COBLR

Project Overview

COBLR is running shoe repair service that utilizes the power of 3D-printed lattice midsoles to create custom footbeds based on users unique foot shape and needs. This project is part of a larger masters thesis. The service incorporates product design, service design, UX/UI design, and Business Modeling.

Background

No two feet are the same, not even one's own left and right foot. Which means no shoes bought off the shelf are tailored to the needs of any individual runner. In casual footwear this is typically fine, but in the case of running performance, millimeters of difference can drastically change the overall experience one has when running in a shoe. When confronted with thousands of options on the market, runners spend precious time, energy, and money in the search to find a perfect running shoe (which does not exist). COBLR addresses the need for runners to finely tune their footwear by providing an iterative repair service that allows them to repair an existing pair of shoes to get closer to the perfect pair.

An additional component to this service is the sustainability of performance footwear. Globally over 22 Billion pairs of shoes are thrown away each year. Because runners wear through their shoes at higher rates than casual footwear, there is a greater rate of consumption for these products. By offering the option to repair, rates of consumption can be slowed by half or more, which means less shoes in landfills, and less energy consumption and emissions from production. 3D printing also presents a unique opportunity to produce parts locally, which reduces transportation costs, emissions, and allows for simpler logistics in the recycle and return process when the shoe comes back in for additional repairs.

Process & Research

Initially I sought to answer the question: Is it possible to create zero-waste regenerative footwear? To find out, I interviewed subject matter experts in the areas of material development, footwear design, climate tech strategy, and more. After speaking further with these experts, I found that high performance materials can have long production life cycles and may take 10 to 20 years to reach a scale that would meet the current demand.

Throughout this process I relied heavily on both primary and secondary research. One key piece of research was a co-creation session held with long distance runners. A major pain point that I identified from the co-creation session is that runners spend a lot of time, energy, and money trying to find a shoe that fits great and feels comfortable. And, because no two feet are the same, people with the same shoe size and model can have a very different experience while running. So when runners find a great shoe, they tend to stick with the same model, often buying multiple pairs. But when these product lines get updated every year, they can in some cases make drastic changes which no longer serve that same individual.

To further investigate the construction and methods of assembly in footwear, I tore down old shoes I had. Then I looked into the factors that affect a great fitting shoe and found four key areas that have been shown by academic research to be the most important for assessing comfort, which are shoe stability, heel cushioning, forefoot flexibility, and forefoot cushioning.

Additionally, to understand how a repair can be made, you need to understand the basic construction of a shoe. Which breaks down into three main parts: The upper holds the foot in place and provides structure around the foot. The midsole absorbs the shock of the foot hitting the ground, and propels the runner forward as they move through their stride. Lastly, the outsole provides traction and grip to the surface underneath the foot.

What's unique about this service is that it relies on 3D printing to produce one-off midsoles that are custom to the unique needs of the runner. This technology allows for products to be made only when there is a need rather than the traditional methods of mass producing hundreds of thousands of pairs to be funneled through a global pipeline. Another benefit of this manufacturing method is the ability to generate complex geometry that can mimic the mechanical properties of a solid foam midsole using less material.

Using parametric modeling software (Grasshopper) I tested a lot of different lattice structures for properties such as stiffness, flexibility, and cushioning. Each lattice structure can be used on different areas of the midsole to maximize the benefit for the user.

Here's a look at the user journey. Once a runner wears out their shoes, they would then come to Cobbler where we would consult on what type of repairs are needed. Then, they would have their feet scanned and their running stride analyzed to provide data that would influence the new midsole design.Once the design is complete, the new midsole would be printed. The existing upper is then rebuilt with a new midsole and outsole.

And, this process can be repeated until the upper can no longer become repaired and maintain its structure and support for the runner. And because this creates a behavior of returning old pairs to the store, we can then recycle old parts that typically get thrown away 95% of the time.

Successes

The feedback I got from this project was overwhelmingly positive! Almost everyone I showed the concept to has asked when it will be open for business. Aside from the kind responses, I discovered a clear need from consumers of not only distance runners but other people outside of my target user group. People form an emotional connection to their shoes, and when they find a great pair they want them to last forever. By providing consumers the option to breathe new life into their old worn out pairs, we can fulfill the customer need and make better decisions that rethink the current system of rapid consumption.

Challenges

Through my research I identified many challenges in the technical aspects of this project. Some of the major considerations that need to be addressed if this project is to go further is the assembly process and method for uppers, outsoles, and midsoles. This would most likely require the production of custom lasts for each customer to ensure that the shape of the repair is true to the design. I would also like to further research the performance of new biomaterials materials like NFW Pliant outsole rubber for running performance.

Outcome

Through this process, I gained an in-depth understanding of shoe construction, and running shoe performance properties such as stack height, midsole foams, drop, geometry, and others. Additionally, I taught myself parametric design in the Rhino plug-in Grasshopper, which has opened up a world of opportunities for using lattice structures in product design for things like lightweighting, reducing material consumption, and improving the mechanical properties of a product with new materials.