Objective:
The Project is to design and print a splash protector for sports shoes through dual-material 3D printing. The protector would consist of a rigid PLA front face panel for impact and splash protection, yet a conforming flexible upper section to accommodate the ankle. This study addresses multi-material design principles and functional integration in consumer wearable protection solutions.
Background:
Splash protectors are essential for athletes and outdoor users exposed to wet or muddy environments. Traditional protectors often compromise between rigidity and flexibility. With advancements in 3D printing, it is now possible to combine multiple material properties within a single component, allowing for functional zonal performance. Using PLA for the hard front and a flexible filament (e.g., TPU) for the top section, the design aims to ensure durability, comfort, and ergonomic fit.
Methods:
- Measurement: 3D scanner to get dimension and shape of shoes.
- Design: CAD modeling in SolidWorks to segment regions for rigidity (PLA) and flexibility (TPU).
- Material Selection: Hard PLA for structural support and flexible TPU or TPE for adaptive upper fit.
- Slicing & Printing: Bambu Studio will be used to assign material zones and prepare G-code for dual-material printing on the Bambu X1C FDM printer.
Testing: The final product will be tested for:
- Fit and comfort
- Splash/impact protection
- Flexural and tensile behavior at the joint zone
Expected Outcome:
A functional and wearable splash protector that showcases effective integration of rigid and flexible materials. The hybrid design is expected to provide enhanced protection without compromising user comfort or mobility.
Significance:
This project demonstrates the application of multi-material additive manufacturing in wearable sports accessories and explores methods for integrating hard-soft transitions in single-build 3D prints. It contributes to the growing field of personalized and functional gear using advanced 3D printing.