Materials and Processes Report
Polymer Scrap
DS-219
PDPM IIITDM Jabalpur
June 2, 2020
Group D
Partha S. Hukai (2018518)
Saurav Basumotari (2018526)
Mentor
Prof. Puneet Tandon
Professor of Mech. Engg; Professor of Design at PDPM IIITDM Jabalpur, India
SUMMARY
This report details a project undertaken by Design undergraduate students at the PDPM Indian
Institute of Information Technology, Design, and Manufacturing, Jabalpur as a part of the course
DS-219. The goal of the project and the course was to gain experience and knowledge on the
manufacturing processes that go behind producing a tangible product.
In this particular assignment, the original objective was for us to design and build a product that
compromises of polymer scrap. Throughout the process, both the assignment requirements and
their corresponding specifications have been kept in mind. The process in its entirety is detailed
throughout this report, including methodology, procedures, analyses, and end results. A detailed
description, including plans and finalized design sketches of the components, is provided as well.
This report serves to document the entire process from the initial background research to final
recommendations for improvement to the final design. This report documents the entire design
process including the final manufacturing plan, the measures are taken to ensure that all
requirements of the assignment have been fulfilled and specifications have been validated, a
detailed description and analysis of every major manufacturing processes that are to be used to
produce the desired product, this also includes a description of the product and its features, and
finally, our recommendations concerning improving the final design and suggested future work.
1
TABLE OF CONTENT
Summary…………………………………………………………………………………………..1
Abstract……………………………………………………………………………………....…....3
Introduction …………………………………………………………………………………....….3
Aim/objective………….………………………………………………………….……………….3
Research……….………………………………………………………………………….…...…..4
Ideation…………………....………………………………………………….………….......…....4
Concept…………..……………………………………….......…………………………………...4
Detailed design and planning………………..….……………………………………………....4-5
Manufacturing……………………….……………………..………………………...…..……..5-8
Tools needed…………………………..………………………….…………………….....5
Materials ………………………………………………………………………....….…....5
Making the shoe pattern…………………..…………………………………………….6-7
Harvesting parts from old shoe……………………………………………….…………...7
Cutting the pattern onto the fabric……………………….……………………..…..……..8
Stitching the shoe panels...…….…..………………………………….…………………...8
Assembling the shoe……….…………………………………….………………………..8
Fitting……………………………………………………....….…………………………..8
Conclusion and reference……………………………..………….……………………………..8-9
Design sketches and plans……………………………………….………………………………10
2
DESIGNING A PRODUCT MADE WITH POLYMER SCRAP
ABSTRACT
This report details the process of concept generation, designing, and manufacturing for a
product with polymer scrap. The assignment was not done in the mechanical lab workshop
and rather we were given the entire semester to design and manufacture the product or
artifact. This required us to initially learn about polymers and its types, we also had to
gather polymer scrap. We were initially required to both design and manufacture the
product but due to the current scenario, this requirement was changed to us delivering the
detailed design and manufacturing processes to be used to generate the product. This
report documents the very process including the measures taken to ensure that all
requirements and specifications of the assignments have been validated, and
recommendations concerning improving the product and suggested future work.
INTRODUCTION
Modern artists and designers are finding ways to recycle and reuse as much waste as possible by
creating useful products while saving the environment at the same time. So to do this we
recycled junk items and use them as materials. Instead of buying new materials, we can just
reuse those recyclable objects. This way, we can cut down costs on materials as well as reduce
the amount of garbage on this planet. Therefore we used polymer scrap to transform into a
product everyone uses every single day i.e footwear. One might think that this recycled footwear
is inferior to the non-recycled ones but major footwear makers like Nike and Adidas have proved
otherwise time and time again.
AIM/OBJECTIVE
The objective of this assignment was initially for us students to design and manufacture a
product with polymer scrap and gain insight into the materials, manufacturing processes as well
as designing a particular product according to requirements. Now however due to circumstances,
the aim of the assignment is to deliver detailed design and manufacturing plans highlighting the
materials and processes used for the same.
3
RESEARCH
From the very start, we knew what we were going to design and make for this assignment which
was a shoe out of scrap. This idea was heavily influenced by the ‘Space Hippie’ initiative taken
up by Nike to reuse their scrap to make new Sneakers. So during this stage, we just had to
perform research on how make the show happen and which kind of scrap we are going to use.
This though was solved relatively quickly as we found a way to repurpose a torn backpack and
an old shoe for this purpose.
IDEATION
We made multiple sneaker designs at this point and explored ideas while keeping in mind our
constraints that were our material choice.
(images are at the end of the report)
CONCEPT
We eventually decided on a high top sneaker which would go well with our objective to make
the shoe laceless and we came up with a good concept to move forward with the detailed design
or making a Tech Pack of the shoe.
(images are at the end of the report)
DETAIL DESIGN AND PLANNING
Detail design is where we make our Tech Pack.
What is a Tech Pack?
If you are a fashion startup or a new designer looking to build your own shoes or leather goods
collection, then a Tech Pack is the best way to convey your ideas to a manufacturer. Think of a
Tech Pack (short for Technical Packet and also known as Specification Sheets) as a blueprint or
a through an illustration of your shoe designs and specifications. A Tech Pack generally explains
your overall design aspects in a structured format to help a manufacturer turn your designs into a
finished product. If you are looking for a time tested template, then you should download the
Italian Shoe Factory Tech Pack guide & template, which includes a PDF guide along with an
Excel spreadsheet with example Tech Packs that you can easily follow.
4
Why is a Tech Pack important?
