jig shoes manufacturer

1. AUTO SPRAY
JIG CREATION
SOP
VERSION 1.0 - AUGUST 2022

2. CONFIDENTIAL
1. Add
1. Rebuilt 3D scan
2. Extended spray cones
3. Spray head position
4. Sharp corners offset issue
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UPDATES
22-JAN-24
PRESENTATION TITLE

3. CONFIDENTIAL
1. Rhino7 software
2. Rhino user with good 3D skills and basic Grasshopper skills
3. Jig creation Grasshopper script (provided by adidas)
4. Rhino Template file (provided by adidas)
Required 2D and 3D data:
1. Auto marking cell 3D file (provided by machine supplier)
2. Spray cone measures
3. 3D Scan of lasted finished shoe as one (closed) mesh in OBJ format. Ideally with mapped textures
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WHAT IS PREREQUISITE TO CREATE A JIG?
22-JAN-24
PRESENTATION TITLE
1. 2. 3.

4. CONFIDENTIAL
The auto spray SOP is split into two main parts:
A. Template file creation
B. Jig creation
Please note:
This version SOP and Grasshopper script version is for one shoe size and one spray head.
A solution for full size run creation and including a second spray head is scheduled for the full production version.
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WHAT ARE THE SOP MAIN PARTS?
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PRESENTATION TITLE

5. CONFIDENTIAL
1. The master file concept
2. Prepare production cell CAD
3. Create spray holder
4. Draw nozzle reference lines
5. Draw spray cone reference lines
6. Save template file
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A. TEMPLATE FILE CREATION
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PRESENTATION TITLE

6. CONFIDENTIAL
JIG CREATION
ONE TIME TEMPLATE FILE CREATION
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1. THE MASTER FILE CONCEPT
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PRESENTATION TITLE
Open master file
Prepare and sort all
relevant reference
geometry into layer
structure
„Save a“s file as
template file
• The master file is provided by adidas and contains the layer structure which works together with the automatic jig creation
Grasshopper script
• It is not allowed to change the layer names or restructure the layer order
• The master file is the base to prepare the template file
• The template file contains all important production cell reference geometry
• The template file only needs to be created one time and can be used to create all jigs
• In case of a change in the production cell (different spray cone measures, changed cell measurements or similar) the reference data
in the template file also needs to be updated.
M T T
Open template
file
J
„Save as“ as jig
file Create jig

7. CONFIDENTIAL
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2. PREPARE PRODUCTION CELL CAD
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PRESENTATION TITLE
Reduce
2.1 Import production cell CAD file and spray head into master template file. Reduce cell CAD that only the rotation center, spray head
and the movable table remains.In case no CAD file of the spray head is avalable, model a placeholder geometry.
2.2 The movable table inculding the different rolles and spray head needs to be straight. The distance (A) to the rotation center is not
relevant. The rotation center needs to be in the Rhino scene zero point (0,0,0)

8. CONFIDENTIAL
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2. PREPARE PRODUCTION CELL CAD
22-JAN-24
PRESENTATION TITLE
2.3 Postion the spray head accordant to the manufacturing quidelines. The nozzle „opening“ center is the key
reference point to align the spray head with the manufacturing cell.
2.4 Sort the the cell geometries into the correct layers

9. CONFIDENTIAL
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3. CREATE SPRAY HOLDER
22-JAN-24
PRESENTATION TITLE
The spray head position in the Rhino file (see 2.3) is the master for the spray head position in the real manufaturing cell.
Reason for that is that the jigs are created based on the spray head position in the Rhino file.
This spray head position needs to be trasnfered to the real manufaturing cell with the help of a jig (spray holder)
There is no blueprint how the spray holder needs to look like. Usually the jig is 3d printed.
The jig is only needed when the spray head is mounted into the cell. After that the jig can be removed.
If the spray angle or the spary head postion is changed a new jig needs to be created.
Spray holder example

