The landscape of footwear manufacturing is undergoing a significant transformation, largely fueled by the advancements in additive manufacturing, more commonly known as 3D printing. This technology’s inherent capability for customization stands as a pivotal advantage in shoe production. Industry analysts project substantial growth, with the global 3d Printed Footwear market poised to reach an impressive $1.97 billion by 2027, as highlighted in a 2023 report by Research and Markets. This surge is propelled by continuous innovation in 3D printing technologies and an escalating consumer demand for personalized footwear solutions. By leveraging 3D scanning and printing technologies, numerous companies are innovating to create superior running shoes, avant-garde high-fashion designs, and remarkably comfortable and durable soles. While complete 3D printed shoes are emerging, many current applications focus on 3D printing specific components like uppers or soles. The synergy between 3D printing and footwear is undeniable, marking this sector as one with considerable future potential. This article delves into prominent examples of 3D printed footwear, featuring innovations from industry giants such as Adidas, Dior, and Decathlon, alongside groundbreaking contributions from emerging companies.
Adidas 3D Printed Golf Shoe: Merging Tech with Tradition
Adidas has firmly embraced 3D printing to revolutionize its footwear offerings, exemplified by their innovative golf shoe featuring a 3D printed midsole. The Adidas MC87 4D model represents a fusion of cutting-edge technology and classic design aesthetics. This limited-edition, unisex shoe is engineered with a high-performance midsole, developed using extensive athlete data to ensure optimal performance. The intricate mesh structure, a hallmark of its design, is manufactured using Carbon’s advanced 3D DLS (Digital Light Synthesis) process. This ensures the midsole is not only exceptionally durable and flexible but also dynamically adapts to the unique movements of each athlete.
Adidas 3D printed golf shoes
ATHOS: Custom 3D Printed Climbing Shoes for Peak Performance
ATHOS climbing shoes, the creation of a Barcelona-based student collective, are rapidly gaining traction within the climbing community. Climbing shoes, often referred to as “rock shoes,” demand an impeccable fit to maximize grip and minimize slippage. Traditionally, climbers often endure discomfort and potential foot deformities by wearing shoes that are intentionally undersized to achieve this crucial snug fit. Recognizing this challenge, the ATHOS team set out to develop bespoke climbing shoes tailored to the precise contours of each climber’s feet. Their innovative approach utilizes HP’s Multi Jet Fusion 3D printing technology in conjunction with BASF’s high-performance TPU (thermoplastic polyurethane) material. The process for obtaining ATHOS shoes is streamlined and user-friendly: customers simply scan their feet using three photographs, personalize their shoe specifications, and then receive custom-made climbing shoes ready for the rock face.
ATHOS 3D Printed Climbing Shoes
ECCO’s Quant-U: 3D Printed Insoles and Molds for Superior Fit
ECCO, a distinguished Danish footwear manufacturer with a rich history, has been at the forefront of personalized footwear since launching its Quant-U service in 2018. This service leverages 3D printing to personalize footwear, starting with a precise 3D scan of the customer’s feet. This detailed scan allows ECCO to determine the exact orthopedic support needed for each individual. Based on this analysis, ECCO designs and manufactures 3D-printed midsoles that are specifically tailored to meet the unique requirements of their customers. The midsoles are crafted from silicone, chosen for its optimal balance of stability and cushioning. Furthermore, these custom insoles are designed for convenience, being easily interchangeable and machine washable. ECCO also integrates Stratasys’ Origin One series 3D printers into its manufacturing process to produce molds for new shoe designs. These 3D-printed molds are instrumental in both prototyping new shoe samples and streamlining the development of innovative models. Additive manufacturing enables ECCO to significantly shorten production cycles and reduce material waste, enhancing efficiency and sustainability.
ECCO 3D printed shoe molds by Stratasys
FitMyFoot: Precision-Fit 3D Printed Footwear for Optimal Comfort
FitMyFoot, formerly known as Wiivv Custom Fit Sandals, emerged from a successful Kickstarter campaign in 2020, raising over $566,000 to bring personalized footwear to the market. True to its name, FitMyFoot utilizes a smartphone app and 3D printing technology to create custom sandals and insoles that offer an unparalleled fit. Customers simply place their foot on a piece of white paper and use the app to scan their feet. This process quickly generates a comprehensive foot analysis, detailing arch height and type, foot width, and length. FitMyFoot then employs 3D printing to produce insoles or sandals tailored to these specific measurements, providing relief and support for conditions such as plantar fasciitis, high arches, and flat feet. The company utilizes Multi Jet Fusion technology and specialized foams to create products that prioritize comfort and therapeutic support.
