Can 3D PRINTED hiking sandals survive the jungle?

Will they carry me through the rainforests of Costa Rica?
BEHIND THE SCENES: / morleykert
Thank you to Chacos for making awesome hiking sandals and providing the inspiration for this design! Check them out here (not a sponsor): www.chacos.com/US/en/home
THINGS I USED IN THIS VIDEO:
Dial calipers: amzn.to/3L7v3bk
Bambu Lab X1 Carbon: bambulab.com/en/x1
TPU Filament: amzn.to/3kOWmg3
PETG Filament: amzn.to/3Ysd7v9
360 degree timelapses - Insta360 X3: amzn.to/3ZP07B0
Barge rubber cement: amzn.to/3SXv4jT
Heat gun: amzn.to/3K0TWFi
Office chair: amzn.to/3F8niOO
Hexagon light feature - Nanoleaf Elements: amzn.to/3ORmFwm
OTHER TOOLS I LIKE TO USE:
www.amazon.com/shop/morleykert
Note: The above shopping links are affiliate links, meaning that, at no additional cost to you, I may earn a commission if you click through and make a purchase.
MUSIC (in order of appearance):
Papa Funk - spring gang
Tortuga - Harvio
Hypnotic - Enigmanic
Silfra - West Zander
Singularity - Lagua Vesa
Varuna - Twelwe
Oak - West Zander
Fences - Jones Meadow
Stays The Same - Gloria Tells
Ghosting - Christoffer Moe Ditlevsen
Wiz Kid - OTE
Tracker - Cristoffer Moe Ditlevsen
Get Up on That Horse - spring gang
B.O.D. - Heyson
Fun While It Lasted - Emil Axelsson
Bella Balearic - Larry Poppinz
Main Jack - OTE
INSTAGRAM: / morleykert
TWITTER: / morleykert
TIKTOK: vm.tiktok.com/xSfbdj/
morleykert.com/
#3Dprinting #DIY #design

[@SunChaserEUC]

Should be an option to go back a layer or two in a print and resume from there.

[@MorleyKert]

I know, right?!

[@thenextension9160]

You just tell the software to start at a certain layer in the preview pane. The green bar can be dragged on the right. Which tells the code where to start.

[@JesperMakes]

I really love how this is both an indept 3D printing tutorial AND a crazy adventure into the wild!

[@alexanderkappreumert]

When other maker-youtubers recommend something, you know it's gold!

[@ale6242]

Speaking of things you wear. i 3D printed my glasses frames after finding the ones i had picked in the store to be uncomfortable. I wear them every single day and love them. I get compliments on them all the time and peoples minds are always blown when i tell them they're 3D printed

[@eLeoLychen]

Oh man I really wanna see you do further permutations on this design, the process is fascinating!

[@georgesenju8665]

I would love to see another version with the improvements you’ve learned!

[@XopherNiven]

I would also like to see that. Maybe higher bottom layer count with only 35% infill might give it ruggedness and durability all the while being able to print faster.

[@Engineezy]

Respects on full sending the hike in those sandals 😂

[@rickalcantara]

You should've used some infill, 100% is too much. I used to make some insoles and we used 25% at maximum, and it was still very rigid. Anyways! Love your videos, excellent job!

[@Luigik99tv]

Yeah I agree !

[@PauIieWalnuts]

If you cross section those Chacos, I bet it's a grid pattern in the middle, with a thick insole and outsole

[@xanderwusky3001]

Agreed, it would also make them more bendable, lighter and easier to print. What might also be a good middle ground is printing only the lowest part of the sole solid. As it would maybe help a bit with lasting longer. But then only do like the first 5-10mm

[@thenextension9160]

This was pretty funny to watch. Winging it but positive all the way.

[@kazolar]

I've tried doing this some years back. I had scans of the foot and used that as my reference, and I also used the sculpting environment to get a more organic shape. Definitely would not go with 100% infill, anything about 60% for TPU is overkill, and likely the cause of the clogs. Also would have gone with a large nozzle, the sandal doesn't have that many fine features, so a bigger nozzle would have mitigated the amount of clogs as well and doing both -- lower infill, and a larger nozzle would allow you to print these faster. Very impressed that you made it through the vacation and didn't give up on these. Big props.

