Description How could we maximize preparation and adaptability in pursuit of rugged warm weather photo opportunities while respecting the packed volume constraints of independent travel?
My sports product design master’s thesis project at the University of Oregon unlocks the ultimate freedom and preparedness for independent adventure photographers from their flight to the field. Using swappable uppers and soles, each adventurer is able to pack multiple footwear types in half the packed volume and weight, allowing them to pack more of what matters without sacrificing comfort and safety in the field and during travel.
MUTA is a modular footwear system comprised of two sole units and three upper units to make a total of five possible unique combinations. These combinations are designed to replace the equivalent separate shoes, reducing weight and packed volume. MUTA replaces, and where possible, enhances the performance and packed volume of rubber boots, hiking boots, hiking sandals, travel shoes, and camp slides. Modularity is achieved with an upper carrier base, which locks into the sole with a press-fit and registering system. This ensures repairability, reliability, and adaptability.
Innovation The primary innovation of this project is the "Snapshed" modular carrier system. This is a snap-fit system that uses a robust base for the uppers to snap and lock into two different soles. This system snaps in and out at the heel with a set of flexible "wings" to provide leverage on the press-fit snap components. These wings also function as heel stability pieces and replace a traditional heel counter. The carrier also has registration points in the toe and under the arch, which double as reinforcement areas for the toe and a shank for under the arch. By using necessary footwear features as the three key areas for attachment and registration, the modular system maintains a similar weight and increased functionality compared to traditional shoes. While the prototype version of this system is relatively bulky, applying this concept with commercial manufacturing techniques would produce an even better result.
More innovations include custom fabric creation, an anatomic waterproof-breathable rubber boot construction with a "mud proof" exterior that fits better and packs significantly smaller, and a dynamic traction system, "Adaptac", that changes shape on soft and hard substrates.
Product Detail The soles use TPU filaments, PETG filaments, metallic fasteners, and foamed TPU filament, sometimes with two materials printed at once
The "lockdown cages" on the soles use a custom-made layered fabric with a TPU top layer, a tetra-axial woven nylon fabric, and a cool-touch wicking bottom layer, both from Teijin. This material was designed to be a higher performing and more eco-friendly alternative to Hypalon. Custom 3D printed eyelets route Dyneema sleeved elastic cord into a Duraflex speedlace system.
The carrier system for the uppers use TPU filament, PETG filament, and Poron foam. The TPU and PETG are 3D printed at the same time on a 3D printer with dual extruders.
The rubber boot upper uses a custom-bonded TPU adhered to a stretch nylon Cordura ripstop woven fabric for the outer layer, provided by Atextile. On the inside, W. L. Gore & Associates provided stretch waterproof materials and seam tapes for a custom-designed close-fitting bootie construction.
The hiking boot and travel shoe use a circular knit polyester upper.
The sandal footbed uses a custom-made Merino wool mesh + TPU bonded textile insert on top of a foamed TPU base.
Custom insoles are 3D printed TPU.
Specification All prototypes were made in Men's 11.5 with a specially designed modular last that functions for both the low-cut footwear and the rubber boot.
Total weight of the system (half pairs only) is 999g.
Colors are black, purple, tan, and red (accents only for modular part registration).
Packed volume for all pieces, half pairs only, is <5L.
Two pairs were made for the hiking boots, but only half pairs were made for the other styles.
Intended design would be unisex and produced from Women's 5 to Men's 14 with half sizes stopping after size 13.
