How safety footwear enhances protection in the workplace

How safety footwear enhances protection in the workplace

by | May 23, 2023

How safety footwear enhances protection in the workplace
23.05.2023 · Jennifer Merkel & Ariane Brinkmann / Editor Karolina Hoffmann
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Safety shoes have an important place in the workplace. They protect the feet against injuries and help to reduce the number and severity of accidents. They can protect against punctures, cuts, burns and impact whilst also offering the individual a better grip when walking on a specific surface.

They have to follow basic requirements and offer additional protection for their area of application. For example, when working on a boat, the surface can be very slippery, so it is important to have a shoe which allows the individual to move around without the fear of slipping. For someone working with electricity, the shoe can prevent electrical hazard. Workers in the forest can also encounter a slippery surface from moss but there is also the possibility of getting cut when working with chainsaws. A safety shoe made from cut resistant materials can help prevent getting cut.

Navigation

What are safety shoes?

Process of making a safety shoe

Fundamental requirements of safety footwear

Process of making a safety shoe

· Safety category S1

· Safety category S2

· Safety category S3

· Safety category S4

· Safety category S5

· Safety category S6 + S7

Summary

What are safety shoes?

Professional footwear can be distinguished into two categories. The first category is work footwear, meaning that the shoe is within the anti-slip and water repellent criteria, but the toecap and insole are not impact resistant.

The second category is called safety footwear, which is a shoe that must meet the EN ISO 20345 norms. This requires the shoe to have a minimum impact resistance of 200 Joules at the front-end part of the shoe and to be slip resistant on smooth and greasy floors in industrial environments. Different specific protections are then added onto the shoe to fulfill the protection criteria the shoe is meant for.

Process of making a safety shoe

A safety shoe begins with a conceptual design, which is then tested until it satisfies the requirements. The material for the upper part of the shoe is chosen depending on the functionality the shoe is supposed to have. The sole and the toe cap are also based on the function of the shoe.

Once all the materials have been chosen, the parts for the upper are cut out, assembled and then placed on the shoe last. Once on the shoe last, the toe cap is added underneath the main fabric and the shoe gets pressed together by a machine to help the shoe take form and make the toe cap fit well around the front part. Thermoplastic is then injected into the molds for the sole to then produce the outsole. Once the sole is connected to the upper part of the shoe, a safety shoe has been made. (You are interested in learning more about the specific requirements, when making a shoe last? Then click here.)

Fundamental requirements of safety footwear

The basic requirements of a safety shoe can be found in the standard basic (SB) degree of protection. This includes a sole which is anti-slip, anti-abrasion oil resistant and anti-static. The non-slip properties must be true on ceramic tiles with cleaning agents (SRA), on steel floor with glycerin (SRB) and on the two types of floors combined (SRC).

Furthermore, the materials used to build the shoe have to be water resistant, breathable, hard wearing, and strong. The shoe needs to be comfortable, and the toe cap needs to be impact and crushing resistant. The toe cap can be made from steel, plastic or aluminum and needs to have an impact resistance of 200 Joules. This means the toe cap should withstand a weight of 20kg from a fall height of 1 meter. A SB safety shoe provides the minimal amount of protection but provides more protection than a normal work shoe.

Process of making a safety shoe

All safety shoes must meet these basic requirements but there are additional requirements depending on the shoe’s area of application. The additional safety features on the safety shoes are depicted on the label via a symbol and can be divided into 3 categories: complete footwear, instep and the sole.

Complete footwear includes the following:

1. Puncture resistant (P) insoles, which are resistant to a puncture force of 1,100N.

2. Conductive footwear (C) which, by evaporating electrostatic charges, is electrical resistant from 0 to 100 kilohms.

3. Antistatic footwear (A) dissipates electrostatic charges between 100 and 1000 kilohms.

4. Heat resistant soles (HI) allows an insulation against heat up to 150 degrees.

5. Cold resistance soles (CI) allow an insulation against cold up to -17 degrees.

6. The heel area must absorb a minimum of 20 Joules energy (E). 

7. Metatarsal protection (M) provides additional safety for any of the bones in the foot.

8. Ankle protection (AN) adds additional ankle protection.

9. Cut resistant (CR) features are zones of the shoe which are resistant to getting cut.

10. Waterproofing (WR) means that the entire shoe must be waterproof.

Instep requirements are specifically directed towards the middle part of the foot. There is only one additional requirement, which is that the upper part of the shoe is resistant to water entering and the absorption of water (WRU).

