Life-Size Barbie Shoes (3D Printed)

The inspiration for this project came from a magical Christmas Day over two and a half decades ago when 7-year-old me received her first Barbie heels. That moment sparked a lifelong love for shoes and heels. Now, I am on a quest to create adult-sized Barbie heels to relive that cherished childhood memory.

The final shoes were printed on a dual nozzle printer, in TPU and PVA supports. Resin and TIG rod were used to strengthen the print.

To start, I chose polymorph as my initial material, mixing in bright pink powder to achieve the perfect colour, which I playfully dubbed "pink soup." After warming up the polymorph to make it mouldable, I attempted to shape it into a shoe. However, I quickly discovered that while polymorph is reusable, it’s tricky to remove from my foot.

I wrapped my foot in clingfilm to create a barrier before moulding the polymorph around it, but this method proved ineffective and made it difficult to create the shoe. Realising that my initial approach wasn’t working, I decided to change tactics and create a mould of my foot instead. Wrapping my foot in polymorph and allowing it to set was a strange experience, but I hoped it would be more successful.

Removing my foot from the polymorph mould was challenging, but I managed it with some effort. Next, I filled the foot mould with silicone, concentrating on filling it thoroughly. However, I soon realised I had made a mistake by not using a barrier between the polymorph and the silicone, making removal difficult.

Despite my attempts to warm up the polymorph for easier removal, the process was time-consuming and frustrating. Acknowledging the potential waste of time and effort, I decided to switch to a digital approach. 

Starting a new day with renewed determination, I turned to CAD and a 3D printer to create the heels. After downloading free STL files and finding them unsatisfactory, I set about creating a more suitable design.

Printing the design revealed that PLA, a common 3D printing material, was too hard for making comfortable shoes. Despite this setback, I remained persistent, experimenting with different materials and methods to achieve the desired result. This journey, though filled with challenges, has been a testament to adaptability and creativity.

The process began with evaluating the initial STL file, which proved inadequate for the project. Recognising the need for improvement, I created a new, more suitable design. Initially, I chose PLA as the material, but it quickly became apparent that it was too hard for comfortable shoes. Instead, I selected TPU for its flexibility and softness, making it a more appropriate choice for this endeavour.

Starting the large TPU print was a significant step, requiring considerable time (1 day and 7 hours) and a substantial amount of filament. Regular monitoring of the print was essential to ensure stability, with tape applied as needed to keep the print secure on the bed. Adjustments to the print settings were necessary to optimise support structures and reduce wobble, crucial for achieving a stable final product.

Upon evaluating the first printed shoes, it was clear that further adjustments were needed. One shoe was unstable, and the other had a missing slice and poor-quality bottoms. Additional supports were added to the model, and a reprint was initiated. This process involved dealing with repeated failures and filament shortages, highlighting the challenges of 3D printing complex objects.

After nearly 5.5 hours, a successful TPU print was completed, showing improvements but still requiring further adjustments. To reinforce the heels and prevent wobbling under weight, I planned to add resin. This didn't quite work as planned. the shoe's were still not stable enough and ended up breaking. (You can watch the full journey unfold in the video)

I was lent a dual nozzle 3D printed by a friend and that meant it was so much easier to print the shoe in TPU and the supports in PVA. Expert advice suggested oven-drying the TPU and PVA filaments to improve print quality. This step proved beneficial, leading to better results in subsequent prints.

The improved printing process involved printing each shoe separately (I split the file really easily in Tinkercad) and used a soluble PVA filament for supports. The supports were then dissolved in water, resulting in a clean finish. Metal reinforcements were added to the heels using coat hanger wire and TIG Rod, providing extra stability. Resin was poured into the hollow heels and bottoms for additional strength, applied precisely with an eyedropper.

Once the resin cured, the stability and comfort of the shoes were tested. This marked a significant milestone in the project, with the emotional moment of wearing the self-made Barbie shoes fulfilling a long-held childhood dream. To celebrate the achievement, I planned to wear the completed Barbie shoes to a special occasion, such as seeing the Barbie movie.

Finally, the sense of pride and accomplishment was palpable as the journey culminated in the successful creation and wearing of the dream Barbie shoes. This project showcased the challenges and triumphs of 3D printing, highlighting the importance of persistence, adaptability, and creativity in achieving a goal.