Structural design and performance of the toe region in flat-knitted fully fashioned lightweight sports shoes

This study introduces an innovative three-dimensional (3D) fully fashioned shoe body knitting technology to streamline the complex process flow of traditional footwear manufacturing. While designing the shoe body with functional partitions and prioritizing lightweight construction as the primary goal, the study focuses on the toe area, which has received less research attention. A differentiated fabric structure and yarn combination scheme are developed for this critical region using the SHIMA SEIKI four-needle bed computerized flat machine to weave 18 groups of single-sided fabric samples and conduct multidimensional performance tests. The experiments systematically examine how fabric structural deformation and yarn ratios influence key performance indicators, including thickness, weight per square meter, strength and elongation at break, fabric stiffness, top breakage, abrasion resistance, crease recovery, air permeability, and moisture permeability. A rating system is used to comprehensively evaluate these indices and identify the optimal solution with the best overall performance, providing a precise path for structural design and material selection in the toe area. The findings reveal the relationship between fabric structures, yarn combinations, and performance parameters, offering a systematic theoretical basis for the design of 3D fully fashioned knitted shoes.