Evaluation and optimization of footwear comfort parameters using finite element analysis and a discrete optimization algorithm

Footwear is subject to bending and torsion deformations that affect comfort perception. Following review of Finite Element Analysis studies of sole rigidity and comfort, a three-dimensional, linear multi-material finite element sole model for quasi-static bending and torsion simulation, overcoming boundary and optimisation limitations, is described. Common footwear materials properties and boundary conditions from gait biomechanics are used. The use of normalised strain energy for product benchmarking is demonstrated along with comfort level determination through strain energy density stratification. Sensitivity of strain energy against material thickness is greater for bending than for torsion, with results of both deformations showing positive correlation. Optimization for a targeted performance level and given layer thickness is demonstrated with bending simulations sufficing for overall comfort assessment. An algorithm for comfort optimization w.r.t. bending is presented, based on a discrete approach with thickness values set in line with practical manufacturing accuracy. This work illustrates the potential of the developed finite element analysis applications to offer viable and proven aids to modern footwear sole design assessment and optimization.