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rustagi@mit.

edu Kevin Rustagi

This was my design to compensate for the awkwardness of the shape of track
shoes in a sustainable way, with 95% of the product made of cardboard and
paper materials. This was done for a design class during IAP. This is the
manufacturing sheet and break down from the class.
Procedure
Using corrugated cardboard we cut out the two soles of the over-shoes in a way
that it has the general outline of the cleat and it can contain the cleat within it.
(See image 1) Note the cleat on top of the sole cut out.

Image 1

From the thin cardboard we cut out the vertical framing that will be used to give
the over shoe its shape and casing. The sizes for these pieces are the following
4 - 8.25” x2.5” rectangle
2- 12” x 3” rectangle
2- 4” radius half circle
(See image 2)

Image 2

The shorter rectangle and the semi-circle are all glued together so that the long
bottom edges of the pieces are aligned. Once dry they are hot glued
symmetrically to the back edge of the sole. The longer rectangle is also hot glued
along the front edge of the sole. (See image 3) One the front piece is in place
two vertical cuts were made 1.5” apart about the center of the front and folded so
that they over lap. (See image 4)
Image 3 Image 4

The next step is making the heel and toe inserts. The toe insert is relatively easy
to make; basically it is two layers of the front third of the sole glued together. The
heel insert is a little more complicated, it is six layers of corrugated cardboard
glued together with alternating patter so that the grains are perpendicular. The
general shape of the heel insert and the toe insert can be seen in image 5.

Image 5

The next step was to fit the inserts into the shoe and make sure it all fits together
(see image 6)
Image 6

Before hot gluing the inserts in place the upper part of the sole was lined with
black paper. The inside of the rear frame pieces were also lined with colored
construction paper. (See image 7)

Image 7
The final step was to punch the holes in the final assembly where the laces are
tied. The final assembly can be seen in image 8 with the laces threaded and
tied.

Image 8
Complications/Solutions
One of the complicated steps was bonding the edges sole to the thin
cardboard frame. Hot glue proved to be the best solution for joining the edges.
Although it was difficult to hold the cardboard sheets in their configuration until
the glue cooled.

For the prototype twine laces were used to secure the cleat to the over-
shoe. The front lace was tied to the cardboard through the punched hole; this
hole happened to be too close to the edge and this caused it to rip the cardboard
the solution was to move the whole back. The lesson here is that regardless of
what sort of straps are used they need to be far enough away from the edge so
they will not rip even if they might not be as aesthetically strategic.

Further Development
Future development for this product would be to upgrade from laces to a
sturdier device. Velcro is probably the best alternative since the straps can be
tightened very easily and it is also very fast and easy to secure and release.
From the testing the conclusion was made that the sole need to be more flexible
so that it will bend with the natural motion of the foot and shoe. Also, we realize
that in order to have more durability the over-shoe needs to be made of a
different material. The obvious choice would be to make it of a light weight
rubber or rubber composite. This change in material also satisfies as a solution
to the flexibility issue because of the material properties of rubber.

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