Sammies — Collapsible Outdoor Shoe
A collapsible, waterproof, lightweight shoe engineered for explorers who refuse to compromise on comfort, performance, or portability.
Problem
Outdoor shoes are traditionally rigid, bulky, and inefficient to pack.
Backpackers and outdoor explorers need a warm, lightweight, comfortable shoe for camp—without adding significant weight or losing performance.
Conventional footwear makes this nearly impossible due to stiff materials and non-collapsible constructions.
Solution
Sammies deliver a completely new approach to outdoor footwear:
A waterproof, collapsible shoe made from high-performance materials and an engineered folding sole. It packs flat, adapts to different terrains, and provides warmth, portability, and comfort in a single lightweight system.
Key aspects of the solution:
- Collapsible sole geometry engineered for compactness
- Waterproof outer body
- Synthetic down insulation
- Lightweight TPU bottom
- Comfortable, adaptable fit
Design
The design of Sammies blends performance materials with collapsible engineering:
- Nylon Upper: Lightweight, water-resistant, durable
- TPU Sole: Flexible but structured for outdoor use
- Synthetic Down Interior: Warmth without weight
- Collapsible Geometry: Sole channels compress and fold
- Ergonomic Fit: Designed around natural foot motion
- Packability: Folds flat to minimize backpack space
The design goal was simple:
A shoe that performs like outdoor gear, but packs like clothing.
Fabrication
Fabrication involved multiple phases:
- CAD Modeling: Full geometry created in SolidWorks
- Material Sourcing: Outdoor-grade, waterproof nylon & TPU sole
- Prototype Stitching: Early uppers hand-assembled to test fit
- Sole Prototypes: Multiple TPU sole versions tested
- Compression Testing: Ensuring the sole collapses without losing durability
- Assembly Process: Combined upper, insulation layer, and sole bonding
The fabrication process prioritized durability, flexible geometry, and water resistance.
Iterations
Sammies went through numerous iteration cycles:
- Adjusted outsole geometry for optimal folding
- Improved wall thickness to balance flexibility & strength
- Modified insulation levels for warmth vs. packability
- Multiple comfort & fit adjustments
- Sole compression resistance testing
- Ease-of-fold redesign to improve packability
Each prototype moved closer toward the final balance of:
- comfort
- durability
- warmth
- flexibility
- compactness
Lessons
Key lessons from the development of Sammies:
- Flexibility vs durability is a delicate balance
- Material layering impacts collapse performance
- TPU thickness and geometry dramatically affect pack-down behavior
- Precision manufacturing tolerances are critical in footwear
- Outdoor shoes can be reimagined when traditional rigidity is removed
Sammies represent an evolved, user-centered approach to footwear for explorers who value comfort and packability.