Smart Shoes

Why can't the toe box on my shoes tell me how fast and how long I've been running?

 

What if you wanted to know the optimal spot on your foot to take a free kick from?

Today, Apple was granted a patent for conductive carbon nanotubes to be used in a fold-able Iphone.

These tubes form flexible strands that hold signals (electricity) and are flexible and resistant to cracking.

Apple has found a way to bend displays and stretch signals over a small folded area.

 

With the release of the Nike HyperAdapt and Air Mag, there is a push to have shoes be more adaptive and responsive to the athlete.

After the fold-able phone, the smart shoe will be next. 

For smart shoes to succeed, the wiring and connections needed to power the shoe have to integrate seamlessly into the shoe.

 

The guts.

The guts.

Embedding conductive carbon fibers into a flyknit upper would create a feedback loop for the athlete.  Using touch sensors embedded in the sole and upper, an athlete could see stride, speed and impact information displayed on a phone, or directly on the toebox.

A soccer player, who now has a target displayed directly on his boot, to guide him to his strongest spot for a free kick.

The basketball player, who can see how high they jumped for the last rebound.

Nike Ease Challenge

On Oct 28th, Nike announced the Nike Ease Challenge, which invites designers, engineers, makers and innovators to advance and reinvent footwear design for athletes of all abilities. The $50,000 challenge continues Nike’s leadership in driving footwear innovations that help all athletes to live more active and independent lives.

I've worn some of the alternative entry system shoes Nike has put out in the past. 

Love the Air Rift.

I dug into the patent vault to learn more.  For the Nike FlyEase, a lacing system is connected to a strap of velcro along with the use of a zipper.  I didn't realize there was a lacing system connected through the strap to make the shoe tighter.  Here are some of the shoe sketches below.

For my design I'm thinking about:

Magnets to open and close foot entry

how can an athlete tighten a shoe with limited mobility?

how can an athlete take off a tightened shoe with limited mobility?

two separate uppers that weave through each other

how can you open an upper for a larger foot, then create an adaptive level of ankle support?

how can you mechanize the closure of a shoe differently than the AIRMAG (motor in sole)?

How can you use rubber and stretch materials to provide support?

an adaptive lacing system in between the liner and the upper

stretch weave materials

A removable heel counter

early concepts from the Nike FlyEase Video

early concepts from the Nike FlyEase Video

Here's some of the videos I watched while coming up with ideas/inspirations.

Sneaker School - Recap

Over 60 hrs of work created a pair of bespoke Air Jordan 1's.  The process of making a pair of sneakers is straightforward: cut leather, sew leather, stretch leather, glue on sole. 

Even with a straightforward process, the shoe maker has the ability to put creativity and innovation into each pair he creates.

Its All A Process

Its All A Process

There were early mornings and late nights, but it was all worth it.  Stitching the leather was the toughest part for me.  A crooked stitch meant the thread had to be removed and that piece of leather might need to be replaced.  There was no room for error.

Dom "The Shoe Surgeon"

Dom "The Shoe Surgeon"

The Box

The Box

I'm extremely proud of what I created.  From the flyknit and leathers down to the lasting and stitching, I made it.  I have a Nike sole and a swoosh, but it was made by Aaron. 

One of One.

The 11 students came from different backgrounds, but all shared a love for sneakers and making.  Throughout the whole class, we learned and worked together.  Everyone helped each other realize thier creations.  I was grateful and inspired by the way we worked together as a team.

Dinner with the class

Dinner with the class

Sneaker School - Day 5

The 5th and last day is also the LAST day.  I started out with a fully stitched upper, sock and toe liner included.  The other students were at various stages of the construction process.  As one person finished learning, they were teaching someone else how to do it.  It was great,

The upper materials now need to stretch (lasted) over the silhouette of the Air Jordan 1.  The shoe last is made in the shape of the shoe, and is made from a plastic so nails can be used to pull the leather tight .  Before the leather is lasted, we nailed a board to the bottom of the last.  This is the strobel, the bottom of the shoe and the part that holds everything together.

