Wooden Sandals

By Dan Chen, August 1, 2015

Measurement / Sizing

While I was at the Haystack Mountain school of craft I realized that I left my sandal at home. luckily, I was living in the FabLab and have the access to a shopbot and some casting materials. I decided to make my own sandal out of my need.

I traced my feet onto a piece of paper and figured out where to drill the wholes for the straps (the hole right next to the big thumb) After taking the measurement, I model the sandal in SoildWorks. It starts out as a 3D design, but is was taking way to long, so I did the cut out in 2D for faster cut time.

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Cut outs / Milling

I used the shopbot to cut out the shape of the shoes with the strap cut outs.

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Make it wearable / Adding the Strap

I used a piece of burlap as the strap, but you can make this out of plastic sting or anything that feels comfortable on your feet. I started from the center hole pulling the burlap down below the shoes, them apply hot glue to secure them in position. I made sure that as I am pulling up, some of the hot glue carries to the top of the hole for better hold. I then measure the length of the strap to make sure that my feet fits comfortably.

 

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Customized / Laser Engrave

I used Katsushika Hokusai as pattern for my shoes, I made the drawing into vector for laser cutting. The engraving added extra grip but it might feel a little uncomfortable. I guess we can use clear resign to make the surface flat for not etching it too deep with the laser.

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Casting the Rubber Feet

The wooden sandal makes a lot of noise around the studio, so I decided to add rubber to the feet. I used MOLD MAX 60 part A and part B to make the rubber.
They take about 24 hours to cure.

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I hot glued the wood model or wall created with wood to contain the rubber casting material.

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Once it’s cured, it’s ready to perform, without loud walking noises.

Finishing touches.

I added a piece of wood just between the wood and the rubber meets to hide the hot glue.

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Thoughts

The down side of the sandal is that it’s a bit heavy but does the trick for shower and walking around the studio.

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