013-03-14 2016-12-07 Jason R Hanft Système et procédés de conception et de fabrication de chaussures de protection pour patient
US10575596B2 (en) 2013-03-14 2020-03-03 Modern Protective Footwear, Llc Protective patient footwear system and methods
WO2014159179A1 (fr) 2013-03-14 2014-10-02 Hanft Jason R Système et procédés de conception et de fabrication de chaussures de protection pour patient
WO2014179705A1 (fr) * 2013-05-03 2014-11-06 Yooshu Llc Chaussures sur mesure, et système et procédés de fabrication de chaussures sur mesure
US20160081435A1 (en) * 2014-09-23 2016-03-24 William H. Marks Footwear recommendations from foot scan data
WO2016049184A1 (fr) * 2014-09-23 2016-03-31 Marks William H Recommandation d'articles chaussants à partir de données de balayage de pied
US9648926B2 (en) 2014-09-23 2017-05-16 William H. Marks Footwear recommendations from foot scan data describing feet of a user
WO2017025779A1 (fr) * 2015-08-13 2017-02-16 Trya S.R.L. Procédé pour sélectionner une chaussure par comparaison des mesures d'un pied aux mesures de formes à chaussure
WO2017144663A1 (fr) * 2016-02-24 2017-08-31 Ecco Sko A/S Système et procédé de commande d'une machine de fabrication de pièces de chaussure
US10772386B2 (en) 2016-02-24 2020-09-15 Ecco Sko A/S System and a method for controlling a shoe part production machine
JP2023052233A (ja) * 2016-02-24 2023-04-11 エッコ スコ アクティーゼルスカブ 靴部品製造機を制御するためのシステムおよび方法
JP7431354B2 (ja) 2016-02-24 2024-02-14 エッコ スコ アクティーゼルスカブ 靴部品製造機を制御するためのシステムおよび方法
ITUB20161214A1 (it) * 2016-03-01 2017-09-01 Annarita Borrelli METODO PER LA REALIZZAZIONE Dl CALZATURE SU MISURA
CN106510097A (zh) * 2016-11-14 2017-03-22 吴志龙 制作定制鞋的方法
CN110179204A (zh) * 2018-02-22 2019-08-30 意礴科技有限公司 推荐鞋楦的系统及方法和预测鞋楦舒适度的系统和方法
CN110179204B (zh) * 2018-02-22 2022-06-24 意礴数字科技(深圳)有限公司 推荐鞋楦的系统及方法和预测鞋楦舒适度的系统和方法
CN108402601A (zh) * 2018-03-15 2018-08-17 李富志 一种营销鞋类的自选搭配制作方法
CN108772992A (zh) * 2018-05-18 2018-11-09 东莞市兴茂橡塑科技有限公司 脚模的制作方法、装置及成品鞋的包裹性判定方法
US20230016881A1 (en) * 2018-06-29 2023-01-19 Bauer Hockey, Llc Methods and systems for design and production of customized wearable equipment
US20210213697A1 (en) * 2018-07-20 2021-07-15 Hewlett-Packard Development Company, L.P. Shoe manufacturing
US11701852B2 (en) * 2018-07-20 2023-07-18 Hewlett-Packard Development Company, L.P. Shoe manufacturing
WO2020201505A1 (fr) * 2019-04-04 2020-10-08 Onefid Gmbh Dispositif pour fabriquer une semelle intérieure configurée individuellement pour une chaussure
DE102019108822A1 (de) * 2019-04-04 2020-10-08 Onefid Gmbh Vorrichtung zur Fertigung eines individuell konfigurierten Leistens
EP3916346A1 (fr) * 2020-05-27 2021-12-01 Medere Srl Procédé de production d'orthèses personnalisées
EP3964098A1 (fr) * 2020-09-04 2022-03-09 ASICS Corporation Appareil de génération de données, système de production de formes pour chaussures et procédé de génération de données
WO2022200973A1 (fr) * 2021-03-24 2022-09-29 Cuini Enrico Système permettant de choisir une chaussure
CN112989669A (zh) * 2021-04-01 2021-06-18 南通大学 一种针对糖尿病足垫的个性化设计方法
CN113360477A (zh) * 2021-06-21 2021-09-07 四川大学 一种大规模定制女式皮鞋的分类方法
CN115067627A (zh) * 2021-10-21 2022-09-20 安世亚太科技股份有限公司 一种定制鞋楦自动生成系统及方法、设备、存储介质、云平台
CN115067627B (zh) * 2021-10-21 2024-05-03 安世亚太科技股份有限公司 一种定制鞋楦自动生成系统及方法、设备、存储介质、云平台
EP4265144A1 (fr) * 2022-04-20 2023-10-25 Min-Chih Shih Chaussure et procédé de moulage de semelle intercalaire

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