A “Scan-Design" Paradigm for Footwear Innovation: Combining Reverse Engineering with Digital Manufacturing

Abstract

In the context of Industry 4.0 and manufacturing digital transformation, the footwear industry needs to shift from experience-driven development to data-driven design and manufacturing. Rather than using finished-shoe scanning as a substitute for foot or last data, this study focuses on the reverse acquisition and digital reconstruction of complex product forms as editable design references for forward innovation. Accordingly, a Scan-to-Design framework integrating three-dimensional scanning, reverse engineering, form redesign, and digital manufacturing is proposed and validated. A high-top canvas shoe was selected as a case object to test complex form capture. Point-cloud data were acquired using a handheld laser three-dimensional scanner and processed in Geomagic Studio for preprocessing, registration, mesh reconstruction, and surface optimisation. Geomagic Qualify was used to verify geometric fidelity through deviation analysis. Based on the reconstructed model, Rhino and ZBrush were applied to develop a new design with a fluidisation language, followed by 3D printing, mould fabrication, PU injection moulding, and physical assembly. Expert trial-wear evaluation showed that the prototype performed well in fit, comfort, stability, and local comfort. The results indicate that the framework connects reverse reconstruction of complex forms with forward creative design and digital manufacturing, improving modelling accuracy, design efficiency, and innovation feasibility.