Creative engineer and designer Luc Fusaro is using additive manufacturing technology to create custom sprint shoes for Olympic athletes. His current working prototype called “Designed to Win” weighs in at 96 grams (3.4 oz) and was developed as his final master degree solo project at the Royal College of Art and Imperial College London. Fusaro claims his custom shoes could improve an athlete’s performance by up to 3.5 percent.
By first scanning the feet of the athlete to create a digital 3D model, Fusano designed soles of varying stiffness before producing the physical items from sintered nylon polymide powder using the additive manufacturing process. After testing the various soles in the lab to match the mechanical properties of the shoe to the physical abilities of the athlete, a final shoe was made, again using the additive manufacturing process.