10. CONFIDENTIAL
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4. DRAW NOZZLE REFERENCE LINES
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PRESENTATION TITLE
4.1 Transfer the measures taken from the spray test into the master file by drawing circles with the correct
diameter, distances and angle.
transfer
4.2 Sort the circles into the layer structure

11. CONFIDENTIAL
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5. DRAW SPRAY CONE REFERENCE LINES
22-JAN-24
PRESENTATION TITLE
5.1 Draw point in the nozzle
opening center
5.2 Draw straight line from nozzle opening center along the spray head.
The line needs to have the same value as the X angle
5.3 Sort the point and line into the layer structure

12. CONFIDENTIAL
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6. SAVE TEMPLATE FILE
22-JAN-24
PRESENTATION TITLE
6.1. Lock the layers under „Machine“ and „spray cone“
6.2 „Save as“ the file with following file name
Auto Spray template – Factory name – V0X
„V“ stands for version.
In case the spray head position or spray cone changes a new version needs
to be created.
6.3 Lock the file that it can‘t be overwritten by checking „read only“ in the file
file properties.
(right click on the file in the explorer)

13. CONFIDENTIAL
1. Open template file and “save as”
2. Load and position 3D scan
3. Draw bite line
4. Draw support line
5. Draw finger contour line
6. Draw spray definition line
7. Reference lines quality check
8. Open and save Grasshopper script
9. Create upper holder
10. Create roller coaster
11. Emboss jig information
12. Bake jig
13. save Grasshopper script
14. Apply fillets
15. Create last holder
16. Export 3D print data
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B. JIG CREATION
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PRESENTATION TITLE

14. CONFIDENTIAL
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1.OPEN TEMPLATE FILE AND “SAVE AS”
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PRESENTATION TITLE
1.1 Open the jig creation template file
1.2 „save as“ the file with following naming convention:
product name – product id – size – version

15. CONFIDENTIAL
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2. LOAD AND POSITION 3D SCAN
22-JAN-24
PRESENTATION TITLE
2.1 Postion the lasted shoe 3D scan above the rotation center and keep a min. 20mm distance. The bottom of the tooling
needs to be aligned as horizontally as possible.
2.2 The machine and spray cone layer can now be turned off, because they are no longer needed, and the Grasshopper
script later pulls the geometry also when the layer is turned off.

16. CONFIDENTIAL
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3. DRAW BITE LINE
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PRESENTATION TITLE
3.1 Use polyline on mesh command to trace the bite line from scan.
3.2 Rebuilt the polyline to a smooth curve with as few point as
possible and with degree 3
3.3 Place the curve into the biteline layer

17. CONFIDENTIAL
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4. DRAW SUPPORT LINE
22-JAN-24
PRESENTATION TITLE
The support line defines the border between the upper areas which shall be holded by the jig and which shall be keept
open. Usually the line runs around the lacing and collar area with a cetrain distance.
4.1 Use polyline on mesh command to trace the bite line from scan.
4.2 Rebuilt the polyline to a smooth curve with as few point as possible
and with degree 3
4.3 Place the curve into the „Support Line“ layer

18. CONFIDENTIAL
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5. DRAW FINGER CONTOUR
22-JAN-24
PRESENTATION TITLE
5.1 Draw four rectangles on the x,y 0 planeto define the finger positions and cross sections.
A good start are following placements and measures:
(Later during jig creation the rectangle position and cross section can be changes on the fly)
5.2 Rotate slightly the rectangles that they match the curvature of the shoe
5.3 Place the rectangles on the „Finger Conture“ layer

19. CONFIDENTIAL
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6. DRAW SPRAY DEFINITION LINE
22-JAN-24
PRESENTATION TITLE
The spray definition line defines the outer conture of the jig on which the two horizontal rolles roll
6.1 Select biteline in the top view and use command
„ProjectToCPlane” with “delete input object” = no
6.2 Turn bite line layer off
6.3 Offset the new curve on the cplane by 35mm
6.4 Delete the input curve that only the offset curve remains
6.5 Rebuilt the offset curve to a smooth curve with as few points as
possible

