Print the Mask

This project explores the exciting potential of creating fully wearable footwear using 3D printing technology. Using flexible TPU filament, I printed a custom-sized shoe that demonstrates both function and form. By scaling the model to suit the intended wearer, the final piece not only looks the part but can also be comfortably worn.

One of the most important steps in this project was orienting the model correctly in the slicer. I angled the shoe with the toes facing downward at approximately a 30-degree tilt. This orientation was required to fit the shoe on the print bed, while ensuring most of the model could be printed without supports and still achieving optimal detail and overall stability. Manual supports were added only to the sole of the shoe, ensuring the rest of the model printed cleanly without unnecessary material waste. To enhance the efficiency of these supports, I selected an organic support type, which offered strength while keeping removal simple.

For slicing, I used the following settings:

• Layer height: 0.2mm
• Perimeters (walls): 3
• Infill: 15% gyroid pattern for flexibility and durability
• Manual organic supports restricted to sole only
• Angled orientation: 25–35 degrees (toe down)

Prior to printing, I dried the TPU filament thoroughly to ensure a successful print result, and cleaned the textured build plate thoroughly with Isopropyl Alcohol.

The printing process itself was a test of patience and reliability. Due to the shoe’s size and detail, the print of a single shoe took just over 2 days to complete. TPU filament requires precise extrusion, so I monitored the process closely to avoid issues such as stringing or under-extrusion.

The final result is a functional 3D printed shoe — lightweight yet durable, with a comfortable level of flexibility thanks to the gyroid infill and TPU’s properties. While not mass-produced footwear, this project highlights how 3D printing can one day reshape how we think about personalized clothing and accessories.

This project draws on a conceptual shoe design originally shared on Thingiverse (thing:5230015).