The sole has two requirements. It can be resistant to contact with heat (HRO)  for temperatures up to 300 degrees and can also additionally be resistant to hydrocarbons (FO) which are highly combustible chemicals.

The different degree of protection provided by these safety shoes are indicated by the S, meaning standard, and a number. The higher the number, the more extensive the protection which goes from S1 up to S7. Safety shoes can be divided into two categories depending on the material the footwear is made from. The first category has a leather or other synthetic material upper (S1-S3, S6, S7) whilst the second category has an upper made from rubber, PVC or PU (S4 and S5).

Do you want to learn more about different plastics used in injection molding. Then check out our blog post here.

1. Safety Category S1

The degree of protection S1 meets all the basic requirements (SB) and additionally has closed, shock and energy absorbing heel (E). In addition the sole must be hydro-carbon resistant (FO) and anti-static.

S1 is good for interior activities in dry places where the importance of the shoe is to have basic protection. Contact with water tends to be non-existent. This applies to jobs such as electricians, mechanics, and craftsmen.

2. Safety Category S2

S2 meets the basic requirements and those of category S1, whilst also providing resistance to water and liquid absorption in the upper part of the shoe.

Safety shoes which follow the S2 requirements are useful in work areas with a high level of humidity where basic protection is still sufficient. This can be useful for someone who works in the food industry in the storage and the transportation. An airport worker would need an S2 safety shoe but with a plastic toe cap which is lighter than metal and allow to have a metal-free shoe which is beneficial in airports.

3. Safety Category S3

S3 meets the standards of category S2 and provides a lugged sole and a resistance to sole puncture. A lugged sole is a thicker outer sole with deep indentations.

Activities which happen in hostile work situations would benefit from S3 safety shoes. The shoe allows the person to have basic protection on their feet with the upper part of the shoe being water resistant and to have a sole which is thick and sturdy. Jobs in mining, agriculture, factories, or construction often use shoes with the S3 standard. A forestry worker needs protection against sharp working tools and slippery surfaces. This calls for a safety shoe with S3 requirements and cut resistant features. Production or factory workers also wear S3 safety shoes as they need to protect their feet from materials falling and be able to move around comfortably.

4. Safety Category S4

Boots with a S4 certification have a reinforced toe cap and are made of waterproof materials. The boots are not only water resistant, but they are meant to not let any water penetrate into the boot.

5. Safety Category S5

S5meets the same standard as S4 and additionally has an 2anti-perforation safety sole made of steel or a strong and durable synthetic material.
People working on boats or near any body of water would benefit from a S4 or S5 safety shoe as they are waterproof and allow for a good sole grip.

6. Safety Category S6 + S7

 

S6 has the same specification as S2 but the whole shoe is water resistant.

S7 refers to the S3 category and the whole shoe is water resistant. A fireman encounters multiple elements such as fire and water. Therefore, the entire shoe must be heat and water resistant. It must ensure that the high heat will not enter the shoe. The sole must be thick enough to stabilize the foot of the fireman when walking on challenging terrain. Shoes with a S7 certificate would come into consideration as they offer the most safety and the whole shoe is water resistant.

Yet, shoes made for the fire department usually follow their own safety standard EN 15090. S6 and S7 safety shoes were introduced as additional protection classes in June 2022 after the EN ISO 20345 norm was reviewed. Because they are freshly introduced, their presence in the safety footwear market is still limited.

