The objective of this work was to examine the mechanical strength properties of polycarbonate toecaps designed for commercially available protective footwear, subjected to repeated impacts simulating workplace conditions. The effects of impacts on the toecaps were expressed as the height of toecap clearance, which has a direct bearing on the safe use of protective footwear. Changes in toecap geometry were evaluated using an originally developed methodology taking into consideration the requirements of Standard No. EN ISO 22568-2:2019. Additionally, external and internal sides of toecaps were scanned in three dimensions after each impact and reverse engineering was used to analyze deformations in toecap geometry by comparing the shape of the toecaps before and after impact. Three-dimensional scanning made it possible to measure the remaining safe distance for toes between the footwear sole and the impacted toecap surface, which is an indicator of the protective properties and safety of toecaps during use.
Keywords: footwear; impact testing; occupational safety; reverse engineering; three-dimensional scanning; toecaps.