20. CONFIDENTIAL
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6. DRAW SPRAY DEFINITION LINE
22-JAN-24
PRESENTATION TITLE
The spray definition line defines the outer conture of the jig on which the two horizontal rolles roll
6.6 Even out areas which have a high curvature by moving the curve
points.
A smooth curve avoids that two horizonal rolls jump away from the jig
during the spray process.
6.7 Place the curve into the „Spray Definion“ layer

21. CONFIDENTIAL
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7. REFERENCE LINES QUALITY CHECK
22-JAN-24
PRESENTATION TITLE
The jig reference line creation is now finished.
7.1 Check if all lines are on the correct layer.
7.2 Check if all curves have as few curve controll point as possible.
This is important because each line can be still manipulated during the automatic jig creation.

22. CONFIDENTIAL
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8. OPEN AND SAVE GRASSHOPPER
SCRIPT
22-JAN-24
PRESENTATION TITLE
8.1 Open Grasshopper
8.2 Load the latest version of the „auto spray“ script provided by
adidas or load script from previouse model which already
contains the settings for the production cell.
Important is that the script file is base on the latest script
version! The version is shown underneth the adidas logo
8.3 „Save as“ the file with following naming convention:
Auto Spray – Model name – product id – Size
Example: Auto Spray – Fluid Flow – 41341 – 8.5

23. CONFIDENTIAL
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9. CREATE UPPER HOLDER
22-JAN-24
PRESENTATION TITLE
9.1 In the „Settings – upper holder“ interface double click on „False“ from
the „enable upper holder“ Box
9.2 Grasshopper creates the fingers based on the reference lines. In case
no fingers gets created, please review the template file set-up and
reference lines.
9.3 By manipulating the „finger contur“ lines and chaning the values in the
„setting – upper holder“ box the fingers can be further shaped and fine
tuned.
• The most important setting is the „max thickness“ value to controll the
finger thickness.
• „Finger Surface offset“ controlls the offset between the 3D scan and the
fingers. In case that the scan fits overall to tight into the jig this value
can be changed
• The other settings usually stay the same across all models

24. CONFIDENTIAL
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10. CREATE ROLLER COASTER
22-JAN-24
PRESENTATION TITLE
10.0 switch to the „Settings – roller coaster surface“
10.1 „simulation steps“ is the amount of spray steps used for
the spray simulation. 100 is a good default value. Below 80 the
simulation gets inaccurate.
10.2 the „roller coaster width“ represents the width of the
whole vertical roll assembly (x+x). The center point of the
„roller coaster width“ is the geometry on the „vertical roller“
layer.
The reason why the „vertical roller width“ is not just width of
the vertical roller geometry is that there might be some
additional nuts to hold the roll or similar construction. They
would then collide with the jig.
10.3 Set „Horizontal roller height“ to a value which works best
for the production cell design
!All these values need to be set one time and can be re-used
for all jigs with the same size!

25. CONFIDENTIAL
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10. CREATE ROLLER COASTER
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PRESENTATION TITLE
10.4 In the „Settings – roller coaster settings“ interface double
click on „False“ from the „enable roller coaster surface“ Box
10.5 Grasshopper creates the roller coaster based on the
reference lines. In case no geomety gets created, please
review the template file set-up and reference lines.
The three black lines on the roller coaster surface are the
„roller coaster width“ and center of the vertical roller geometry
(see 10.2)
10.6 In case two red lines show up, there is a intersetion
beween the spray definition line and the fingers. Scale the
spray definion line bigger or make a larger offset.

26. CONFIDENTIAL
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10. CREATE ROLLER COASTER
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PRESENTATION TITLE
10.7 Double click „False“ in the „Spray cone preview“ box.
The spray simulation, which is the key for defining the jig
shape, gets visible. The spray cone and rolles visualization
is taken form the „machine“ and „spray cone“ reference
layers
10.8 Move or scale of the „spray definition line“ or their curve
points until most of the bite line is in the green ideal spray
area.

