HOME
LINKEDIN
Personalised Flip-Flops Addressing Supination
Design for Additive Manufacturing
Project Duration: 3 months
Solo Project
Foot pressure data collection and analysis, parametric design translation using MATLAB and CAD, mechanical design of multi-material soles (including lattice structure optimization and heel geometry), 3D modelling (SolidWorks), simulation of stress distribution and energy absorption, and additive manufacturing preparation (DfAM and MJF process setup). Conducted material selection (TPU and PA12), developed functionally graded lattices (gyroid and Schwarz D), and performed design validation for comfort, ventilation, and durability.
This project, Personalised Flip-Flops Addressing Supination, reimagines everyday footwear through Additive Manufacturing (AM) to provide bespoke biomechanical support. Motivated by personal experience with supination, I conducted foot pressure mapping and used MATLAB to translate the data into a CAD model, designing a flip-flop tailored to my gait. The final design integrates multi-material 3D printing using TPU and PA12 with functionally graded lattice structures — a gyroid midsole for shock absorption and a Schwarz D lattice upper sole for targeted reinforcement. Elevated heel geometry enhances stability, while traction grooves improve grip. Manufactured via Multi Jet Fusion (MJF), the design eliminates traditional tooling, reduces material waste, and enables rapid, cost-efficient customization. This project demonstrates how digital fabrication and parametric design can enhance comfort, durability, and ergonomic performance in personalized wearable products.
Scroll for Overview of Each Section