FitMyFoot 3D printed custom arch support
Hilos: Pioneering Sustainable 3D Printed Shoe Manufacturing
Hilos, a startup based in Portland, Oregon, established in 2019, is dedicated to reshaping shoe manufacturing by integrating advanced technology with traditional craftsmanship. By leveraging additive manufacturing, Hilos aims to address pressing environmental concerns while delivering high-quality footwear. A cornerstone of their business model is on-demand production, which eliminates overproduction by manufacturing shoes only after a customer order is placed. Hilos is committed to circularity, designing fully recyclable shoes and encouraging customers to return worn pairs for material reuse. Furthermore, 3D printing empowers Hilos to accelerate product development, enabling them to rapidly prototype and launch new shoe lines in under 90 days, significantly faster than conventional methods.
Parametriks Print 001: A Monolithic 3D Printed Sneaker
In 2022, designer Nathan Smith introduced the Parametriks Print 001 sneaker, a groundbreaking 3D printed shoe conceived through parametric design principles. This innovative approach, which combines design and material science for advanced part engineering, resulted in a shoe celebrated for its exceptional comfort and unique aesthetic. Nathan Smith utilized Grasshopper, a visual programming language integrated with Rhinoceros 3D modeling software, to design the Parametriks Print 001. Manufacturing of the shoe relies on SLA (Stereolithography) 3D printing machines and TPU material, resulting in a single-material, entirely 3D printed shoe.
Parametriks Print 001 3D printed shoe
Pleko: High-Performance Carbon Fiber 3D Printed Running Shoe
Pleko is the brainchild of Italian middle-distance runner Miro Buroni and the renowned Diadora company, representing a significant advancement in performance running footwear. The Pleko shoe incorporates numerous 3D printed components, including the insole, outsole, spikes, and structural ribs. Constructed from advanced composite materials, specifically carbon fiber, and manufactured using powder bed fusion technology, these components collectively create a shoe that is exceptionally flexible, highly resistant to wear, and remarkably customizable. Utilizing 3D scanning and sophisticated motion simulation software, the developers of Pleko can tailor the shoe to the individual biomechanics of athletes, delivering a durable and comfortable solution for enhanced athletic performance.
Pleko 3D printed carbon fiber running shoes
Act’ble New Pointe Shoe Sole: Revolutionizing Dance Footwear with 3D Printing
The Purmundus Challenge 2021 recognized Act’ble, a pioneering startup, for its innovative “New Pointe Shoe Sole,” developed in collaboration with elite athletes. This 3D printed pointe shoe is designed for classical ballet and contemporary dance and promises to last five times longer than traditional pointe shoes. Engineered to significantly alleviate the physical strain experienced by dancers, Act’ble focused on 3D printing the sole of the shoe. While the specific 3D printing process and materials used remain undisclosed, the innovation marks a significant step forward in dance footwear technology.
Act’ble 3D Printed Ballet Shoes
Zellerfeld Heal Your Sole: Fully Recyclable and Customizable 3D Printed Shoes
Zellerfeld, established in Brooklyn in 2020, is committed to revolutionizing shoe production through complete 3D printing manufacturing. Their automated production process champions an ethical manufacturing model, eliminating the need for conventional factories. Zellerfeld’s Heal Your Sole shoe is notable for its full customization, achieved through a smartphone foot scan that tailors the shoe’s shape to the customer’s exact foot dimensions, while also offering standard sizing options. Featuring an intricate lattice structure, this 3D-printed shoe is seamlessly constructed without adhesives, ensuring maximum comfort. It is designed to be breathable, machine-washable, and odor-resistant. Emphasizing sustainability, Zellerfeld offers a closed-loop system where worn-out shoes can be returned for complete recycling, and customers receive a new pair. The 3D printing process for Heal Your Sole minimizes material waste by using only the precise amount of material needed for each shoe.
