Raise3D: 3D printing to replace traditional footwear production

Gradually, 3D printing penetrates into all areas of our life. In addition to the usual directions, such as prototyping, the creation of architectural models, parts, master models, household items, etc., 3D printers are used for other purposes. The production of shoes using additive technologies is not a new direction, but at the moment it is not widespread. There are companies that use 3D printers, as an additional element to the main production - the creation of accessories, jewelry, footwear design elements. Some also make shoes on a 3D printer "turnkey" from the insole to the sole)

Among the clients of Raise3D there are two companies that use 3D printers for the manufacture of specialized sneakers and the manufacture of intelligent insoles. Let's tell their stories.

Creation of specialized sports shoes on Raise3D 3D printers

At 25, Oliver Brossmann has already become an entrepreneur and developer of unique sports shoes. In childhood, he, like many boys, dreamed of becoming a professional footballer. But after the knee surgery in the upper grades, I had to say goodbye to the dream. During the period of recovery, Brossmann began to study approaches to running and exercises with minimal stress on the joints and knees. In Brossmann College, in addition to the main subjects, I visited a couple of computer science and prototyping classes. Pursuing the goal of realizing his business idea and putting his knowledge into practice, Oliver left college and began working on his own startup Prevolve. This project was developed from scratch with a small investment from a private investor. Oliver’s start-up at the moment is Oliver himself, a couple of part-time employees and his sister, who helps with working moments.

After 3 years, Brossmann officially launched his company's first product, called BioRunners. The shoes were created on the BioFusion platform, developed by Oliver for 3D printing of special sports shoes. In combination with a professional foot scanner that produces an accurate scan, the product became better and better with each iteration.

Prevolve shoes are printed from thermoplastic polyurethane, a material that is durable and resistant to abrasion. In the online store Prevolve, customers can choose the appropriate color, thickness of the shock absorber and tread - for the trail or street run.

“Each pair of shoes is designed for a specific foot and, accordingly, the shape of each shoe is unique. I am still thinking of upgrading the design to make sneakers more attractive and increase productivity, ”says Oliver.

Printing Prevolve shoes on a 3D printer, depending on the size, takes from 20 to 30 hours. Oliver uses Raise3D printers, the construction area of ​​which is optimal in size for printing sneakers.

Buyers of Prevolve shoes are sportsmen, professionals and amateurs, as well as people with foot features (different sizes of legs, flat feet, etc.). Shoes printed on a 3D printer, is the most budget and fast to manufacture option compared to orthopedic., Made to order in the traditional way.

3D printing of intelligent insoles on Raise3D N2

Dr. Roy Cheng from Gait & Motion Analysis Lab is the creator of smart intelligent insoles printed on a 3D printer. Roy himself is interested in running and wanted to buy smart insoles for himself, but the expensive market value made him think about the implementation of this project himself.

Roy specializes in running biomechanics, the effectiveness of prophylactic devices for athletes, conducting training in rehabilitation and injury prevention, and received major research grants for his designs.

Both the creation of a custom-made insole and the development of a smart insole using traditional methods is a complicated and expensive process, and the target audience is very narrow.

Disadvantages of the traditional method used at the beginning by Roy Cheng and his team:

The traditional production method is:

Using Raise3D N2, the company was able to:

Production process:

The equipment list includes: a computer, a scanner, a printer instead of a thermoforming and grinding machine.

Smart insoles consist of electronic sensors and thermoplastic bases. The production process can be divided into three main stages:

- Foot scan;
- Modeling insoles and sensor layout / design;
- Printing / installing electronics.

First, the feet are scanned, the result of the scan will be used to model the insole. Using the visualized scan data in the modeling software, you can easily find the right solution for the location of the sensors on the insole, taking into account its shape and scanned leg model. Two pressure sensors are placed around the heel and metatarsal bone. Bluetooth modules are installed in the fold area.

Using a rendered model and 3D printing, Roy maximized the protection of electronics located on the insole. It was possible to do this by correctly placing all the components on the insole and controlling the hardness of the insole by selecting the desired filament and the percentage of filling the model when printing. All electronic components are placed between the layers.

Using 3D printing, Roy’s company was able to remove most of the insole manufacturing processes. Raise3D N2 can build a finished product in and out with an individual insole shape and a specific arrangement of elements, and automatically leave space for the circuit. After installing the circuits, the printer completely covers the electronics, printing the upper additional layers.

By automating this process, labor costs, equipment costs and lead time are reduced.

Most importantly, Raise3D allows you to customize the printing of the insole and the placement of the pattern in one print session. As a result, the cost of the insole decreases several times, the production time is reduced from 2 weeks to 5 days (or less).

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The team of the company Color World

Source: https://habr.com/ru/post/408307/

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