3D printing technology is a rapidly growing field in the context of footwear production, and in combination with computational design and foot scanning tools and algorithms, this allows for a shift from mass production to mass customization of footwear. This thesis considers the design of a new circular product-service system for children’s footwear, with the purpose of extending the benefits of mass customization to the target segment of children up to twelve years old, with their parents as key decision-makers in the footwear selection process. The development of this system also provides new insights for possible business opportunities for 3D printed footwear, and lays out opportunities and challenges around accelerating the shift towards a circular footwear industry.

A central aim of this thesis is to explore what constitutes a perfect fit for children’s footwear, how 3D printed footwear can be used to overcome challenges related to finding a perfect fit, and what retail experience and services need to be provided to create a system that removes barriers and promotes healthy foot development, considering this essential for healthy lifelong mobility. In this thesis, fit is constructed of three elements: physical, identity and social fit. The tensions and relations between these forms of fit are explored and translated into a concept design consisting of three parts: a physical product, an in-store experience, and a mobile service. Together, these deliver a system that aims to remove the need to compromise on aesthetic value or physical fit, put the child at the center of the footwear selection process, and inspire and facilitate more pro-active consumption behavior of children’s footwear. This project involved the creation of various physical and digital prototypes that were used to gain insights on key aspects of the proposed product-service system. Qualitative data resulting from exploratory customer research and user testing of the proposed concept, with parents as end-users, have resulted in a greater understanding of the technical and perceived challenges with regards to the implementation of such a new system for 3D printed children’s footwear.

In addition, this thesis oscillates between two equally critical perspectives: that of the user and that of the system. Technical and perceived tensions between personalized footwear and reuse of pre-owned footwear are revealed, and opportunities for take-back systems and end-of-life solutions are discussed. Furthermore, opportunities for rapid product improvement and more detailed analysis of foot and gait development are explored, as a result of the circularity of the system.

A strategy for market implementation of the proposed product-service system is detailed, highlighting the opportunity to create a system that onboards users of 3D printed footwear from the very first steps, and creating a membership and subscription based approach. Key strategic partners are identified for the realization of the proposed system, addressing complexities of the system, strategic positioning along the product and service supply chain and the need for expertise, specifically in the areas of production and fit measurement. Finally, this research highlights several key areas of interest and opportunities for future research and development.