The demand for innovative footwear solutions is rapidly increasing, and 3d Print Shoes are at the forefront of this revolution. Zellerfeld, a pioneering company in this space, is experiencing this surge firsthand with a significant five-month waiting list for their unique sneakers. Customers are securing their production slots with a modest $10 down payment, finalizing their sneaker choices as their slot becomes available. An impressive 80% of Zellerfeld’s clientele are opting for personalized sneakers, meticulously sized and fitted using smartphone scans of both their left and right feet. This level of customization highlights the growing appeal of 3D print shoes that cater to individual needs and preferences.
Production efficiency has seen remarkable improvements over time in the 3D print shoes sector. Three years ago, prior to a substantial investment by Thiel, Zellerfeld operated with just four standard FMD printers. Back then, producing a single shoe could take several days. Now, equipped with hundreds of custom-built printers, the production time has been dramatically reduced to approximately 20 hours. Cornelius Schmitt, the founder of Zellerfeld, indicates that ongoing refinements in their processes could potentially decrease this turnaround time to mere minutes in the future. This progress underscores the increasing viability of 3D print shoes for broader market adoption.
“Each shoe comprises 6 million individual nozzle movements – a process that inherently takes time. However, we are actively working on achieving faster production cycles,” Schmitt explains. A crucial component of this strategy is the development of a new iteration of their specialized 3D printer, specifically engineered for sneaker production, which is currently being prepared for mass manufacturing.
“This advanced printer will fabricate the complete shoe, and upon completion, it will automatically drop into this designated area,” Schmitt demonstrates, as he opens a small, white aluminum door, revealing the drop zone to WIRED, along with the space allocated for one of his next-generation printers. “Subsequently, the production of the next shoe will commence immediately.” This vision of seamless, continuous production highlights the potential for scalability in 3D print shoes manufacturing.
Schmitt’s entry into the world of 3D print shoes was somewhat serendipitous. A self-proclaimed sneaker enthusiast since his youth, he found himself increasingly uninspired by merely printing trinkets on the 3D printer at Clausthal University of Technology, where he was pursuing industrial engineering studies. During one weekend, he decided to redirect his focus towards footwear.
“For me, 3D printers are the most fascinating machines imaginable,” Schmitt reflects. “That weekend endeavor to attempt printing a sneaker has now, eight years later, become my life’s work.” This personal anecdote illustrates the transformative potential of 3D printing technology and its application to 3D print shoes.
Scaling 3D Printed Footwear: Industry Perspectives
Schmitt is set to be a prominent speaker at Footwearise, scheduled for early December in Barcelona, Spain. This expo is organized by Nicoline van Enter, a consultant in the footwear industry and an expert in 3D printing. Footwearise marks its second year, building upon the success of its predecessor, Footprint 3D in 2023, which was a sold-out event, along with a spin-off event in Portland, Oregon, earlier in the year. Footwearise is expected to host over 300 delegates, including designers, technology specialists, and executives from major sneaker brands, all converging to explore the future of footwear and the role of 3D print shoes.
Van Enter, a seasoned professional in the footwear sector, originally from the Netherlands, relocated to Barcelona three years ago to establish Footwearology, a footwear training academy. Footwearology conducts regular webinars and provides specialized classes in 3D footwear printing. Her insights are crucial in understanding the industry’s shift towards 3D print shoes.
“The initial plan was to move to Vietnam to create a manufacturing innovation hub. However, with the onset of Covid, we opted to remain in Europe,” van Enter recounts. “My business partner at the time was based in Barcelona, so we initiated operations here instead of Asia. This proved to be a fortunate decision, as numerous companies have since expressed their desire to reshore sneaker production to Europe and America.” This trend towards regionalizing production aligns perfectly with the on-demand capabilities of 3D print shoes.
Van Enter’s overarching objective is to revolutionize the footwear supply chain, guiding it towards a more efficient and sustainable model. She aims to demonstrate to companies the feasibility of localized, automated, on-demand footwear production, minimizing waste and incorporating end-of-life systems, including recycling. 3D print shoes are central to this vision.
“There is a common misconception,” van Enter points out, “that the scalability of 3D printing in footwear is hindered by technological limitations. This is inaccurate. The primary challenge lies in the necessary evolution of the business model. To effectively implement 3D printing for shoes, a transition to an on-demand business model is essential. This is a shift that major sneaker corporations are either unable or unwilling to undertake. Giants like Nike, Adidas, Puma, New Balance, and others depend on importing large volumes of shoes from Asia and operating on a stock-based sales model.” This perspective highlights the disruptive potential of 3D print shoes and the necessary changes in business strategy to fully capitalize on this technology.