[@NinaThoren]

Loved that this video contained both the concept, design and production of the sandals but also durability testing, would love more of these videos with useful things you can 3D print!

[@JesseProjects]

Anybody else yelling "just print it on paper!" at 2:00? Might be a bit cheaper/faster test of the size-to-foot comparison, lol. Joking aside, great work, as always, Morley!

[@FixitFingers]

Brave man taking a prototype on holiday 😅Great design exercise and learning experience, as well as life experience mate.

[@dhp5865]

The sandals made your family happy. They worked 😄

[@kauredo]

Definitely keep refining these! Excited to see the next steps

[@testingapril]

The buildup to this video had me anticipating it. And it paid off! I'd love to see you refine it and give it another go. It would be interesting to watch your rapid iteration testing approach from your free 3d peint fix videos with these sandals. Maybe the goal could be adapting to a different size shoe for someone else once you have it more functional?

[@davebauerart]

There’s so many ways to iterate on these! It would definitely be interesting to model some flexible structures into them.

[@CH1CK3NNU66375]

You need to glue some water wicking material to the top layer of the sandals for extra grip.

[@shanomac]

Always enjoy watching your thought process. Great job Morley!

[@josephvitale4357]

Great video, It provides an excellent in-depth explanation of the design process used in creating the sandals. I like it because it is not something you usually see on You Tube , a detailed step by step tutorial.

[@MorleyKert]

Thanks for the feedback!

[@yuriylutsyshyn3495]

Thank you for the colors, we struggle here so much, hello from Ukraine. Enjoying your videos!!.

[@JernD]

Great work Morley! Despite not being 100% satisfied with the result, it is pretty amazing it is possible to make something like this at home. I feel a conundrum with deadlines like this, on one hand you have to "get it done" but on another you have to accept more flaws or take more risks than you otherwise might!

[@davey4731]

This project is so cool!!! My Brain is running wild with ways to iterate this and improve upon it.

[@Keasbeysknight]

These are the types of things I look forward to in the future. Once 3d scanners are super affordable alot of things like this can be brought to the masses. Jetsons here we come!

[@GeekBoi]

I love this. The best pair of river sandles I've ever owned were alpes. The were small and lightweight with good straps. The size was great for stuffing in the back of a small whitewater playboat. They had little concave "buttons" for tread that was great at gripping wet rocks. Unfortunately Teva bought them and made several changes that really did not work well. I'd love to be able to make my own pair like that. I've not tried any flexible filaments yet.

[@Rouverius]

Yeah, real world testing is a must. Hey, maybe a follow-up project one day with design improvements? Finally, Happy Birthday, Mrs. Cathy!

[@ultimatedude80]

God this is so cool I love all the stuff I learn about modeling and printing from your channel

[@Earl3]

Awesome video, Morley! I don't know that I have the guess to try making my own shoes, but if I did, I definitely don't think I'd have committed to using them as my primary (and only?) pair of shoes for a while vacation (I guess I'm assuming here...). I love your dedication to your craft!

[@NordicSpartan]

This is the content I follow you for! Would love to see a second iteration :)

[@jungles87]

awesome work as always! printing with TPU give me flashbacks! I was kinda of surprised the bamboo handled it that well. i've had to slow down my prints significantly to get TPU to even begin printing :)

[@MorleyKert]

Thanks! Just used the default TPU settings

[@daliasprints9798]

@@MorleyKert Based on the time that's only around 3 mm³/s. I'm not sure if the Bambu has issues with gripping the TPU that limit it, but you should be able to go considerably faster, at least 2-3x that. My TPU Benchy was something like 17 mm³/s average.

[@TroyRubert]

Man, I used to live there, and I miss it so much. The people are the kindest, most welcoming people in the world. Pura Vida!

[@MorleyKert]

Everyone we met was incredibly nice and generous.

[@monsterman2043]

you make great videos man, keep it up, always joy sparking when watching you!

