To address inefficiencies, low material utilization, mechanical limitations of single-polyester uppers, and thermal instability in conventional footwear manufacturing, this study proposes an innovative composite design for fully formed flat-knitted athletic shoe uppers. The design integrates a diamond-shaped fabric architecture with an ultralightweight polyester/aramid interknitted construction, in which aramid fibers enhance strength while preserving the lightweight characteristics and structural stability, thereby satisfying the requirements of “efficient molding + high-performance” footwear. Through a systematic evaluation of five fabric structures and four yarn combinations, 20 single-layer specimens were fabricated and tested for areal density, air permeability, moisture vapor transmission, abrasion resistance, low-speed impact performance, and tensile properties under extreme temperature conditions. Factor analysis identified yarn combination C, primarily composed of 930 Dtex aramid multifilament, as optimal for mechanical performance and comfort stability. Substructures C4 and C2 exhibited superior mechanical performance and comfort, respectively, rendering them suitable for high-stress regions (e.g., toe cap, heel) and fit-critical areas (e.g., vamp, tongue). This research advances beyond conventional single-layer uppers by demonstrating the efficient adaptability of composite designs in footwear manufacturing. It provides both theoretical and practical guidance for precise partition design of flat-knitted shoe uppers, supporting the transition toward lightweight, durable, and integrated manufacturing processes.
He et al. (Thu,) studied this question.