Stratus: Extreme Hiking Footwear

Side view of a modern outdoor sneaker with black, beige, and neon yellow accents.

About the Design

In collaboration between Industrial Designer, Srivats Srinivasan, we were able to bring both of our skills together to successfully design and fabricate this footwear design. While this was a team effort to ideate and decide on the final design direction, Srivats was in charge of the 3D modeling & CAD for the project and I (Will Gates II) was in charge of the sketching and fabrication of the upper & assembly of the shoe.

This design is the future of hiking footwear and takes 3D printed footwear and ergonomics where it has never gone before for the ultimate perfomance hiking boot.

Click to Access: Srivats Srinivasan Portfolio
Close-up of a seashell with a fossilized fish inside, showcasing vibrant colors and intricate details.

Lattice Cushioning Technology

Using pressure-map data from the impact of the extreme hiker, we were able to design a full length, lattice cushioning pod. The different types of lattice flow seamlessly within the pod for the perfect balance of cushioning and support.

Exploded view of a modern sports shoe showing various internal components such as the sole, insole, padding, and upper part on a plain background.

Tech Pack

Design concept of a hiking or outdoor shoe with different color sections labeled with Pantone color codes: beige, gray, black, and lime green, with a detailed side view.
A side view of a modern sneaker showing different color sections labeled A to D.
Technical diagram of a sports shoe sole with color-coded sections in black, gray, and yellow. The side view shows the profile of the sole, while the top view displays the tread pattern with yellow highlights. The bottom left corner notes the color key with Pantone codes, and the bottom right mentions the shoe model and parts.
Line drawing of a hiking shoe with measurement annotations in millimeters, highlighting various dimensions of the shoe and its components.
Line drawing of a sneaker with labeled parts indicating different materials such as soft leather, nylon ripstop, reflective coated canvas, vibram rubber, duck canvas, and nylon webbing.
Line drawing of a boot with different materials labeled. The upper part mostly made of soft leather, nylon ripstop, and duck canvas, with various rubber components and reflective canvas. The image includes detailed labeling for materials like soft leather, nylon ripstop, reflective coated canvas, vibram rubber, and nylon webbing, with corresponding key explanations.

Raw Process

Gallery

Design process of athletic shoes with sketches, blueprints, and color renderings taped onto a display wall, illustrating steps from initial concepts to detailed illustrations.
Design sketches of a futuristic shoe, with drawing tools, markers, ruler, and sketches on paper scattered on a wooden work surface.
A prototype shoe covered in masking tape with hand-drawn notes and measurements, placed on top of a plan or blueprint related to shoe design.
Design schematics and technical specifications for a shoe, including construction process, midsole and outsole CAD drawings, with a decorative drawing of a smiling cactus in a pot on the wall.
Colorful hand-drawn diagram of a scheme with various patterns and labels, including sections marked as 'Construction Process', 'Step 5', and 'Stratus Pattern Mapped Out'. The diagram features different colors representing materials or steps, such as black for 'Rubber/Leather', orange for 'L. Greys R. S.', green for 'D. Greys R. S.', and blue for 'Cream Leather'. Measurements and directional labels are also present.
Cardboard cutouts labeled with construction parts such as 'RUBBER TOE,' 'HEEL PAD,' 'LIVIN' STRATUS,' 'EYELID,' and 'RUBBER HEEL,' arranged on a fabric surface for shaping a prototype.
Three images showing different stages of a muslin mock-up for testing shoe form. The first image shows a shoe mock-up secured with blue painter's tape. The second image shows a side view of the shoe mock-up on the floor with the label 'STEP 7.' The third image displays the mock-up on a worktable with measurement tools and additional materials around, indicating a work-in-progress in shoe construction.
Blue prototype pattern templates on a worktable with grid lines, a green book, a pencil, and a small electronic component nearby.
Wooden table with various fabric pieces and foam padding for shoe upper construction, with text overlay that says 'CONSTRUCTION PROCESS STEP 9: ASSEMBLE FABRICS TO CREATE UPPER'.
Disassembled pieces of foam and fabric used for creating foam lining for interior structure on a wooden work surface.
Photo showing the process of constructing a suit, with a sewing machine on the left, sewing tools and materials in the middle, and a partially assembled suit with foam padding on the right.
A pair of climbing shoes positioned on a surface, with gray and black color and green accents, surrounded by a metallic, reflective backdrop. The text overlay indicates the construction process, specifically steps 12 and the Stratus Hong Kong TR checkpoint 1.
Construction shoes with bright green socks, scaffolding tool, scissors, pens, tape, and a container of screws on a workbench with labels indicating steps in the mold rubber application process.
3D model of a curved construction project labeled 'CONSTRUCTION PROCESS STEP 14 MIDSOLE + OUTSOLE CONSTRUCTION' on a digital design grid.
A workbench with a shoelace attached to a shoe and several tools, including scissors, a pen, a glue stick, and parts of a shoe, scattered around.
A person performing an upper adjustment on a piece of equipment based on a previous proof check, with a label indicating this is step 16 of the construction process.
Arranged shoe components and accessories on a wooden surface, including a shoe last, insoles, a shoe shoe, and various outsole parts.
A black shoe insole with a yellow lattice structure inside, labeled with 'Construction Process', 'Step 18', and 'Stratigrid Lattice Tests', placed on a wooden table.
An image showing a sneaker sole with a separate tread pattern and yellow accents, alongside a sneaker with a yellow and black color scheme, used during the midsole and outsole gluing step of the construction process.
A work-in-progress athletic shoe on a table surrounded by tools and materials, with visible instructions overlayed indicating a construction process.
Person tying the laces of black and gray mountaineering shoes on a dirt trail surrounded by small rocks and grass.

