The objective of the work was to establish strong correlations between midsole materials, biomechanics assessment and field test concerning running shoes and thus, for two crucial parameters: cushioning and ride.                A large range of mechanical testing (Shock tower, Compression, Dynamical Mechanical Analysis, Hardness) was carried out on EVA (Ethylene Vinyl Acetate) foam planks used in midsoles. Distinct sample sizes were needed according to the lab test and external machining was utilized to get appropriate specimens. Similar experiments have been led on prototypes finished shoes (Shock tower, Hardness) when it was feasible. The whole toolbox of current Salomon Footwear midsole formulations was so reviewed in detail. A phase of Biomechanics assessment of cushioning and ride was then undertaken with the help of a dozen of testers using sensors, procedures and data processing software. The field test was conducted at the same time to have the perception of the runners about several criteria once they worn the shoes in real condition.                Computational software were used to elaborate correlations matrices between determining parameters (finished shoes) and explicative ones (foams) while reducing the number of laboratory testing.  Prediction models for shoe performance anticipation were developed for the cushioning. Unfortunately, ride prediction model was not realized due to time and feasibility limitations. Shoe rebound resiliency and biomechanical parameters (Kurtosis and Power Spectral Density) proved to be strongly linked to the foam properties (Shock tower, Compression, Dynamical Mechanical Analysis). It could thus be forecast before making any shoe prototype. The reorganization of the Salomon Footwear toolbox has been started with the aim of finding one proper midsole for one proper application or runner practice. Established prediction models have been used to elaborate a cushioning index to sort the foam formulation according to their performance, density and price. Recommendations have been made for the choice of materials.

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The research contained within this thesis formed part of an Engineering and Physical Sciences Research Council (EPSRC) funded project based at Loughborough University, which aimed to investigate the use of additive manufacturing (AM), and in particular sintering technologies, for the production of running footwear sole units. Laser sintering (LS) is an AM process which produces parts directly from a computer aided design (CAD) file by selectively fusing successive layers of powdered material using a CO2 laser. LS imparts significant advantages over traditional manufacturing techniques including extensive design freedom, the ability to manipulate the local properties of a single material part as well as economical manufacture of bespoke items due to the elimination of tooling. Modifying the mechanical properties and/or geometry of sole units has been shown to provide benefits in the areas of performance, injury risk reduction and comfort, especially when considering elite athletes on a subject specific basis. Given the attributes of LS outlined above, the technology offers significant potential to produce sole units offering high added-value compared to conventional counterparts which are limited by the constraints of traditional processing techniques such as injection moulding. However, the mechanical capacity of LS polymers in context of such application was unknown. Accordingly, this research investigated the suitability of a laser sintered elastomer (LSE) material, in view of key selected mechanical properties, for the manufacture of running shoe midsoles. The midsole is the primary functional component in the sole unit of a running shoe used for distance running on hard surfaces. Following a preliminary assessment of the selected LSE (TPE 210-S), a new dynamic test method was designed to assess the compressive, fatigue and time dependent recovery properties of midsole material specimens under loading conditions representative of in-service use. The method was successfully implemented on an electro-mechanical test apparatus (previously unreported upon in literature) and used firstly, to benchmark the aforementioned properties of a range of ethylene vinyl acetate (EVA) and polyurethane (PU) midsole foams representative of the range currently used in production, and secondly, to establish the same property set for TPE 210-S specimens produced across a range of laser powers (LP's). Initial cycle operating ranges in terms of key compressive properties were established for EVA and PU materials. All conventional variants showed considerable deterioration from these initial values over the 125,000 cycle test regime, but subsequently demonstrated partial recovery when left unloaded post-test. PU grades generally exhibited better fatigue performance and findings were consistent with those of previous studies. Whilst variation in LP facilitated linear variation in displacement and stiffness properties for TPE 210-S, all specimens yielded a stiffer and more elastic response than that of conventional foams at the outset; initial compressive operating ranges, whilst within close proximity, did not overlap. However, fatigue performance was found to be superior with only relatively small property changes occurring over the test regime regardless of LP. Furthermore, no signs of catastrophic specimen failure (e.g. cracking) were visually apparent. In this respect the material showed good suitability for midsole applications, but further work is required to address increasing the available compressive property range which fell outside the scope of this work.

Tandis que les bénéfices physiologiques de chaussures de référence dans le milieu de la course à pied d’endurance sont montrés dans la littérature scientifique, les effets spécifiques et contrôlés de certaines propriétés mécaniques des chaussures demeurent peu connus. L’objectif général de ce travail de thèse était d’étudier les effets du retour d’énergie des semelles intermédiaire des chaussures et de la raideur en flexion des chaussures sur la performance physiologique et biomécanique en course à pied d'endurance. Que ce soit à court-terme ou lors d’une course à pied prolongée, le coût énergétique métabolique (critère utilisé pour évaluer la performance en course à pied) n’était pas significativement modifié par les propriétés mécaniques testées en moyenne parmi le groupe complet de participants. En revanche, les réponses spécifiques aux participants, à la fois à court-terme et lors d’une course à pied prolongée, ont permis de mettre en évidence des combinaisons de réponses biomécaniques et de caractéristiques intrinsèques aux participants expliquant les variations du coût énergétique métabolique en fonction des propriétés mécaniques chaussantes. Une nouvelle stratégie a notamment été mise en évidence chez les participants bénéficiant de la raideur en flexion des chaussures qui se traduisait par une redistribution descendante des activations musculaires des articulations de la hanche et du genou vers l’articulation de la cheville avec la durée de course. Ce travail de thèse soulignait l’importance de considérer une offre de conception de chaussures adaptées à des groupes de coureurs aux réponses biomécaniques et/ou aux caractéristiques intrinsèques similaires. / While physiological benefits of baseline running racing shoes are shown in the scientific literature, the specific and controlled effects of some shoe mechanical features remain not well known. The main purpose of this work was to study the effects of the midsole energy return and the shoe longitudinal bending stiffness on the physiological and biomechanical performance during endurance running. In both short-term and prolonged running duration, the metabolic energetic cost (criteria used to evaluate the endurance running performance) was not significantly altered by the tested mechanical features in average over the group of participants. The main finding was that the shoe mechanical features induced different effects on the metabolic energetic cost depending on the participants. Taking into account the participant-specific responses (in both short-term and during a prolonged running duration) enabled to highlight combinations of biomechanical responses and intrinsic participant characteristics explaining the variations of the metabolic energetic cost as a function of shoe mechanical features. A novel strategy has been highlighted in participants benefiting from the shoe longitudinal bending stiffness resulting in descendant redistribution of the muscular coordination from the hip and knee joints to the ankle joint with the running duration. This work showed the importance of considering a footwear design offer suitable to groups of runners with similar biomechanical responses and/or intrinsic characteristics.