Abstract

Customised cycling soles are extremely complex to design and manufacture since the plantar pressure distribution and anatomical shape are specific for every foot. This paper explores the potential of topology optimisation and additive manufacturing of continuous fibre reinforced plastic. The highly abstract material distribution resulting from the topology optimization software was interpreted considering the additive manufacturing constraints for getting the detailed design. The selected printing strategy consisted of concentric fibre orientation to better fit load-paths, and the build-orientation aimed to maximise the fibre content, resulting in 30 hours for printing each sole. Regarding the specific stiffness at the hallux and the hell, the new soles are at least 60% higher. Therefore, it has been confirmed that the proposed approach is a powerful tool to design the cycling shoe adapted to the local stiffness of each foot.