Hey guys thank you so much for the continual enthusiasm!
It does look like ver1.1 has done it's job! Not suitable but it's got us all thinking and talking!
If I could design a shoe from scratch (someone please do this!) I'd insert a framework in the toe, similar to a rib cage with thin flat ridge arches as part of the toe fabric, vacuum formed prior to sewing/assembling. They would compress when bending, but provide support in "bridging" over the foot.
Thermoplastics used for splinting are a great option as a single shaped disc could mould to fit in any shoe. There is still a question on fit & size as they will need to be a certain thickness and no-ones going to buy new shoes just to fit their toe caps (well, maybe on this forum
)
External protection is possible, I made samples last year and they threaded with the laces and wrapped under the midfoot sole. Will look into this in more detail.
Otherwise the secret weapon is still unreleased, I have a knitted material (yes like your socks) which is thin, breathable and sets rigid once "activated".
So,
Better shoes would help to start!
Outer protection could additionally include padding on the side of feet facing the bowler.
"gumshield" type protection would fit, but will be sweaty and possibly get in the way
Knitted option, I need to show this working
Again, thank you everyone for your continual help, you all fricking rock!