Additive Manufacturing of High Heels Using the Input–Transformation–Output Model: Comparative Evaluation of PLA, ABS and ABS Photopolymer Resin Materials

The use of additive manufacturing in structural applications has increased in industry; however, reliable material selection criteria remain limited when printed components must withstand real service loads. The following study provides a comprehensive evaluation of polymeric materials (PLA filament, ABS filament, and ABS-like resin) used in additive manufacturing technologies for the production of footwear heels. Consequently, five heel models were designed using reverse engineering based on real industry references and analyzed within a decision framework based on the Input–Transformation–Output (ITO) model. Within this framework, each material was subjected to static mechanical tests (tensile, compression, flexural and hardness), scanning electron microscopy (SEM) analysis and numerical simulations. In addition, functional tests were carried out by mounting the printed heels on real sandals, allowing for evaluation of their performance under service conditions. Significant differences in surface morphology were observed, attributable to the physical state and consolidation mechanism of each material. Uncontrolled environmental conditions during printing and testing were identified as a limitation affecting reproducibility. The ABS-like resin showed the highest compressive load capacity (10.8 kN), together with a tensile strength of 14.99 MPa and a deformation at break of 0.076 mm/mm. SEM analysis revealed a more homogeneous surface morphology and greater structural continuity after curing, consistent with the numerical simulations, which predicted stresses between 19.98 and 196.23 MPa, displacements up to 8.917 mm and unit strains up to 0.1378. The integrated interpretation of the experimental, microstructural and functional results provides technical criteria for material selection in reverse-engineered footwear components and structural elements manufactured by additive manufacturing.