[@MorleyKert]

Thank you so much!

[@SICresinwrks]

This was a wild ride, loved seeing the whole creative process, but then again thats one reason why I love the videos you make😂 I wasnt very confident that they would last, so im glad I was wrong! Great video

[@3DJapan]

Lowering the infill will also make them more flexible.

[@davidburris120]

Congratulation on a successful first version

[@mikededmon]

This was insanity and a total blast.

[@cseymour97]

I think doing this in stages would be good. So have a base foundation set up at a lower infill then do the footbed as a separate piece, and maybe just get some Eva for the outsole for more grip and cushion and then you'll have a proper shoe!

[@onewhowatchesfires2673]

Loved the video man! Tip with the arch! Think of it like a bridge, you dont support the arch of a bridge in the middle, you support the parts on either side of the arch! Good luck in future videos~

[@viv3d]

Very cool project! When designing sandals I think the fusion 360 form workspace works better than solid modeling because it results in more natural curves.

[@JoesWorkbench]

They held up really well, super successful v1.0 👍🏻🍻

[@simplybeanjelly]

Like others were saying, I definitely want to see you try these again with some refinements in the future! Could definitely make a good followup video

[@TheKingMJackson]

Dude, I would love your next video to be you putting these through trial and error and eventually perfecting them😊

[@rman8028]

'Size 9' he says! Small feet? I'm sitting here with Size 7 feet and glad I have that size, considering I wore corrective shoes until grade 6. Loved seeing the Costa Rica footage, since I lived in the Canal Zone (Panama) 7 years growing up. It brought back memories.

[@joakim3964]

I just want to say, I actually dont care about 3D printing, I just like your woodworking videos, but I watched this video anyway because i love your energy 😄

[@davidjoshea4064]

I would look into a foaming TPU (Filaflex for example) compared to a regular TPU if you’re looking for comfort. Also for your sole patterning you could make the process more efficient by sketching your sole pattern on an offset plane, then using thin extrude to extrude the sketch profiles to the base of the sandal. You could also create a cutting contour to cut deeper into the sole!

[@MorleyKert]

Great ideas!

[@thewarpsyrhead]

Good stuff!

[@whataboutbort]

you should have more subs and views this is great

[@danielngai]

That’s so amazing to see how you use the 3D printer

[@ChilledTheMage]

I think we need a version 2!

[@kylebija]

This is a job for the "Mesh" modeler in Fusion 360. But respect for working out how to get organic shapes in the "Solid" modeler!

[@johnjaikumar4317]

Great video man! Could you please do more videos of you showing a design process using fusion 360? Today's video was really informative and fun to watch.

[@3DProjectsRC]

Next time you should try to have infill so it can compress and make it more comfortable and also reducing print time

[@ThunderSmell]

Great video. shoutout to cathy kert!

[@TikTokDutch]

If you ever go to The Netherlands you should make your own clogs (wooden shoes)

[@inalakk]

amazing

[@supergiantbubbles]

This is like a masterclass in how to not make a good pair of 3d printed sandals. I'm surprised at how bad the Bambu Labs printer is at printing TPU.

[@3DJapan]

I think a sculpting software like 3D-Coat would be better for modeling this to get nice smooth surfaces.

[@RichardThompsonCA]

Great project! I'd recommend getting a 3d pen, you can us it to fix any problems in your print.

[@MorleyKert]

A 3D pen would’ve been perfect!

[@user-bh7bk2ok7d]

Awesome :D In the same time, expensive sandals and failure :D I love your 3d printer. You upgraded from Prusa?

[@STILLWILLPHOTO]

Should have made some clogs, then when you have a print error you can be like, oh man, clog? Yes! Mission complete!

[@ftrueck]

Well i guess what could work better: Solid bottom layer 5-7mm. Solid top layer: 3mm, wall thickness 3mm, 40-50% infill. This way you will not even need to remove the arch, as the less dense infill will give way to your feet pretty well. What you also could consider: 1-3 solid middle layers of 1-2mm so that the forces are spread better across the infill. Maybe even variation in infill where the downward forces are higher like in the toe area and on the heel area.