Summary

In summary, a safety shoe is used in multiple applications to help protect the feet from any injuries and to facilitate movement in the workplace. There are basic requirements which all safety shoes must follow but they differ in their degree of protection. S3 shoes have the most extensive protection in the market at the moment.

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3D Modelling in footwear creation

3D Modelling in footwear creation

by | May 5, 2023

3D modelling in footwear creation
05.05.2023 · Expert René Medel / Editor Luisa-Maria Mrcela
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3D modelling has become an integral part of the footwear design process in recent years. It allows designers and developers to create and visualize their designs in a virtual environment, allowing for greater accuracy, efficiency, and innovation. In this blog article, we will dive into 3D modelling and its importance in footwear design.

Navigation

What is 3D modelling?

Why is 3D modelling important in footwear design and development?

Where can I apply 3D modelling in footwear design and development?

What is the best 3D modelling approach for footwear design and development?

· NURBS

· Polygonal Meshes

· Polygonal Subdivision

Generative Design

Lattice & Additive Manufacturing

· Lattice Structures

· Additive Manufacturing

Extended Reality & Artificial Intelligence

· Extended Reality

· Artifical Intelligence

Summary

What is 3D modelling?

3D modelling  is the process of creating a three-dimensional representation of a physical object or scene using specialized software. 3D modelling software allows designers to create a virtual representation of a shoe, from the sole to the upper, but also creates a base information to share with 3D Printing and later with development (Inline) for production.

3D modelling software allows designers to create and manipulate virtual 3D objects, such as shoe lasts, sole units, components, and reinforcements using a variety of tools, in particular shape and form manipulators, texture mapping, and lighting controls. It gives designers greater control and flexibility over the design process. In this blog article, we will dive into what 3D modelling is, its benefits, and its applications in the footwear industry.

Why is 3D modelling important in footwear design and development?

3D modelling is a powerful tool for footwear designers, offering increased speed, accuracy, and visualization capabilities. By adopting this technology, designers can create better products, faster, and with greater efficiency.

1. Greater accuracy and efficiency: 3D modelling software allows designers and developers to create a precise and accurate representation of a shoe before it’s even produced. This reduces the need for traditional sketching and physical prototyping, which can be time-consuming and expensive. The ability to quickly create and modify designs also allows footwear brand creation teams to work more efficiently, consistently, with improved quality and on time.

2. Enhanced collaboration: With 3D modelling, designers and developers can share their designs with team members and stakeholders in a virtual environment. This makes it easier for designers to collaborate and receive feedback, even if team members and factory partners are located in different parts of the world.

3. Innovation and creativity: 3D modelling software like Rhinoceros allows designers to explore new designs and push the boundaries of traditional shoe design. With the ability to create complex shapes and textures, designers can experiment with new materials and construction techniques, leading to the creation of innovative and unique shoe designs.

4. Improved visualisation and communication: 3D models can be easily shared and viewed from multiple angles, making it easier for designers, developers, engineers, shoe factory partners and other stakeholders to visualize and understand the design. This can help facilitate communication and collaboration throughout the design, development and production process.

Where can I apply 3D modelling in footwear design and development?

3D modelling has a wide range of applications in footwear design and development, including:

1. Concept development: 3D modelling can be used to quickly create and refine new design concepts, allowing designers to explore different ideas and variations before committing to a final design.

2. Tech packs: 3D models can be an efficient part of a tech pack. Footwear developers share tech packs with their shoe factory partners to give instructions on how to develop and manufacture the model. 3D Models have a much higher informative level if they include 360-degree 3D models of computer-aided design (CAD), shell pattern, tooling layering, measurements and upper layering. Particularly, showing the CAD in all its 5 typical views (lateral, medial, top view, outsole view, and heel view) becomes obsolete if it can be substituted by a single 3D model.

3. Prototyping: 3D models can be used to create physical prototypes using 3D printing or other rapid prototyping methods. This can help designers and developers to test and refine their designs before committing to mass production.

4. Production: 3D models can be used to create production-ready designs and tooling, which can help ensure consistency and quality in the final product.

