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Updated: Jun 24, 2025

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Mathematical model for footwear upper material consumption estimation.

Muhammad Naimul Hasan1, Md Elias Uddin1, Anower Jahan Tamanna1

  • 1Department of Leather Engineering, Faculty of Mechanical Engineering, Khulna University of Engineering & Technology, Khulna, 9203, Bangladesh.

Heliyon
|June 3, 2024
PubMed
Summary
This summary is machine-generated.

This study introduces a mathematical model for estimating footwear material consumption, reducing waste by 2.06%. This innovation enhances material utilization and supports economic and environmental sustainability in shoe manufacturing.

Keywords:
2D nesting normFootwear industrySustainabilityUpper material consumptionWaste minimization

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Area of Science:

  • Industrial Engineering
  • Computational Geometry
  • Operations Research

Background:

  • Material costs significantly impact footwear production expenses.
  • Accurate material consumption estimation is crucial from the design phase.
  • Optimizing material utilization is vital for economic and environmental sustainability in footwear fabrication.

Purpose of the Study:

  • To develop a mathematical model for predicting footwear upper material consumption.
  • To enhance the material utilization ratio through optimized nesting on leather.
  • To minimize waste in the footwear manufacturing process.

Main Methods:

  • Utilizing two-dimensional geometry of footwear components and definite integral calculus to determine component areas.
  • Applying five distinct rotational arrangements for component nesting on leather.
  • Employing a minimal-area polygonal enclosure concept for maximizing material utilization.
  • Using ImageJ software and image processing techniques for real-case analysis of material consumption and waste estimation.

Main Results:

  • The proposed mathematical model accurately predicts footwear upper material consumption.
  • The model demonstrated a reduction in average material requirements by 2.06%.
  • ImageJ software facilitated precise computation of material consumption and waste, including the fourth waste.

Conclusions:

  • The developed model offers a more accurate estimation of upper material requirements for footwear.
  • The study supports improved material utilization, leading to economic and environmental benefits.
  • This approach provides a valuable tool for the footwear industry to enhance sustainability.