Winter 2025
Product Design
A low-cost footwear concept exploring how flat-pack construction could simplify manufacture, transport and assembly for humanitarian use.
Flat-Pack Sandal
overview
This project began with a question: how could affordable footwear be manufactured and distributed more efficiently for people in need? I explored the whole product journey, from material sourcing and production to shipping, assembly and repair, with a production-cost target of £2 per pair.
I developed and prototyped three directions before selecting an adjustable flat-pack sandal. The final proposal uses die-cut EVA and a simple metal buckle, bringing together material comparisons, concept sketches, assembly studies and design evaluation.
View full portfolio (PDF) ↗
deliverables
Product Design
Footwear Design
Material Efficiency
Prototyping
01 — Brief & Research
Defining the footwear brief through humanitarian distribution, product research and material comparisons.
about
Research considered both the needs of the wearer and the practicalities of supplying low-cost footwear. Mapping manufacture, transport, use and repair helped turn the brief into design priorities: affordable materials, compact packing, simple assembly and an adjustable fit.
I compared EVA, cork, recycled rubber and leather, alongside existing footwear concepts. EVA offered a promising combination of low weight, flexibility and cushioning, with the potential to cut components from sheet material and transport them flat.
02 — Ideas, Prototypes & Selection
Moving from fifteen ideas to three concepts, then using physical models and feedback to select a direction.
about
I generated fifteen ideas before developing three approaches: a punch-out flip-flop, a recycled-tarpaulin slider and a flat-pack sandal. Foam prototypes explored proportions, folding and connections, revealing issues such as weak strap holes and the difficulty of keeping thicker material flat.
A weighted evaluation considered cost, feasibility, usability, durability and assembly. The flat-pack sandal was selected for its potential for adjustment, repair and efficient transport. Peer feedback then highlighted the need for clearer assembly guidance, better grip and more resolved fastening details.
03 — Final Design & Evaluation
Resolving the selected sandal and assessing the proposal against its cost, assembly and performance targets.
about
The final proposal combines a die-cut EVA blank with a zinc-alloy buckle, using an adjustable strap and a 10 mm sole. Sketches, a storyboard and technical drawings explain how the flat components would be manufactured, packed and assembled into a wearable sandal.
Material-cost calculations, packing estimates and CAD loading studies were considered alongside feedback from Imperial peers. These helped evaluate the proposal against the brief, while identifying further work on visual assembly instructions and a replaceable buckle.
nicholas elton
menu
close