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Additive Manufacture Design

BRIEF

‘Design a flip-flop for a specific user group that leverages the advantages of additive manufacturing principles ’

March 2020

 

SKILLS

 

CAD

FEA

 
 

This was a solo project to design a flip-flop for additive manufacture. Mine included an optimised lattice structure in the heel, innovative strap design, customised insole layer for flat-feet and customised outsole layer for material optimisation.

I recieved the prize for best project in this module. This was competing against over 50 others from a variety of different degrees.


mass reduction

Two main attempts to remove mass form the sole where attempted. Initially using topology optimisation and generative design algorithms with Fusion 360, and then later using the lattice software NetFabb to create a more optimised design.

 
Topology optimisation, showing organically optimised, but failed struture

Topology optimisation, showing organically optimised, but failed struture

 
 
Cross section showing a pentra-cube lattice embedded within the heel of the flip-flop

Cross section showing a pentra-cube lattice embedded within the heel of the flip-flop

 
 
Outsole of the flip-flop optimised for my weight distribution

Outsole of the flip-flop optimised for my weight distribution