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Injury prevention is essential in running due to the risk of overuse injury development. Tailoring running shoes to individual needs may be a promising strategy to reduce this risk. Novel manufacturing processes allow the production of individualised running shoes that incorporate features that meet individual biomechanical and experiential needs. However, specific ways to individualise footwear to reduce injury risk are poorly understood. Therefore, this scoping review provides an overview of (1) footwear design features that have the potential for individualisation; and (2) the literature on the differential responses to footwear design features between selected groups of individuals. These purposes focus exclusively on reducing the risk of overuse injuries. We included studies in the English language on adults that analysed: (1) potential interaction effects between footwear design features and subgroups of runners or covariates (e.g., age, sex) for running-related biomechanical risk factors or injury incidences; (2) footwear comfort perception for a systematically modified footwear design feature. Most of the included articles (n = 107) analysed male runners. Female runners may be more susceptible to footwear-induced changes and overuse injury development; future research should target more heterogonous sampling. Several footwear design features (e.g., midsole characteristics, upper, outsole profile) show potential for individualisation. However, the literature addressing individualised footwear solutions and the potential to reduce biomechanical risk factors is limited. Future studies should leverage more extensive data collections considering relevant covariates and subgroups while systematically modifying isolated footwear design features to inform footwear individualisation.
For some years now, additive manufacturing (AM) has offered an alternative to conventional manufacturing processes. The strengths of AM are primarily the rapid implementation of ideas into a usable product and the ability to produce geometrically complex shapes. It has also significantly advanced the lightweight design of products made of plastic. So far, the strength of printed components made of polymers is previously very limited.
Recently, new AM processes have become available that allow the embedding of short and also long fibers in polymer matrix. Thus, the manufacturing of components that provide a significant increase in strength becomes possible. In this way, both complex geometries and sophisticated applications can be implemented. This paper therefore investigates how this new technology can be implemented in product development, focusing on sports equipment. An extensive literature research shows that lightweight design plays a decisive role in sports equipment. In addition, the advantages of AM in terms of individualized products and low quantities can be fully exploited.
An example of this approach is the steering system for a seat sled used by paraplegic athletes in the Olympic discipline of Nordic paraskiing. A particular challenge here is the placement and alignment of the long carbon fibers within the polymer matrix and the verification of the strength by means of Finite-Element-Analysis (FEA). In addition, findings from bionics are used to optimize the lightweight design of the steering system. Using this example, it can be shown that the weight of the steering system can be drastically reduced compared to conventional manufacturing. At the same time, a number of parts can be saved through function integration and thus the manufacturing and assembly effort can be reduced significantly.