27. CONFIDENTIAL
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10. CREATE ROLLER COASTER
22-JAN-24
PRESENTATION TITLE
10.9 In areay with higher curvature is often not possible that
the biteline is in the green area. The reason for that is that in
step 6.6 explained the „spray definition line“ got smoothed
out and the „spray definition line“ is no more a straight offset
of the biteline.
The goal is to find good balance that the horizontal rolls can
smoothly roll and the spray cone is not touching the red
area.
10.10 When adjusting the „spray definition line“ also take a
look at the distance beween the simulation inner vertical role
and outer finger surface. A too big distance leads into a
larger jig with longer print times.
biteline
spray definition
line
smoothed

28. CONFIDENTIAL
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10. CREATE ROLLER COASTER
22-JAN-24
PRESENTATION TITLE
10.11 Double click on „False“ in the „Induvidual position“ box
to engange the single spray positions
10.12 By moving the slider in the „position index“ it is
possible to go through the simulation step by step and
indicate potentional proplem areas.
10.13 Check if the lowes point of the collar coaster is within
the minimal height sepcifications for the production cell.
If the height is too low it can causes collitions during
production.
By moving the „biteline“, „support line“ and 3D scan up, the
overall jig heigth can be changed.

29. CONFIDENTIAL
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11. EMBOSS JIG INFORMATION
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PRESENTATION TITLE
11.1 If needed enter the relevant jig information under „Text
options“. This is very handy to identify the jigs later.
Until the option under „cut out name and version“ is still on
„False“ the text on the jig is just a preview
11.2 If the jig is finished and the all needed text information
is entered, the text can be embossed in the jig geometry.
! If the texts got embossed during fintuning the jig shape, the
embossing calculation is re-triggered everytime when one of
the reference curves gets edited. Therefor only emboss the
text before baking the jig!

30. CONFIDENTIAL
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12. BAKE JIG
22-JAN-24
PRESENTATION TITLE
12.1 To convert the Grasshopper geometry into 3D NURBS
data Rhino can further process, right click on the „jig
geometry“ box and select „Bake ...“ in the dialogue.
12.2 Select the layer on which the jig shall be placed
12.3 Close Grasshopper to only see baked jig.
Everytime Grasshopper can be re-opened and the jig is
created again with the latest references.
Grasshopper bakes the upper holder fingers and the roller
coaster as seperate geometries. Because the geometry is
anyhow saved later as mesh data for printing, it is not an
issue to have not one closed geometry.

31. CONFIDENTIAL
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13. SAVE GRASSHOPPER SCRIPT
22-JAN-24
PRESENTATION TITLE
13.1 Save the Grasshopper script to save all settings and
text options for this model
13.2 Close the Grasshopper window

32. CONFIDENTIAL
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14. APPLY FILLETS
22-JAN-24
PRESENTATION TITLE
14.4 Apply fillets on the finger edges that the lastet upper
can be put better into the jig later during production

33. CONFIDENTIAL
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15. CREATE LAST HOLDER
22-JAN-24
PRESENTATION TITLE
15.1 Use „Mesh Box“command with XCount=10 YCount=10
ZCount=10 and scale and position the box in the heel area
of the jig.
15.2 Further scale and position the box that it intersects with
only the last of the 3d scan
15.3 Create a copy of the 3D scan and offset it about 0.5mm
with the „offset mesh“ command
15.4 Use the “MeshBooleanDifference” command to
subtract the offseted 3D scan from the mesh box.

34. CONFIDENTIAL
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16. EXPORT 3D PRINT DATA
22-JAN-24
PRESENTATION TITLE
16.1 Use „mesh“ command to create a polygone mesh of
the roller coaster and upper holder fingers for 3D printing.
Create enough polygones that the details of the jig like small
fillets are well represented.
16.2 Export the roller coaster, upper holder and last holder
polygon mesh data as one STL.
Done!