Rekk Danny Batz
Resources: REI Staff. (2015, August 4). Bike Shoes: How to Choose. Retrieved from: https://www.rei.com/learn/ expert-advice/cycling-shoes.html 3m Vinyl Carbon Fiber Sidi Wire Carbon Road Cycling Shoe Giro Empire Road Cycling Shoe DNB R1.0 Cycling Shoe Shimano R170 SPD-SL Road Cycling Shoe Garneau Air Lite Cycling Shoe
Danny Batz Desn 254 Matias Ocaña Spring 16
Contents 01 03 05 07 11
Research Design Mock Up Build Final Product
Research
Before designing the shoe I studied current cycling shoes to understand the features and variations that exist.
Features Ventilation
Structure Ventilation
Structure/ Hold Closure System
Structure Stiff/Slim Sole
• Vents are for allowing air to flow, keeping the foot cool during the ride. • Stiff sole is for transferring energy better to the bicycle. • Heel is structured to hold the foot in during an upstroke 1
Values
In order for a final product to be successful, a set of values must be set. My values for a competitive cycling shoe were: • Speed • Comfort • Adjustability
• Weight • Aerodynamic
Closure System
Their are four closure options with cycling shoes, each has their own pros and cons.
• Laces
• Velcro Straps
Pro: Flexible, Light, Custom Fit Con: Stretch, Can get stuck in chain
Pro: Less Stretch, Secure, Quick Con: Not as adjustable
• Notched Cam Strap
• BOA System
Pro: Greatest clamping, Adjustable Con: Can jam
Pro: Secure, Quick, Micro-adjustability Con: Pressure Points, Can jam 2
Design
Thumbnail sketches were used to discover the form and explore options. A dialogue was formed between the two main elements; the shoe body and the straps. Each Influencing one another’s form until a final form was agreed upon.
Body
3
Straps
4
Mock up
Mock ups were made of foam and paper. They helped to discover the form and how the many pieces would fit together before committing to the final build.
Foam Shoe Mock up
5
Paper strap Mock Ups
Paper mock ups were used for working out the final form and build for the straps.
6
Build
The build required several steps; starting with forming a perfect last that fulfilled the technical aspects of the shoe, vacuum forming the necessary layers, and finishing the piece with a paint job.
The Last
The last was modified for a cycling shoe.
First a mold from another last was made by using a carefully made vacuum form 7
The mold was filled with plaster, allowed to dry, and then formed with a rasp and sandpaper
Modifications were made in the front foot and the heel
Heel cup rounded
Mold Mold
Modified Last
Modified Last
Tighter fit around front of foot
8
Body
The body was build by using vacuum formed layers. They were then cut out into their desired form.
9
In order to create more depth, indented details were made by layering in cuts and vacuum forming over them.
Sole
The nature of a cycling shoe sole is slim, stiff, and aerodynamic. In order to achieve a similar look, the sole was made by carving foam and then vacuum forming it and covering it with carbon fiber vinyl. Holes for attaching shoe to bicycle pedals
Holes for rubber pads
Finishing
The pieces were primed, painted, and clear coated.
10
Final Product BOA Closure
Efficient and minimal look
Structured Sole Keeps heel in shoe
11
Velcrow Straps with Elastic Laces
Offers best of Velcrow Straps with more elasticity
Ventilation
Airflow during ride
Carbon Fiber Sole Light weight and Stiff
12
Danny Batz Spring 16