From Our Performance Sole to Yours

Why isn’t footwear designed for… well, feet?

 

Our feet, the unsung heroes of our daily grind, deserve nothing less than the pinnacle of support and comfort. The innovation behind the proprietary TFR performance sole is grounded in this belief. As a seasoned performance footwear designer, entrepreneur and professor of the world’s first accredited sneaker design minor, crafting the insole for TFR shoes was an exciting challenge! It wasn’t just about fitting the insole within the timeless silhouette;  it was a deliberate effort to integrate modern materials and engineering akin to those used in high-performance athletic footwear. 

Having designed footwear for athletes in the NBA, WBA, NFL and MLB, I deeply understand the essential attributes they require to perform at their best while ensuring comfort. I often use the analogy of designing a Ferrari: if you can design a high-performance, luxury vehicle, you can certainly design a reliable everyday car like a Honda. Our goal for the TFR insole was to create a high-performance “Ferrari” insole for your foot. Designing such a product requires meticulous attention to detail, focusing on millimeter precision and a thorough understanding of a woman’s foot. 

My approach to the design of performance footwear is based on a simple formula – one that I teach to my students at the Savannah College of Art & Design (SCAD). It boils down to understanding “the who,” “the what” and “the why,” which ultimately leads you to “the how.”

Biomechanical Expertise and Women's Foot Health - the "Who"

The TFR design philosophy revolves around optimizing movement, performance and comfort. We recognize the unique characteristics of women’s feet and that the shoes you wear throughout the day are vital in empowering you to reach your greatest potential. That’s why every aspect of the insole was designed with you in mind, ensuring you both feel and perform your best. Integral to the TFR insole innovation is the invaluable expertise and partnership of TFR Podiatrist Consultant Dr. Terri Ronna, DPM, a seasoned podiatric physician with a profound understanding of women’s foot health. Dr. Terri’s wealth of experience and years of data on women’s feet with variables like gait (a person’s walking style), arch height and age formed the bedrock of our design process. Using those insights into biomechanics, we could delve into the unique demands of women’s foot health, ensuring that the custom insole not only performs but nurtures the health of its wearer.

Meticulous Engineering to Enhance Performance - the "What"

The engineering of the TFR insole involved a meticulous focus on key design elements crucial for both comfort and performance, ensuring precision in every detail without compromising the elegant silhouette of the shoe. In the world of footwear, the marriage of form and function shouldn’t be exclusive to athletic shoes!

Metatarsal Support and Cushioning: Your metatarsals, the long bones in the forefoot of your feet, form the framework supporting your arches, making their support crucial to alleviating stress and impact on your feet during daily activities. We designed the metatarsal pad so you can feel the support and cushioning when you step into the shoe without experiencing crowding. Additionally, a unique wave pattern is embedded in the pad to offer traction and prevent your foot from sliding inside the shoe.

Arch Support: Recognizing the biomechanical significance of arch support, we designed the insole to ensure proper alignment, reduce stress on joints and mitigate the risk of overuse injuries. We strategically elevated dimensions throughout the foot arch to effectively redistribute weight and pressure, enhancing shock absorption.

Extra Rear Heel and Security Comfort: We know a significant pain point for women’s shoes is the stability and security of the calcaneus (heel bone), especially during activities involving movement or extended periods of standing. The deep and sculpted heel lip alleviates discomfort, provides ultimate containment and helps avoid pronation or supination.

Heel Crash Pad: The crash pads within the insole add a layer of comfort and cushioning, reducing heel impact loads and supporting the heel bone for stability during daily activities. The crash pad complements the rear heel lip, as the horseshoe shape created by both elements helps cradle the heel bone to limit movement in the rear foot while wearing the shoe.

Flex Zones: The debossed areas of the insole, the flex zones, are intentionally designed and placed within the forefoot of the insole to enhance flexibility and reduce stress on the foot. Think of it like trying to bend a stiff piece of cardboard – it would be rigid. But if you make cuts in the cardboard, it becomes more flexible. Similarly, the flex zones assist the natural flexing of the foot during movement.

 

Early stage design sketch of the TFR Power Sole

 

Designed With You In Mind At Every Step - the "Why"

The emphasis on forward design – using data to understand and anticipate your needs, diving deep into the finite details, and leveraging modern technology in design and manufacturing – is what, in my opinion, sets TFR performance insole apart from the rest. The unique perspective and access to data that Dr. Terri brought to the collaboration, coupled with my over 13 years of experience and understanding of the nuances of manufacturing design of performance footwear, has allowed us to create a shoe that transcends mere aesthetics. In the intricate world of footwear design, precision is paramount, and attention to detail, down to the 10th of a millimeter, will make all the difference in your comfort and performance throughout the day.

Innovation, Collaboration and Iteration - the "How"

Using the valuable insights from Dr. Terri’s data analysis and Rhinoceros (“Rhino”), a 3D design software, I created a 3D last–an anatomical copy of the foot–to guide the design process. I then sketched multiple iterations of the insole, adjusting the dimensions of each of the key design elements until the first version of the prototype was ready to be modeled in Rhino and sent to the factory in Italy for manufacturing.

To produce the insole, we partnered with Miami SRL, a leading insole manufacturer based in Morrovalle, Italy, renowned for their injection and thermoforming technologies expertise. Collaborating with the factory, we experimented with foam options, durometers and placements, transitioning from digital to physical prototypes. We ultimately chose to manufacture the TFR insole using thermoforming technology, which allowed us to create an organic shape with precise arch support and varying degrees of density throughout the insole to provide extra support and cushioning where necessary. Real-world testing on Dr. Terri’s patients provided crucial feedback for fine-tuning the final design and foam placements for optimal comfort and fit. 

The entire insole was crafted from a proprietary, high-density compression molded EVA foam, a lightweight and flexible material known for its superior cushioning properties, impact resistance and durability. We’ve chosen a specially treated Italian Alcantara top liner to enhance the luxurious feel inside the shoe. This sustainable, suede-like material provides a premium touch and features sweat-wicking and antimicrobial properties. 

These iterative steps and collaborative efforts from the TFR team of experts in design, manufacturing and foot health were instrumental in achieving the perfect insole design. However, it was the invaluable real-world feedback from women that truly guided our refinements, ensuring the final product met the highest standard of comfort and performance.