Learning About : 3D Drawing

October 22, 2016

The outsole of this Reebok was printed using a technology developed for the automotive industry.

As a first step, this technology can create an outsole pattern without a mold. However, the problems found in traditional footwear manufacturing of adhering the upper to the midsole is still present.

I could see this printing out a full upper if a last is used to help retain the shoe's shape. If the machine could incorporate threads, the upper gets even more strength. The next challenge would be creating a one piece upper/midsole to mechanically attach to the mesh outsole.

Sources

http://www.gameplan-a.com/2016/10/tips-truly-innovate-former-nasa-engineer/

Learning About: Hyperbolic Geometry

October 21, 2016

Hyperbolic geometry is tough to explain, so I dug into youtube to help explain using crocheting as an example.

Traditional flat knitting machines can produce a 1 piece upper, but the end result still requires seam sewing and steam lasting to form to the foot. A hyperbolic knitted/crocheted upper could potentially be made in one complete piece, without the need for lasting. The key is where and how to increase the number of stitches when knitting.

Starting with the strobel as the base standard knit pattern, the hyperbolic knit would sweep outwards around the last spiraling upwards until it met at the top of the shoe. By increasing or decreasing stitches, the upper would loosen or tighten as it wraps around the upper. Creating support zones on the shoe is also an option, The bottom 1/2 could be a stretchy weave to allow for give and the top 1/2 of the upper could be tighter weave to create the support.

Hyperbolic geometry is important because it came about back in the 1800's, and wasn't represented in a simple physical model until 1978. Hyperbolic geometry is challenging convention, so it must be important.

“A hundred years ago, the mathematician David Hilbert proved a theorem that it is impossible to represent the hyperbolic plane in three-dimensional space analytically,” he says. “ ‘Analytically’ means ‘with equations.’ Everybody left off the word analytically later on. They were worried that mistakes or errors would creep into mathematics through geometric intuition, and so they discouraged the study of geometry and everything associated with this weird kind of thinking.”

Sources

http://theiff.org/oexhibits/oe1.html

http://discovermagazine.com/2006/mar/knit-theory

http://crochetcoralreef.org/about/hyperbolic_space.php

Sneaker School - Recap

October 20, 2016

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.

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.

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.

Sneaker School - Day 5

October 19, 2016

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

October 19, 2016

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...

UP NEXT - DAY 5 - Lasting and Sole Bonding

Sneaker School - Day 3

October 15, 2016

After day 2, The Shoe Surgeon took our leathers to be skived. Skiving is the removal of leather to reduce the thickness. The overlapping pieces of leather were skived to fit together properly during bonding and stitching.

In Learning About: Flat Knitting, I researched traditional sewing and found this video that explain the sewing process nicely.

Sewing is all about repetition. I worked one stitch at a time on scrap pieces, until I felt comfortable to work on my pieces. A sewing machine engages everything: arms, legs, eyes and ears. The foot pedal, holding lining up the materials, listening to the hum of the machine.

After a few sloppy stitches, I started comparing my work to the one created by Nike on a high volume production line. Perfect lines sewed by a person with years of experience?

Should I start that row over? Should the stitches look exactly like the original? No. Our learning comes from making "mistakes".

Each stitch told the story of learning by doing. I am gaining confidence and building my custom creation, one stitch at a time.

UP NEXT - DAY 4 - More stitching/sewing and Lasting

Sneaker School - Day 2

October 15, 2016

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.

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

October 14, 2016

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.

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.

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.

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.

The end result was 15 pieces needed for pattern tracing.

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

Kaizen Kung-Fu

October 12, 2016

Kaizen is the concept of making improvements to make people, processes, things incrementally better.

The 36th Chamber of Shaolin is one of my favorite movies. I discovered it through listening to Wu-Tang Clan. One of my favorite examples of Kaizen is in this movie.

A majority of the film takes place in a Shaolin monastery, where the main character San-Te, is learning Kung-Fu. Through each of the 35 training chambers, he is met with unique physical and mental challenges. Through repeated failure along with incremental improvements, San Te is able to defeat all 35 chambers faster than anyone before.

The justice officer for the monastery, seeing San Te unfit, challenges him to a duel. In the first match, San Te is defeated. Using the Kaizen process, he chooses a different weapon. In the 2nd match, his fighting skills improved, but he still loses. After the 2nd loss, instead of using an existing weapon, San Te created one.

To defeat the sword, he needed a weapon that could create distance and light for attacking, but also strong for blocking. He made a three sectioned staff.