Direct digital manufacturing of shoe heels through Fused Deposition Modeling

Additive manufacturing process chains for direct part production in the footwear sector are being investigated almost exclusively for athlete shoe soles and orthotics. This paper focuses on the direct digital manufacturing of high heels for woman shoes, which could provide solutions for personalized production and complex design for high added-value shoes. The study aims at testing the introduction of additively manufactured components into conventional shoe production lines. Sample heels of two common designs have been fabricated by the Fused Deposition Modeling technique, assembled with conventional mounting machines, and tested for wearability according to standard procedures. The experimentation has shown that fully process compatible and functional heels can be produced for a basic design under some restrictions, and has allowed to identify critical issues to be dealt with for future applications on more critical heel shapes. These results will help to develop methods for a robust heel design exploiting the flexibility and creative freedom allowed by additive processes.