Zellerfeld 3D printed Heal Your Sole shoe
Dior Carlo Oxford: High Fashion Integrates 3D Printing for Style and Sustainability
The Dior Men Fall-Winter 2023-2024 collection unveiled the Dior Carlo Oxford, a shoe that elegantly incorporates 3D printing into its design. Featuring an ultra-lightweight 3D-printed black Cosmo rubber upper and sole, these shoes are engineered for exceptional comfort. 3D printing lends a unique aesthetic to the Dior Carlo Oxford, making it lightweight, comfortable, and recyclable, underscoring its commitment to sustainability. With the tongue, under-sole, and laces removed, 80% of the shoe material is recyclable. The manufacturing process utilizes a polymer powder developed by HP specifically for its MJF 3D printers, and the printing process itself takes just 12 hours, adding to the exclusivity of this limited-edition fashion piece.
Dior Carlo Oxford 3D printed elements
Puma and Porsche Design 3D MTRX Sneakers: A Fusion of Performance and Design
Puma and Porsche Design have collaborated to create the 3D MTRX sneaker, a distinctive shoe that integrates 3D printed components. Specifically, the midsole features elastic resins formed into a honeycomb structure inspired by the Porsche Design logo—a series of interconnected cubes. This complex geometric design, unattainable through traditional manufacturing methods, is made possible by 3D printing, although the specific printing technology used is not disclosed. Puma and Porsche Design emphasize the 3D MTRX shoe’s durability, comfort, and lightweight nature. The upper of the shoe combines carbon fiber with leather accents, blending high-performance materials with luxury detailing.
Puma Porsche Design 3D MTRX Sneakers
Decathlon 3D Printed Sports Shoe: Emphasizing Customization and Eco-Design
Decathlon, in partnership with HP and the Lonati Group, has developed a sports shoe using 3D printing technology. Utilizing HP’s Jet Fusion 5200 3D printer, the shoe features a midsole and outsole made from Ultrasint TPU01 material, a versatile thermoplastic polyurethane powder from BASF. This initiative showcases the advantages of 3D printing in delivering customization, design flexibility, and enhanced comfort in sports footwear. Beyond these benefits, Decathlon chose 3D printing for its positive environmental impact. The shoe is designed for glue-free assembly, facilitating easy repair and extending its lifespan. Furthermore, the use of a single material for the soles enhances the shoe’s overall recyclability, aligning with Decathlon’s sustainability goals.
Decathlon HP 3D printed sports shoe
ASICS ACTIBREEZE™ HYBRID Sandal: 3D Printed Comfort and Breathability
ASICS introduced the ACTIBREEZE™ HYBRID SANDALS, leveraging 3D printing to enhance sandal design. Collaborating with LuxCreo, ASICS developed these sandals with a focus on sole comfort and breathability, utilizing a lattice structure achieved through 3D printing. Available in coral and black, these sandals offer a redesigned structure to maximize wearer benefits. Reflecting ASICS’ core philosophy of “A healthy mind in a healthy body,” these sandals are engineered to deliver exceptional quality and comfort, further expanding the applications of 3D printed footwear.
ASICS ACTIBREEZE™ HYBRID 3D printed sandals
Koobz 16kw Shoe: Washable and Comfortable 3D Printed Sports Shoe
Koobz, a California-based company specializing in 3D printed footwear, offers the 16kW shoe model, available through their online platform. Designed in collaboration with Fabrizio De Lucia of Affinity Space Design Studio, this unisex sports shoe is fully washable and manufactured in Italy, with printing operations in the USA. The 16kW stands out for its comfort, attributed to the use of flexible and supple polyurethane, a recyclable thermoplastic material. This material elasticity ensures extended wear comfort for various activities, from running to dancing, both indoors and outdoors, providing ample toe space and adapting dynamically to foot movement.
Koobz 16kw 3D printed shoe
The diverse examples presented underscore the transformative impact of 3D printing on the footwear industry. From enhancing athletic performance and enabling mass customization to promoting sustainability and pushing design boundaries, 3D printed footwear is rapidly evolving. As technology advances and materials innovate, the future of footwear is increasingly being shaped by the limitless possibilities of 3D printing.
