Methods and Systems for Creating Custom Hard Shelled Footwear

Abstract

Methods for creating a piece of hard shelled footwear are provided. The method may include determining a first set of data, where the first set of data represents a three-dimensional shape of a foot. The method may also include determining a second set of data based at least in part on the first set of data, where the second set of data represents at least a portion of an exterior shape of a piece of hard shelled footwear. The method may further include fabricating a mold shape based at least in part on the second set of data. The method may moreover include fabricating the piece of hard shelled footwear in the mold shape.

1 . A method for creating a piece of hard shelled footwear, wherein the method comprises: 
 determining a first set of data, wherein the first set of data represents a three-dimensional shape of a foot;    determining a second set of data based at least in part on the first set of data, wherein the second set of data represents at least a portion of an exterior shape of a piece of hard shelled footwear;    fabricating a mold shape based at least in part on the second set of data; and    fabricating the piece of hard shelled footwear in the mold shape.    
   
   
       2 . The method for creating a piece of hard shelled footwear of  claim 1 , wherein determining the first set of data comprises performing a three-dimensional digital scan of the foot.  
   
   
       3 . The method for creating a piece of hard shelled footwear of  claim 1 , wherein determining the second set of data is further based at least in part on at least one selection from a group consisting of: 
 at least one offset;    a thickness of a liner to be used in the hard shelled footwear;    a fastening system to be used in the hard shelled footwear; and    a thickness of material to be used to fabricate the hard shelled footwear.    
   
   
       4 . The method for creating a piece of hard shelled footwear of  claim 3 , wherein the second set of data is further based at least in part on at least the thickness of material to be used to fabricate the hard shelled footwear, and wherein the thickness of material to be used to fabricate the hard shelled footwear is variable in different portions of the hard shelled footwear.  
   
   
       5 . The method for creating a piece of hard shelled footwear of  claim 4 , wherein the thickness of material is about 1 millimeter in some portions and about 2 millimeters in some portions of the hard shelled footwear.  
   
   
       6 . The method for creating a piece of hard shelled footwear of  claim 1 , wherein determining the second set of data is further based at least in part on a selection from a group consisting of: 
 an amount of space required around a toe area for comfort of a user;    a space occupied by a heating system;    a space occupied by an insulating system; and    a space occupied by a sole cushion.    
   
   
       7 . The method for creating a piece of hard shelled footwear of  claim 1 , wherein determining the second set of data comprises using a three-dimensional modeling software program and an automated sub-routine.  
   
   
       8 . The method for creating a piece of hard shelled footwear of  claim 1 , wherein fabricating the mold shape comprises using a fabrication apparatus, and wherein the fabrication apparatus is selected from a group consisting of a selection from a group consisting of: 
 a three-dimensional printer;    a stereolithography machine;    a rapid prototyping machine;    a solid freeform fabrication machine; and    a bladder molding system or a pressure bag system.    
   
   
       9 . The method for creating a piece of hard shelled footwear of  claim 1 , wherein fabricating the piece of hard shelled footwear comprises a selection from a group consisting of: 
 using carbon fiber construction system;    using a laminate vacuum molding system;    using a fiber-reinforced thermoset resin system;    using a fiber-reinforced thermoplastic resin system;    using an un-reinforced thermoplastic resin system; and    using a prepreg epoxy system.    
   
   
       10 . The method for creating a piece of hard shelled footwear of  claim 1 , wherein the method further comprises at least one selection from a group consisting of: 
 coupling fastening systems to the piece of hard shelled footwear;    coupling wear plates to the piece of hard shelled footwear; and    coupling binding interface elements to the piece of hard shelled footwear.    
   
   
       11 . The method for creating a piece of hard shelled footwear of  claim 1 , wherein the determining the first set of data occurs remotely from at least one of determining the second set of data, fabricating the mold shape, and fabricating the piece of hard shelled footwear.  
   
   
       12 . A method for creating a piece of hard shelled footwear, wherein the method comprises: 
 determining a first set of data, wherein the first set of data represents a three-dimensional shape of a foot;    determining a second set of data based at least in part on the first set of data, wherein the second set of data represents the interior volume of a piece of hard shelled footwear;    fabricating a mold shape based at least in part on the second set of data; and    fabricating the piece of hard shelled footwear around the mold shape.    
   
   
       13 . The method for creating a piece of hard shelled footwear of  claim 12 , wherein determining the second set of data is further based at least in part on a thickness of a liner to be used in the hard shelled footwear.  
   
   
       14 . The method for creating a piece of hard shelled footwear of  claim 12 , wherein determining the second set of data is further based at least in part on a space occupied by a sole cushion.  
   
   
       15 . The method for creating a piece of hard shelled footwear of  claim 12 , wherein fabricating the mold shape comprises using a stereolithography machine.  
   
   
       16 . The method for creating a piece of hard shelled footwear of  claim 12 , wherein fabricating the piece of hard shelled footwear comprises using a prepreg epoxy system.  
   
   
       17 . The method for creating a piece of hard shelled footwear of  claim 12 , wherein the method further comprises coupling fastening systems to the piece of hard shelled footwear.  
   
   
       18 . A system for creating a piece of hard shelled footwear, wherein the system comprises: 
 a scanning apparatus configured to determine a first set of data, wherein the first set of data represents a three-dimensional shape of a foot;    a computer configured to determine a second set of data based at least in part on the first set of data, wherein the second set of data represents at least a portion of an exterior shape of a piece of hard shelled footwear;    a fabrication apparatus configured to fabricate a mold shape based at least in part on the second set of data; and    a molding system configured to fabricate the piece of hard shelled footwear around or in the mold shape.    
   
   
       19 . The system for creating a piece of hard shelled footwear of  claim 18 , wherein the second set of data also represents at least a portion of an interior shape of a piece of hard shelled footwear.  
   
   
       20 . The system for creating a piece of hard shelled footwear of  claim 18 , wherein the scanning apparatus is remotely located from at least one of the fabrication apparatus and the molding system.