With the strobel tacked onto the last, I started pulling and nailing the leather to the last.  First you pull down the heel, the the toe then alternate from side to side until the leather takes the shape of the last.

After lasting, the leather is bonded to the strobel, then the nails are removed.

The excess material on the bottom of the shoe is skived off to fit into the outsole. 

After seating the upper into the outsole cup, you mark the permeter of the shoe with a pen, this is the cement bond line to hold the shoe together.

The outsole and upper are bonded together, then the upper and sole are stitched together.

Tomorrow, I'll share pictures of the sneakers and what I learned from the course.

Sneaker School - Day 4

Day 4 was all about finishing sewing 30 pieces of leather, flyknit and fabric into two uppers.

With symmetrical patterns, the medial (inside) and lateral (outside) part of the shoe are the same.   The small cutouts on the top of the pattern (image to the right) are the stitching paths, to help line up each of the pieces.  The bottom row of cut outs are the guide for bottom edge of the shoe.

As each piece was stitched on, scraps turned into pieces, pieces turned into sections.  Once all of the outward facing pieces were sewn together, the shoe liner was added. 

One of my favorite aspect of Day 4 was being able to select the thread color.  I had a chance to do contrast stitching on the white leather and red swoosh, but still keep a black stitch on the pattern pieces.

To match the sole and the swoosh, I picked a red sock liner.  The sock liner is sewn on inside out to the outside of the shoe, foam is glued on, then its flipped and sewn onto the inside of the shoe. 

 

Day 4 was tough, lots of sewing and gluing. I didn't spend much time taking pictures, wanted to finish my shoe on time.

One of the final stitches was connecting the toe box to the upper.

The end of day 4 was a fully sewn upper and an outsole.  Time to connect the two...

IMG_5992.PNG

UP NEXT - DAY 5 - Lasting and Sole Bonding

Sneaker School - Day 2

I came in early on Day 2 because I wasn't very confident in the accuracy of my patterns.  After removing loose threads and adhesive from the edges and being more deliberate, the re-cut patterns were ready to roll.

Normally, the left and right shoe are made with different patterns.  For time and simplicity, we used one pattern to make the left and right shoe.  We had to take extra effort to ensure that certain pieces were symmetrical.

Next was material selection.  Ecco Leather had so many different colors and textures that it was tough to decide on the 2-3 to work with.

The pair I deconstructed had a white/red outsole, so I knew it was best for the swoosh to match the outsole. 1st color - Red.  The design of the AJ 1 incorporates a straight lines throughout (see below), so I wanted to pick a textured natural pattern to offset those lines but also connect with the outsole.  2nd color - black and white textured natural pattern.  I went with a natural white leather to balance the pattern.  3rd color - white leather.

Air-Jordan-1-341.jpg

 

Along with the base materials, I choose two accent pieces, a hexagonal stamp pressed leather, along with a swatch of my own deconstructed Airmax 2016 FlyKnit's.   The hex and flyknit pieces are my way of infusing technology and personal inspiration into my design.

Here are the four materials I selected for my AJ 1 (brought to you by Ecco Leather.)

Next step was tracing the pattern onto the leather pieces and cutting the material.

The end result from day 2.

UP NEXT - DAY 3 - Skiving and Sewing

Sneaker School - Day 1

The Decon/Recon course started today in Downtown LA.

Prior to the start of class, we selected a base shoe for customization. 

I chose to build my custom sneaker from the Air Jordan 1, designed by Peter Moore.  Besides the color of the outsole, the base colorway of the shoe doesn't matter, we will be replacing all the upper materials with a selection of leathers from Ecco Leather.

Air Jordan 1

Air Jordan 1

The first step in the deconstruction is removing the stitching and the outsole from the upper.

The bone folder, one of the tools we received with the class, is vital for separating the leather from the outsole without damaging either surface.

Removing the sole using a bone folder

Removing the sole using a bone folder

After the outsole is removed, I deconstructed the upper starting with the swoosh.

A thread puller and exacto knife were used to remove each component with surgical precision.

