DfAM TPU Flip Flop

The module brief was direct: design a flip flop ready to be mass produced and sold online, with 3D printing as the manufacturing route. Taking it seriously meant sizing everything against HP Multi Jet Fusion in TPU: build orientation, part packing, unit cost, wash cycle. Not just the form.

The midsole is a functionally graded lattice, denser at the heel, opener through the arch, medium at the ball. The grading is driven by the pressure map of a walking gait, and it prints overnight in a single piece. The rest of the work is the boring, necessary side of DfAM: which face lies on the build plate, how many pairs fit in a job, how the strap survives de-caking.