A tech pack may include the shape, structure, materials to be used, grading, colorway, sizes,
labels, etc. A clear Tech Pack also helps in getting a quote for your prototype sample and
production orders as per quantity requirement. Some of the items that a Tech Pack may include:
● Details of materials to be used for each component of the shoe or bag
● Color specifications and Pantone number for each component
● Blueprint for the sole design if necessary
● Image references of hardware or any jewelry accessories
● Placement and style of brand labels within the shoes or leather goods.
● Box Packaging and branding details
(images are at the end of the report)
MANUFACTURING
Tools needed
Scissors
Shoe Glue
Stitching kit
Sewing Machine
Exacto knife
Measuring tape
Masking tape
Ruler
Cutting mat
Shoe last (Can be made using POP)
Materials
Torn Backpack
Used shoe
Foam
5
MAKING THE SHOE PATTERN
Taping our Last
The first thing to do is to cover one of our lasts with masking tape (it doesn't matter if we choose
the left or the right).
It is important to try to place the tape on to the last as smoothly as you can, however, it is
inevitable we will have some creases.
1. Start by placing a line of tape along the front and the heel section
2. From the heel, begin to place horizontal lines of tape along with the last (it is important that
they at least meet the centerline of tape, if not cover it entirely)
3. Once we have done one half, repeat on the other
4. Start to put tape vertically over the horizontal tape to create a second layer. Work from the
middle towards the heel.
5. Once we have added the second layer to the back of the last, begin to cover the front. Use
unbroken lengths of tape to cover the entire front.
6. We should now have a last completely covered in TWO layers of tape- in a grid pattern.
7. With our knife trim along the feather-edge o f the last (the faint line that runs around the
circumference on the bottom of the last) and remove the ends of your tape.
Apply our Design on to Your Last
At this stage, we can draw our design on to our last.
1. Take a long length of tape and stick it to your cutting mat.
2. With a ruler draw a line down the middle of the tape
3. Place this lined tape down the center of the last at the front and the heel. This will give us a
helpful reference point when designing.
6
4. Mark our counterpoint on the heel. This is found by first getting your Standard Last Length -
this will be provided by the factory supplying lasts to you, or tables are available online. Divide
this length by 20% and measure up the line from the bottom of the last. This is our counterpoint
and marks where the shoe sits on the heel.
5. From the counter-point start drawing your design on to the front of the last.
6. When drawing on the side parts of the shoe we would be careful not to place the top-line over
where the ankle bone will sit.
Transfer our 3D Tape Pattern Into a 2D Pattern
1. Using our knife, carefully slice around the top-line of our design. While being careful, it is
easy for the knife to slip into our tape pattern (bad) or hand (worse)
2. Cut along the vertical line at the heel
3. Slowly peel the tape from the back until it has come off the last, all in one piece
4. Gently place this on our card
5. Flat sections of tape are easy to flatten down. Where the tape has curved along the toe we will
need to make some snips to help it to go flat. 5-10mm snips all around the toe should do the trick
6. To help press the tape to the card we can use something hard and smooth.
7. Once the tape is flat and crease-free, cut around the edge of the tape with your knife
8. Use this stencil to draw around the silhouette on to a new piece of card
After completing the above-mentioned steps and making our pattern according to the technical
specification we can move to our next step.
HARVESTING PARTS FROM OLD SHOE
We can save ourselves a lot of time and give our shoes a more professional look if we harvest
parts from other shoes you don't use anymore. In particular, shoe soles are good as they'll give us
a reference for the rest of your stitching. Provided they're in good enough shape, we should
salvage the parts we think might work in our new shoe, taking care to remove them slowly and
carefully with a scalpel knife.
7
CUTTING PATTERN INTO OUR FABRIC
Using our pattern or personal design, we will cut each necessary section of fabric from our ton
backpack. We will also use a ruler or protractor to help us with the incisions.
While cutting our pattern, we should leave at least an inch of extra material along the bottom
edge of the shoe, as well as a centimeter or so, where the different pieces of the upper join
together. This will be our seam allowance.
STITCHING THE SHOE PANELS
A fluid stitch is one of the most skill-testing parts of making our own shoe. We have to be
meticulous and slow as we're piecing it together; while it may be easier to go faster, bad stitching
will certainly show in the final product, and our shoe won't look as good as it should. We should
try to get the stitches as close to the end of each piece of fabric as we can. Overlaps might leave
unnecessary ridges on the shoe. If we intentionally cut our pieces to be slightly bigger than
necessary for the sake of having stitching space, we should remember to take that into account.
We don't want to end up with a shoe that's too big, or too small for the sole.
ASSEMBLING THE SHOE
Stitching the fabric to our sole won't work, at least not by itself. It's recommended we pick up a
shoe-specific adhesive to glue our fabric to the sole. We will apply the glue slowly and evenly.
This will maximize the waterproof seal for our shoe, and keep it sturdy. If our blueprint suggests
any additional stitches, we would do those as well.
Make use of the last inside the shoe as we are putting it together. It will make a great point of
reference and support while we are getting the tricky stitches done.
FITTING
At this point our shoe is complete and we can proceed and wear it to check its comfort and
fitting.
CONCLUSION
The objective of this assignment was initially for us students to design and manufacture a
product with polymer scrap and gain insight into the materials, manufacturing processes as well
as designing a particular product according to requirements. Now however due to circumstances,
8
the aim of the assignment is to deliver detailed design and manufacturing plans highlighting the
materials and processes used for the same.
To that extent, it has to be concluded that the objective of the assignment has been successfully
achieved as the team was able to not only learn more about the process but also deliver detailed
design plans for a product.
REFERENCE
https://www.italianshoefactory.com/how-to-start-a-shoe-line/what-is-a-tech-pack/
.
9
Pattern for the upper of he shoe
10
Tech pack for the mid-sole of the shoe
11