IMG_5831.JPG

There are over 1000 individual stitches in each shoe.  During the deconstruction process, I could see deeper into the footwear manufacturing process.  I started to understand how and why pieces are shaped in a certain way.  Why double and triple stitches exist at critical points in the shoe.  You can see the amount of labor that goes into making each pair of shoes.

Swooshless

Swooshless

The end result was 15 pieces needed for pattern tracing.

The final product of deconstruction

The final product of deconstruction

The final task for day 1 was pattern tracing.

Along with tracing the outside profile of each piece, we had to trace the stitch lines for all pieces that overlap other pieces.

UP NEXT - DAY 2 - material selection and pattern cutting

Sources

http://www.complex.com/sneakers/2015/05/why-the-chicago-jordan-1-matters

Decon & Recon - The Shoe Surgeon

““The capacity to learn is a gift; The ability to learn is a skill; The willingness to learn is a choice.” ”
— Brian Herbert

Next week, I'll be in taking the Decon/Recon course offered by The Shoe Surgeon.  Over 5 days, with a handful of other students, we will take an existing shoe, deconstruct it, cut/sew new patterns and end up with a one of one shoe. 

Custom AJ 1 - The Shoe Surgeon

Custom AJ 1 - The Shoe Surgeon

I'm excited to work with The Shoe Surgeon (Dominic Chambrone).  His story is inspiring and we share a similar vision for improving and creating newness.

“I want to evolve and do stuff that no one else has done yet in the industry and be ahead of the game”
— Dominic “The Shoe Surgeon” Chambrone

The course will also bring together students who share a passion for shoes and learning.  Until now, there were few places where people can gain footwear experience outside of a shoe repair store or working for a large footwear company.  Learning by doing is the best way to gain footwear experience.

Besides gaining experience, the course give you the skills necessary to start your own footwear business.

I'm looking forward to creating a story through my pair.  Selecting the colors and materials, cutting and sewing using my hands.  The end product is a true reflection of my creativity, hard work and attention to detail.

 

The future of footwear

Imagine a time in the not too distant future. 

You will walk up to a automated machine in the mall, put on a headset and begin to design you own shoes.

Nike's recent patent for augmented and mixed reality technologies.

Nike's recent patent for augmented and mixed reality technologies.

When the upper and midsole designs are finalized, it's sent over to two separate machines, where the upper and midsoles are printed out. The upper is a flat knitted.  The midsole would either be 3D printed, or fully injection molded and kept in on-site inventory.

For this scenario to become a reality, the next step in the process, the bonding of the upper to the midsole, would have to be automated.

From the two videos above, and for 99% of shoes created today, the upper/midsole connection is a hands-on labor intensive process.

I believe that bonding process is the biggest constraint to the future of the rapid manufacturing in the footwear industry.

Count the number of hands that were involved in the manufacturing of these ultraboosts below.

Nike, recently submitted a patent for a steamer used on a knitted upper to give the consumer a one of a kind fit.

I think something else could be going on.

With water activated adhesives already in use in the industry, this steamer box could become part of a new process to bond the upper to the midsole.  If the fibers were coated in a water activated adhesive, then knitted on the base of the upper and the perimeter of the shoe, you could potentially create a strong enough bond between the upper and the midsole during the steaming process.  When the customer tries on the shoes for the first time, they would apply pressure to the upper/midsole bond and form the shoe to their foot.

Another possibility, would be to mechanically knit the upper directly to the midsole during the initial manufacturing steps.  The design of the midsole would have to be modified to allow for fibers to loop through and provide support. 

Below is the concept in action on the Nike Considered line back in 2007.

Nike Considered Long Ball Slip-On

Nike Considered Long Ball Slip-On

With negative environmental effects from shipping, labor costs rising, and the demand customized products, I'm know Nike and Adidas have something cooking in the kitchen.

Sources

http://www.investors.com/news/flyknit-future-nike-files-for-portable-shoe-steaming-box-patent/

https://hypebeast.com/2007/9/nike-considered-long-ball-slip-on

http://uploadvr.com/nike-ar-system-design-clothes/