What is the best 3D modelling approach for footwear design and development?

When it comes to 3D modelling for footwear design, there are several different approaches that can be used. Three of the most common approaches are NURBS, polygonal meshes and SubD. Each approach has its own features and benefits, which are outlined below.

 

1. NURBS

NURBS (Non-uniform rational basis spline) is a mathematical representation of 3D geometry that is widely used in computer-aided design (CAD) applications. NURBS surfaces are defined by control points and curves, which are used to define the shape of the surface. NURBS surfaces are highly accurate and can be manipulated with precision, making them ideal for modelling complex shapes and curves. Some of the key features and benefits of NURBS for footwear modelling include:

1. Highly accurate surfaces: NURBS surfaces can be precisely controlled, allowing for accurate modelling of complex shapes and curves.

2. Smooth surfaces: NURBS surfaces can be smoothed and refined, resulting in highly polished and visually appealing designs.

3. Efficient workflow: NURBS surfaces can be easily edited and modified, allowing for an efficient workflow and faster design iterations.

2. Polygonal Meshes

Meshes are a popular approach to 3D modelling that involves representing 3D geometry as a series of interconnected polygons (triangles and/or quads). Polygonal meshes are widely used in gaming and animation but are also used in footwear design.  All the models we use for 3D printing, are Meshes.

Some of the key features and benefits of polygonal meshes for footwear modelling include:

1. Versatility: Meshes can be used to create a wide range of shapes and designs, making them highly versatile.

2. Realistic textures: Polygonal meshes can be textured and shaded to create highly realistic and detailed designs.

3. Large amount of polygons: Meshes are not that easy to manipulate and edit, since they are made of many polygons, and usually requires to repair the geometry, to have all the polygons and vertices connected.

When a shoe last master model is finished by hand, it is scanned, and this digital process gives us a mesh file.  This mesh file could have thousands or millions of polygons to have the best resolution and accuracy.

3. Polygonal Subdivision

Polygonal Subdivision (SubD) is a type of polygonal mesh (low polygons) that is used to create smooth, organic shapes utilizing algorithms like Catmull-Clark commonly used for 3D animation industry since 1978.  SubDs are defined by a set of faces, edges and vertices that can be moved and adjusted to create complex shapes. Some of the key features and benefits:

1. Smooth surfaces: SubD can be smoothed and refined, resulting in highly polished and visually appealing designs.

2. Organic shapes: This topology is ideal for creating organic shapes curves, such as those found in sport footwear.

3. Efficient workflow: SubD geometries can be easily edited and modified, allowing for an efficient workflow and faster design iterations.

Generative Design

Generative Design is an innovative approach to 3D modelling that uses algorithms to create complex designs almost automatically. By inputting design criteria such as shapes, geometric rules, and performance specifications; Generative Design software (like Grasshopper) can generate multiple design options (iterations) quickly and efficiently. This technology also named Algorithmic Modelling, has many potential benefits for the footwear industry, including:

1. Faster design iteration: Generative design allows footwear designers to create and evaluate multiple design options quickly and easily. This can help reduce the time and cost of the design process, while also enabling designers to explore more creative and innovative design solutions.

2. Improved design quality: Algorithmic modelling algorithms can take into account a wide range of design parameters, such as materials, geometries, mechanical properties, loads, and performance requirements. This can help ensure that the final design is optimized for its intended use, with improved functionality and performance.

3. Enhanced customization: Generative design can also be used to create highly customized footwear products tailored to the specific needs of individual customers. By inputting personalized data such as foot shape and size, generative design algorithms can create unique designs that are optimized for the individual’s needs.

4. Increased sustainability: It can also help reduce waste and promote sustainability in the footwear industry. By optimizing designs for materials and manufacturing processes, generative design can help reduce the amount of material waste and energy used in the production process. (You want to learn more about other ways to promote sustainability? Check out our blog post about green materials here.)

