Decathlon, in partnership with printing specialists HP and the Italian-based Lonati (manufacturer of circular knitting machines), unveiled an innovation in shoe manufacture at the ITMA trade show in Milan, presenting a 3D-printed shoe.
The shoe combines a sock made using Lonati’s XT-Machine and Double Cylinder E1530XS knitting machines, which enable the production of uppers with single or double-layer fabric, and a midsole and sole produced using HP’s Jet Fusion 5200 3D printer. To ensure optimum performance, these components are made from BASF Ultrasint TPU01, a versatile thermoplastic polyurethane powder known for its shock absorption and flexibility. The shoe is also highly customizable.
Unlike traditional shoe manufacture methods – which require numerous parts, adhesive materials and labor hours – the 3D printing and digital knitting process has a number of possible advantages, which could even promote a more sustainable approach to footwear production, including:
- Reparability. The glue-free assembly means the shoe can easily be repaired, and the cushion and upper parts separated
- Circularity. Single material construction from TPU (thermoplastic polyurethane), for the grip and cushion increases the recyclability of the shoe
- Local production possibilities. Reducing transport emissions and supporting local economies
- Production on demand. Reduces waste
In July 2022, Asics launched a 3D-printed sandal which quickly sold out.
