2026, Vol. 11, No. 2. - go to content...

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Belitskaya O.A., Litvin E.V., Shestakova A.V. Development of a methodology for designing shock-absorbing soles for outdoor footwear using 3D-printing. Journal of Clothing Science. 2026; 11(2). Available at: https://kostumologiya.ru/PDF/04TLKL226.pdf (in Russian).

Development of a methodology for designing shock-absorbing soles for outdoor footwear using 3D-printing

Belitskaya Olga Alexandrovna
Russian State University named A.N. Kosygin (Technologies. Design. Art), Moscow, Russia
E-mail: belitskaya-oa@rguk.ru
ORCID: https://orcid.org/0000-0002-7808-4027
RSCI: https://elibrary.ru/author_profile.asp?id=673248

Litvin Evgeniy Viktorovich
Russian State University named A.N. Kosygin (Technologies. Design. Art), Moscow, Russia
E-mail: litvin01@list.ru
ORCID: https://orcid.org/0000-0002-8383-8284
RSCI: https://elibrary.ru/author_profile.asp?id=368621

Shestakova Anastasia Vasilievna
Russian State University named A.N. Kosygin (Technologies. Design. Art), Moscow, Russia
E-mail: nastya_shesta@bk.ru

Abstract. Modern footwear for active recreation places increased demands on cushioning, foot protection, and stability on various surfaces. Cushioning in athletic shoes refers to the ability of the sole to absorb and redistribute shock impulses generated upon contact with the ground. Insufficient cushioning leads to rapid fatigue and musculoskeletal disorders. The objective of this study was to develop and implement a design methodology for cushioning soles using additive manufacturing and CAD systems.

This paper analyzes the current technologies of leading athletic footwear brands and materials, such as ethylene vinyl acetate, polyurethane, and thermoplastic elastomers. Particular attention is paid to thermoplastic polyurethane, which combines elasticity, strength, and suitability for 3D printing. The influence of filling parameters and cell structure types, including auxetic structures (with a negative Poisson’s ratio), on cushioning, strength, and durability of products is examined. An eight-step design methodology was developed, regulating material selection, lattice geometry, print settings, and post-processing.

Practical implementation was conducted: a last was digitalized using a Rangevision Spectrum 3D scanner, and 3D models of soles with internal auxetic stiffeners in the heel and shank areas were created in ZBrush, Blender, and SolidWorks. Prototypes were manufactured using FDM printing on an ANYCUBIC KOBRA 2 PLUS printer using Easy FLEX TPU plastic. The developed prototypes formed the basis for the «DEPO» sneaker collection, which includes five models. The results confirm the potential of the proposed methodology for creating highly effective shock-absorbing soles.

Keywords: footwear; outdoor footwear; shock-absorbing soles; 3D printing; thermoplastic polyurethane; cellular structure; auxetic materials; design methodology; additive manufacturing

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