[@mtayseer82]

This was a nice experiment to watch. As everyone else said, up to 25% or 30% should be enough. Also, there was a video by @3dprintingnerd with Andrew Sink where they mentioned they have variable infill ratios depending on the area. Also I remember @makeanything mentioned a flexible filament made of car tires. Maybe it will be grippier?

[@DifferentAverage]

Too awesome, lucky you!! I'm a size 12 so none of the models will fit on my Bambu plate unless I rotate them both diagonally and vertically. Even then it's not very practical, a 2nd bigger printer is needed lol

[@j.tsessions3132]

Truly amazing and entertaining content please just keep being you man !

[@joelrobles9092]

You rock.. happy birthday mom

[@Djorak]

I'm both impressed and horrified!

[@dmon670]

Definitely could've saved that print and the material! You can modify the gcode to pick up from the layer the clog started on with every other fdm printer. Happy to help if you run into this again :)

[@gavinhicks7621]

The carbon runs on special uneditable g-code (or atleast I believe that’s what I heard from other reviews) that’s why they have their own slicer and everything. It still does use gcode and you can of course edit it but the printer has specific gcode instructions to make it run right I think. I don’t own an x1 carbon so I’m not 100% sure but I think that’s why.

[@bigboypapaboy]

i swear tpu clogs nozzles when it is too cold? im confusesd now but i now my nozzle would clog occasionally until i got a better nozzle. the bondtech cht, has three holes that converge in one, that kind of nozzle. granted I think there comes a time where the nozzles also get worn out and that can also clog a nozzle

[@daliasprints9798]

If you want to iterate this further, maybe try foaming LW TPU.

[@Tomd8002]

I have size 16 feet (yes you read correct) and have been looking at 3D printing some sandals/shoes for a long time as I cannot get anything in my size in the UK… due to my size I’d probably have to print it in two parts and might try making a mould with it. I can then cast it using some tough resin/plastic.

[@BenWolkWeiss]

Yeah making a mold is a much better idea. Especially for the footbed of the shoe. You can use floral foam and press your foot into it evenly to get a perfect mold of your arch and foot. Then you can use that to cast a positive that can be combined with a 3d printed mold for the rest of the sole. The foam impression is basically how custom orthotics are created.

[@Salamattder]

I wear barefoot shoes no arch support needed, that is a spring built into your foot, you just blocked it from functioning. Also, you should have made them much thinner. Overall a great video. I love the practical application of the 3d printing and your ability in the CAD software.

[@MrBenedictHeyer]

It would be so cool if you landed on a design and then built a mold cast to use a more flexible material and be able to do all kinds of colors etc in a fraction of the time. Would make for a cool video, too! Although, thinking about it, the tunnels for the straps could not be made that way...

[@Brendan945]

Great Video! Did you consider using emboss/deboss for your tread?

[@MorleyKert]

Thanks! That was my original plan, but it didn’t work on the curved surface

[@schawn4925]

Everyone else on the trail-“ ENOUGH OF THE SANDALS”

[@davey4731]

I’d be curious if deeper grooves would help for grip. My trail shoes have maybe 1/4 to 1/2 wide rectangles raised above the base of the shoe about the same to double. If they weren’t there it would be a flat surface. I find these are fantastic for grip because of this.

[@MorleyKert]

I think deeper grooves would’ve definitely helped, tighter spacing too!

[@davey4731]

@@MorleyKert fantastic video!!! Always a better day when you post. I got a pair of chacos for dirt cheap at a Nordstrom rack as my second pair and they’re the BEST!

[@crono6664]

Watching this type of video makes me want to get a 3D printer, but this video also reminds me why I don’t get a 3D printer… clogs, filament… ugh

[@daliasprints9798]

I'm not sure if the Bambu firmware lets you do this, but adjusting the Z offset while paused would have let you resume printing without a gap, at the cost of losing that height.

[@cheery-hex]

cool video! Arch supports are the most uncomfortable thing ever to wear... I can't wear them for 1 minute

[@ticso24]

Wonder how the result would be with foaming TPU, like varioshore. From what I’ve seen it is also possible to easily sand those print.

