Introduction of CAD/CAM

Computer-aided design, or CAD, involves creating two-dimensional (2D) or three

dimensional (3D) computer models defined by geometrical parameters. It uses both
computer hardware and graphics software to generate model drawings. Every parts of the
created model can be further modified by changing the relevant parameters.
Computer-aided manufacturing, or CAM, is a system that uses geometrical design
data to control automated machinery. CAM allows the production of finished products by
using computer controlled production machines. Normally, CAMs are associated with
computer numerical control (CNC) systems. Both the CAD and CAM use computer-
based methods to encode geometrical data, thus, the design process and manufacturing
process can be highly integrated.
In engineering practice, CAD/CAM are utilized in various ways by different
people. CAD/CAM is utilized to produce drawings and document designs, employ as
visual tool by generating shaded images and animated displays and perform engineering
analysis on geometric models.
Over the decades, CAD/CAM has been widely used in the practical industries,
such as automotive industry, medical industry (prosthetics and orthotics), footwear
industry and so on. In this project, the usage of CAD/CAM in foot wear industry is
studied.







CAD/CAM in Footwear Industry

Background
CAD was introduced in footwear industry in the 1970s. It was initially used for pattern
grading only as CAD can perform complex grading easily and quickly.
Nowadays, CAD systems have been developed with much more functions.
Manufacturers use CAD for designing and grading of shoe upper patterns, shoe lasts and
sole moulds. Besides that, latest CAD systems can be used to scan shoe lasts, or feet to
produce custom-fitting shoes, and also to estimate footwear costing. In term of
manufacturing process, manufacturers use CAM software for the pattern nesting and
cutting, and even for creating stitch path for auto-stitching machines.

Popularity
CAD/CAM have been widely used in the footwear industry. One of the well-known shoe
manufacturer that uses CAD/CAM in the design and production line is Nike Inc.. Nike
Inc. has invested over a million dollars in high-speed, high-precision machine tool at its
Mold & Tooling Center (MTC) in its headquarters campus in Beaverton, Oregon, USA. It
was reported by using CAD/CAM, 80% of the tool pathing process of Nike shoe
production has been automated.
Besides that, Adidas is another company that utilized CAD/CAM in its shoe
making process. It was found that by using CAD/CAM, Adidas can produce moulds of a
consistent high quality and complicated designs shoes.
Nowadays, almost every mass shoe production manufacturers, including Puma
and Bata, use CAD/CAM in their designing or manufacturing processes.



Usage
1. Shoe last design
By using CAD systems in shoe last designing, last shapes can be modified quickly and
simply due to designers no longer have to wait for the last to be modified by hand.
Variation in toe shape, heel curve and toe spring are easily achievable. The combination
process of different lasts takes only a few minutes with CAD systems. Sophisticated
shapes can be generated accurately from CAD software. Popular last design CAD
software are Delcam CRISPIN LastMaker, FootWare Design software and Canfit
Insole Design software.


2. Sole design
CAD/CAM software are used to generate machining data for shoe sole models and
moulds. Mould design and production techniques are able to be strengthen by shoe mould
makers to meet seasonal high market demand, to improve quality and handle versatile
pattern. This would allow sports shoe producers to manufacture their products and
introduce them to the market faster than their market opponents. Example of sole design
software are Delcam CRISPIN ShoeMaker and SoleEngineer and FootWare Design
software.

3. Pattern grading
Shoe upper patterns need to be graded for the whole scale of the assortment of the
required shoe sizes, which can be European, American or Asian sizing. Designers can
change the grading specifications quickly and re-grade the parts easily.

4. Die making
Cutting dies in footwear production are used to cut uppers from leather, textile or
synthetics. Some CAD systems offer modules, which enable long-distance transfer of
data for footwear production preparation through the Internet. After that, the graphics
data of patterns designed can be transmitted easily to the die producer. The system also
calculates the circumference of the die which is the role factor of the die cost.

5. Cost estimation
CAD software is able to perform instant and accurate calculations for material
consumption and product cost of the shoe by using the graphics date generated and stored
in computer. This helps to eliminate time-consuming calculation work.

6. Automated cutting and stitching
Computerized cutting systems use graphics data output of CAD systems as input, and
with the integration of CAM systems, shoe leather and pattern cutting process can be
automated. Besides that, CAM software like StitchTec enable manufacturers to fully
utilize an auto-stitching machine. Automated cutting and stitching helps to reduce labor
costs and lead time. Example of CAM software used in footwear industry are Delcam
Knifecut, Delcam PatternCut and FootWare Central Fabrication system.






Benefits / Drawbacks
Benefits of using CAD/CAM in footwear manufacturing are:
- Reverse engineering from existing models,
- Easy design modification,
- Accurate designs regardless of complexity,
- Easy different patterns grading,
- Realistic onscreen visualization for some customers,
- Fast generation of molds from product designs.

The disadvantages of using CAD/CAM are:
- Lose of data if a computer problem occurred,
- Initial setup of production line is costly.

Future trend

The future CAD/CAM systems used in footwear industry would be more concerned on
stimulating the shoe on different situation, for instances, on a stony road, smooth wooden
floor or wet floor. This simulation helps manufacturers know the strength and weakness
of their designed products. Besides that, CAD/CAM systems also would help to
determine shoes durability, elasticity, hardness and how hard the shoe can be stretched.

References
1. http://www.orthopaedic-
cadcam.com/languages/fr/news/cstudy_article.asp?releaseId=117
2. http://www.footwear-cadcam.com/
3. http://www.vorum.com/english/footware/