Lattice & Additive Manufacturing

Lattice structures and 3D printing are powerful technologies that can be used to enhance the 3D modelling process for footwear designers. Embracing these technologies, designers can create innovative and highly functional footwear designs that are optimized for specific performance requirements, while also promoting sustainability and customization in the footwear industry.

 

1. Lattice Structures

Lattice structures are complex, interconnected structures that can be used to create lightweight, yet highly durable shapes. Lattice structures can be found in nature, such as in the internal structure of bones, and can be replicated using 3D modelling and printing techniques. By using lattice structures in footwear design, designers can create shoes that are lighter, more flexible, and more comfortable, without sacrificing durability or support.

2. Additive Manufacturing

Additive Manufacturing (AM) is the part of the Industry 4.0 which uses different technologies commonly named 3D printing. This is a process by which a three-dimensional object is created from a digital model. 3D printing technology has advanced significantly in recent years, allowing for the creation of highly complex and detailed objects, including footwear products. By using 3D printing in footwear design, designers can create prototypes and even finished products quickly and efficiently, with a high degree of accuracy and precision and using several types of materials.

By combining lattice structures and 3D printing, footwear designers can create highly complex and customized designs that are optimized for specific performance requirements. For example, designers can create lattice structures that are tailored to specific pressure points on the foot, or that are optimized for specific types of movement or activity. These lattice structures can then be 3D printed using a range of materials, including plastics, metals, and even bio-based materials, to create highly functional and sustainable footwear products.

Extended Reality & Artificial Intelligence

Extended Reality and Artificial Intelligence are two emerging technologies that are transforming the footwear industry. Using these technologies, footwear designers and manufacturers can create better products, faster, and with greater efficiency, while also improving the customer experience. As these technologies continue to evolve, we can expect to see even more innovative uses in the footwear industry in the future.

1. Extended Reality

Extended Reality (XR) is an umbrella term that encompasses a range of technologies, including Virtual Reality (VR), Augmented Reality (AR), and Mixed Reality (MR). XR technologies are being used in the footwear industry in a variety of ways, including:

1. Design: XR technologies can be used to create immersive design environments that allow designers to explore and refine their designs in a virtual space.

2. Prototyping: XR technologies can be used to create realistic virtual prototypes that can be tested and refined before physical prototypes are created.

3. Retail: XR technologies can be used to create immersive shopping experiences that allow customers to try on and customize footwear products in a virtual environment.

  

2. Artifical Intelligence

Artifical Intelligence is another technology that is being increasingly used in the footwear industry. AI is being used to:

1. Improved design creation and ideation: Large Language Models (LLM) can be used to analyze customer data and feedback to inform design decisions and create personalized footwear products.

2. Optimize production: AI can be used to optimize production processes and improve supply chain management, reducing costs and increasing efficiency.

3. Enhance marketing: Text-to-Image and Image-to-Image can be used to analyze customer data and behavior to create targeted marketing campaigns and improve customer engagement.

4. Better understanding of the market and consumer behaviour: AI could help us to know more about Intellectual Properties (IP) rights and patenting of concepts, before turning them into products.  Brands and consumer data are also easy to reach, using the right prompts.   

In summary, 3D modelling has revolutionized the way footwear designers approach their work, providing them with a range of powerful tools and technologies to create innovative and functional shoe designs.

Advancements in technology, such as Extended Reality, Artificial Intelligence, Generative Design, Lattice structures, and 3D printing have transformed the way designers and developers work. There are several approaches to 3D modelling for footwear design, each with its own features and benefits.

NURBS, Meshes, and SubD are three of the most common topologies. By embracing 3D modelling technology, footwear designers can create more innovative and functional shoe designs than ever before, paving the way for a more dynamic and exciting footwear industry in the years to come.

If you would like to learn more from René, make sure to also check out the webinar he did with McNeel Europe.

If you liked this article, make sure to follow our Social Media channels. You can contact us anytime via LinkedIn, Instagram & Facebook. We are happy to receive any feedback and tell us what other topics are of interest to you. We will try to address them in the near future.


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