[@MorleyKert]

Oooo that’s a cool idea!

[@magnustangen6269]

Your best video to date, loved the deisng phase! im a product design student and you inspire me to get better at fusion! Maybe i missed it, but why did you use 100% infill? would be cool to see with like 90% or something with maybe the gyroid infill to get even weight distribution and support! Maybe even different infill in different places of the shoe to get more comefort and rigidity? Nonetheles, great video!

[@MorleyKert]

Thank you so much! I think I was just overly-concerned about the sandals being strong enough, and lost sight of the importance of flexibility. I should’ve printed some test pieces with different infills

[@magnustangen6269]

@@MorleyKert you live and you learn! time constraints are no joke! much love from Norway!

[@sohanraghavendra3966]

Why don't you try post print processing like 1. Drill holes thru and thru , it removes material and increases the grip on both sides 2. Use a sander with coarse grit ? Maybe make some more gutters at the sole with an angle grinder ?

[@Noctura1138]

Your desk chair is very interesting. How comfortable is it and can you link it?

[@MorleyKert]

It's great! I added a link to the description :)

[@Elektrotechniker]

Why have you printed the strap buckles standing up instead of laying flat on the build plate? I imagine that they will be waay more vulnerable to break under tension from the straps pulling on them 🤔

[@Luigik99tv]

Great job, only think is i would have printed it faster... with my voron 0.1 i don't mind printing tpu at higher speed, mabuy you could have had less problems

[@highbutplanted4217]

Neat idea! Could you take a 3D scan of a real sandal and use that as your starting point? Size it up to your foot template?

[@MorleyKert]

Totally!

[@JGDeRuvo]

You could call them Kerts!

[@AlexanderSmith600]

The 3 day print was that with a 0.4mm nozzle? You should have installed a 0.6mm to save so much time and prevent clogging!

[@crono6664]

I wonder how much of difference it would have been, if he just glued an insole onto the sandals. It would let the bottoms of his feet rest on cushions and not hard plastic.

[@sepehromidi7944]

You can put them in the oven for 5 minutes 150F , then press your fit on top of it and it'll reshape.

[@Ideatronic1]

Me gusta soy de Colombiaaaaa

[@thesnapz54]

I'm curious of the end cost, if you're open to sharing, Morley? Feels like you did this for the experience anyway, but I'm curious how much material cost here versus these types of sandals as purchased products, which can get pretty costly. Obviously a lot of labor and lost sleep in there as well, but that seemed like a lot of raw material.

[@MorleyKert]

Each sandal took 800g of TPU, so at about $25/kg, that’s $40 USD

[@trevordoeseverything219]

WE GOT TO SEE HIS FEET FOR FREE!!!!! I took screen shots and will upload to the feet database in case he blurs them!!!!!! Thank you Morley!!

[@danhunters8226]

Think 100% infill is the way to go, would just make them thinner.

[@xltk5546]

Do you need a different extruder to print with that material?

[@MorleyKert]

Just using the stock nozzle on the X1 Carbon!

[@josephknowlton7246]

Liked n commented.

[@simon_samuelsson]

I think these shoes are the most succesful shoes on youtube to date?

[@ederplays2788]

How did the channels of the shoe print with no supports?

[@MorleyKert]

TPU is great at bridging gaps

[@johnscott2126]

All this foot based content for free? This could have been a Patreon Exclusive. Lol just kidding.

[@Jonathan.R.Pereira]

Will we ever see a Morks Mark 2?

[@marknthetrails7627]

Yea, I hate having to babysit a long print through the night. So what sensor would you have to have to sense a clog? 👍✌🖖🥃 It seems you lacked a little research into how shoes work. I hope you had backup shoes...🤣

[@ronvalentini475]

Totally hate the colour you picked. I think the point of them being to big. Enough said on that. The strap material could of been better along with the traction was a little sketchy . I noticed you didn't do a price breakdown hmmm. All in all congrats. can't wait to see them on the Walmart shelves, we need a name and the wild colours could be the gimmick Good stuff