Enhanced Digital Capability Through the Use of Simulation in Footwear Product Creation

Abstract

Digital simulations, such as those utilizing the Finite Element Analysis method, are a common engineering tool in product development to build confidence in product performance and robustness of design. Footwear product creation has historically been a blend of art and science, with design teams relying on 2D sketches sent to factory partners to create physical samples of shoes with the desired aesthetics. These samples were then tested mechanically and on athletes to verify the structural integrity of the design. This thesis explores how FEA simulation can be implemented into the footwear development process, especially in the environment and context of an onsite product creation center.

First, a case study on plate bending analysis to measure relative stiffness of cleated footwear design features is presented, exploring three approaches: mechanical testing, beam theory calculations using plate geometry, and FEA simulation. All three approaches will provide similar results for design teams. However, depending on the project timeline, level of complexity, and resources available, a team should evaluate the best approach.

Next, a framework for a qualitative cost-benefit analysis is developed to aid footwear business leaders to decide if investment in digital tools such as FEA are worth their expected benefits. The major costs of implementing FEA into a product creation center will be the start up time and financial cost of FEA engineers, software programs, and integration into the companies design process. However, the benefits could provide increased product quality, higher customer satisfaction with performance, and positive mindset shifts within design teams, allowing cross-functional team members to be more collaborative and efficient in their communication.

While the potential benefits could increase sales and brand loyalty in the long run, investment in a digital service like FEA may not be suited for a product creation center, whose main focus is on building low volume physical footwear prototypes. Instead, FEA simulation and other digital capabilities should be integrated directly into design teams responsible for footwear projects. The hope is that the case study and associated cost-benefit analysis developed in this thesis can be applied to the evaluation of other technologies and digital tools into the footwear industry.