Design Process

Pair of black and beige hiking shoes with green accents, displayed on a beige background with rocks.
Technical drawing of a snowboard with various measurements labeled, including lengths and widths, showing a side view with a curved tail and a flat nose, from the Stratus HK Trainer series.
Technical drawing of a shoe sole with measurements in millimeters, showing detailed dimensions of various parts of the sole, including heel, toe, and midsection.
Technical schematic of a shoe outsole with measurements, including pattern details and dimensions in millimeters.
Image of a shoe sole, labeled as Stratus HK Trainer, featuring StratusGrid cushioning with green accents on a black background.

Outsole Components

The Stratus HK Trainer outsole is designed using a multi-directional lug shape which allows the user with a sense of reassurance with every step on their journey. The green lugs are made with a higher density rubber for longevity and to withstand rugged terrain.

Internal Components

The Stratus HK Trainer has an interior and exterior carbon fiber shank for both propulsion and structural support. The lattice unit is inserted during manufacturing similar to a drop-in midsole with a cap on top. The toe of the shoe features an over-lasted component to eliminate any debris or water from breaching in.

Technical diagram of a yacht's midsection assembly showing shank plate, shell lid, lattice unit, and base midsole unit, with labels and a gray background.
A technical diagram showing lateral section view of a shoe sole with measurements. The diagram highlights where lattice placement and shank plate of 3mm thickness are to be added. Details include lattice placement in green dotted area and shank plate in red, with measurements in millimeters indicating thickness and positions.
Color-coded footprint sole diagram showing ground contact and recess zones for a STRATUS HK trainer, with key indicating different measurements and feature placements.
A black hiking or trail shoe with a textured sole, captured against a dark, earthy background with rocks, emphasizing its rugged design.
A rugged outdoor hiking shoe in gray, beige, black, and neon yellow, shown between rocks with a cloudy sky background.
Technical drawing of a sneaker sole viewed from multiple angles, with labeled sections and a detailed tread pattern.
Technical drawing and design of a helmet with front and back views, detailed eyelet and wiring specifications, and including measurements for components.
Graphic showing different insole options for a training shoe, including printed graphic, lace options, and reflective hotmelt application, with color codes and specifications listed on the side.
A whiteboard filled with sketches, diagrams, and design plans for athletic shoes, including detailed shoe drawings, color studies, and engineering notes, with blue tape securing various papers and sketches.
A cluttered worktable with various crafting and design supplies, including shoe prototypes, sketches, fabric swatches, tools, and materials for shoe design.