Optimizing Work Shoe Performance with Dr. Geoffrey Gray Part 4: Fit

Believe it or not, we couldn’t even measure shoe fit accurately until 2014, despite fit being the #1 driver of comfort. Yet, poorly fitting shoes still line store shelves. In the final part of our four-part series, Dr. Geoffrey Gray of Heeluxe™ breaks down the science and the solutions behind proper fit.

Where’s the Squeeze? The Uncomfortable Truth about Fit

When it comes to shoe comfort, fit is everything. Shoes that fit “normally” generate the highest comfort scores, while “tight shoes” tank those scores fast. But what exactly do we mean when we talk about fit? According to Dr. Gray, it’s the relationship between foot shape and shoe shape. 

Here’s the kicker: 63-72% of people wear shoes that are too short or too narrow. But why? Many shoe factories still rely on outdated 1950s sizing data—when people were generally shorter and smaller. Today, our feet are wider relative to length, but shoe design hasn’t kept pace.

And it gets worse—work shoes and boots have historically been 11% tighter around the ball of the foot than everyday shoes. Even more extreme? Women’s work shoes fit 19% tighter around the toes compared to men’s styles. That’s a problem, says Dr. Gray, because most of our nerve endings live in our toes—making this the most critical area for comfort. 

That’s where testing makes all the difference. Fortunately, there are brands nowadays that hit the ball out of the park, like Timberland PRO^®, Reebok Work, SR Max^®, Florsheim and SKECHERS Work. In fact, the SKECHERS Slip Ins won the highest comfort score against other leading brands in Heeluxe™ Wrapped testing, that’s a whopping 6.7 out of 7 for overall comfort. Even though the industry has come a long way, Saf-Gard^® is working daily to further optimize shoes for comfort.

 

Rewriting Comfort: How Saf-Gard Is Solving Fit Problems

If you want your team in the most comfortable work shoes, foot shape must be part of the conversation. That’s why Saf-Gard^® partners with Heeluxe™ to bring cutting-edge fit data into our product development process.

The SmartLast system uses a sensor-equipped foot replica to simulate human testing—only faster. We’re talking about a matter of seconds. In fact, they were able to test 492 shoes in a mere two days, offering insights to improve footwear during development. New tech, like the SmartLast system, makes data collection a lot easier. But there’s more to it.

When your team members are out shopping for new work shoes, they often assume that foot size remains the same over the course of one’s life. AKA, once a medium-width size 10, always a medium-width size 10. But like the rest of our body, feet do evolve as we age. Yep, you heard that right. Feet can actually widen, lengthen, experience arch flattening and even lose elasticity over time. Dr. Gray recommends retesting your foot shape every 2-3 years in order to help achieve optimal fit every time.

The Brannock device is a useful, tried and true tool. You know, that metal shoe sizing equipment you see at most shoe retailers. It might seem old school, but it works. Even so, times are changing, and you now have access to 3D foot scanners, which offer much more precise foot data. Dr. Gray highly rates the Aetrex Foot Scanners, which is why we’ve installed them in most of our retail locations and are in the process of loading them on select Mobile Shoe Stores. In a matter of seconds, you can get tons of foot data like foot length and width, arch height, instep shape, pressure points and more. Armed with this data, our shoe experts will then help your team members find the perfect pair, whether you’re looking for slip-resistant styles, safety toes, electrical hazard protection or anything else. 

 

 

Real-World Fit: How Tech + Expertise Create Better Outcomes

How does this work in the real world? At Saf-Gard^®, we’ve implemented innovative processes. While your team takes advantage of our 3D foot scanners to get the essential foot data, our shoe experts can use the SmartLast testing info to check the specific shoe they’re interested in. Maybe the shoe your employee is interested in is one with a narrow toe box, but their foot data indicates they need a slightly looser fit in the toe. This info lets our pros know to recommend a ½ size larger in order to achieve the optimal fit in the shoe they like. Alternatively, they will highlight other options that might fit better with their specific foot shape. Dr. Gray notes that this strategy is on the cutting edge, and the good news for consumers is that it’s spreading. 

Fit isn’t just about comfort—it’s about performance, safety, and helping your team feel amazing on the job. Thanks to Dr. Gray and the tech at Heeluxe™, we’re stepping into a smarter future of occupational shoe design. At Saf-Gard^®, we’re proud to bring that innovation to your team, combining cutting-edge fit data with real-world expertise to help your team find their perfect pair.

 

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