How to make custom shoes using plantar pressure measured by gait analysis equipment?

Custom shoes are made through measuring plantar pressure with gait analysis equipment, and the main process is as follows: collect plantar pressure and gait data via gait equipment — computer workstation (data analysis + customized last design) — output of digital last parameters — complete shoe production line including cutting, stitching and forming.

First, collect plantar pressure and dynamic gait data by means of gait analysis equipment.

This step is extremely critical, because if there is deviation in the collected gait and pressure data, the finished shoes will suffer problems such as uneven force bearing, cramped feet, foot fatigue during walking and high risk of ankle sprains.

During measurement, users need to walk barefoot naturally on the gait pressure testing platform. In the measuring process, maintain a normal walking posture with even and steady steps. Do not stiffen the body or exert force deliberately. Meanwhile, look straight ahead and keep the whole body relaxed. The walking path shall follow the standard testing channel, and feet should be placed straight. Avoid tiptoeing, dragging steps or twisting feet on purpose.

Data collection shall be conducted with accompaniment of professional technicians. The whole gait test only requires dozens of steps and can be finished within tens of seconds. After measurement, visualized plantar pressure distribution maps, gait trajectory reports and corresponding dynamic plantar parameter data files can be obtained simultaneously.

Second, carry out gait data analysis and customized last scheme design.

After obtaining raw plantar pressure and gait data, import the data into professional analysis software for data noise reduction, trajectory correction and pressure zoning calibration. Commonly used software includes professional plantar pressure analysis systems, gait parameter analysis software, shoe last adaptation CAD design software and so on.

Carry out targeted design on sole hardness zoning, arch support, heel stabilization, forefoot cushioning and upper wrapping degree according to customers’ walking gait characteristics, concentrated plantar pressure areas, arch height and heel valgus/varus conditions.

Establish parameter models based on imported gait pressure data, and convert users’ dynamic walking foot shape data into digital customized last parameters matching personal gait.

Third, complete solidification of customized last parameters and process adaptation.

Export well-designed customized last parameters and conduct data processing for process adaptation. Import revised and optimized parameter data into the digital shoemaking system, match corresponding shoemaking equipment to realize solidification of last process parameters, so as to provide accurate data support for subsequent customized production of uppers, outsoles and insoles.

Fourth, carry out upper pattern development, customized outsole production and overall stitching & shaping.

With customized last parameters adapted to personal gait and plantar pressure, complete exclusive design of upper paper patterns, outsole templates and insole support structures within footwear CAD systems, including customized optimization of forefoot cushioning zones, arch support zones and heel stabilization zones.

Conduct numerical control precision cutting of leather/fabric, piece-by-piece stitching of uppers, lining lamination, assembly of cushion foam, support pads and other accessories according to customized design data.

Then assemble and fit stitched uppers, customized outsoles and functional insoles. Complete upper fitting and outsole bonding mechanically or manually, followed by heating shaping and pressure solidification. These procedures enable the overall shoe structure to perfectly fit personal plantar force bearing characteristics and walking gait habits. Whole shoe shaping is completed after cooling and stable shaping.

Finally, conduct edge polishing, upper finishing, fine stitching and quality inspection, as well as gait fitting test, to ensure the shoes fit the foot shape, match gait and relieve plantar bearing pressure。