3D Printer for Making Shoes

Finding a pair of shoes that feel super comfortable no matter how long you are using will be a reality, thanks to 3D printing. No matter what types of shoes you want, if you have the best quality 3d printer for making shoes, you can create a pair of shoes for your own using digital design files of shoes that you can download from the internet.

But how to buy the right printer? Well, to help you out with this, we have created this shoes 3D printer buying guide. Here you will get to know all the things related to 3D printing in the shoe industry and how it changes the industry. So, keep reading to discover more.

With time, 3D printing is slowly being incorporated into different industries, and the global fashion industry is no exception to this technology. 3D printing has opened up for creative possibilities, solutions, and more. You can witness the magic of 3D printing in jewelry to the custom design field. Now, another industry that is extensively adopting this technology is the global footwear industry.

You all know that 3D printing in the shoe production sector has taken off over the past few years. Shoes are challenging items to produce and will take a lot of time, especially if you are creating customized shoes. However, using a 3d printer for making shoes, you can make it easier. 3D printing can be found in everything, starting from prototyping and detailing the shoes to prototype.

While there is still time to see a 100 percent 3D printed pair of shoes, some brands are now working for mass production through 3D printing. By partnering with 3D printing brands like Formlabs and Carbon, shoe companies like Nike, New Balance, and Adidas are getting more success in the industry. They are using 3D printers to develop uniquely-designed and customized footwear and individual components for foot apparel and shoes.

Thanks to the evolution in 3D printing, it is no longer restricted to athletes’ shoes or those who are willing to pay more money to get the best quality footwear. Here, we will discuss how 3D printing in influencing the global shoe industry.

A little knowledge of history

Earlier, the shoemakers used to produce shoes entirely by hand. As their natures, footwears are considered as intricate items. Traditionally, they were quite time-consuming to produce.

Shoes manufacturing first began to take a new way during 1959s by introducing a shoe stitching machine by Lyman Blake and the lasting machine by Matzeliger. Such advancements led to a whole new approach to shoe production, letting the makers enjoy mass-production of shoes.

Today’s scenario

Now, 3D printing technology is a well-established and cost-effective way for rapid prototyping. It was implemented to be used during the product development stage in the industry. However, looking at all the technical capabilities, it can be said that 3D printing can play a much more significant role in the shoe production process.

The most crucial contribution of 3D printing technology to the global shoe industry is the mas-customization. Custom-made products designed for exclusivity and ergonomics are now possible thanks to the changing additive manufacturing processes. Imagine how amazing it will be when you have a stylish and unique pair of brand-name shoes designed based on your requirements.

If you are using sport shoes, you may know that such shoes call for extra requirements. These are durability, stability, and control. These factors can be easily achieved by the right choice of materials and sophisticated design. These are the core qualities of 3D printing.

On the other hand, using a 3D scanner makes it relatively easy to create custom-fitted and comfortable shoes for sportspeople. This will significantly enhance the athlete’s control in the fined, and the shoes will automatically get adjusted with the movements.

For all such reasons, well-known companies are now investing their money and time to produce 3D printed sports shoes.

Why are a more significant number of footwear brands adopting 3D printing?

As per the market analysis report, 3D printing footwear revenue contributes around 0.5 percent of the global footwear industry revenue. However, looking at the current trends, the figure is expected to increase by 1.5 percent of the global footwear revenue by 2029.

Even though the projected figure is looking a little encouraging, the figure will be small if you compare it to the industry’s overall market revenue. So, some market experts have suggested that the 3d printed shoe soles will not replace the traditional manufacturing process, at least not for now.

However, they have informed that this can shoes 3d printer can be a crucial resource for the manufacturer as 3D printed shoes may become the largest segment in the field of consumer products 3D printing. Such types of evolution are projected to be driven by two major vital trends. These are:

1. The increasing focus on digital manufacturing
2. The ever-growing consumer demand for highly personalized products.

The demand for personalized products is growing

Talking about today’s consumers’ landscape, they are now demanding more personalized and customized experiences. On the other hand, the footwear companies let their customers choose shoes with limited personalization by choosing the color.

On the other hand, 3D printing has enabled footwear manufacturers to unlock a lot of customization options. All thanks to the printer’s ability to create footwear tailored to the customers.

Even though the possibilities related to mass-customized shoes are still in the early stages, the companies have started developing different strategies to carry out shoe customization in mass. Very soon, both the producers and the customers will enjoy more options for customization.

There is an increased focus on modern digital manufacturing

Another primary driver for the use of the 3d printer for making shoes is the automation and digitization of shoe production.

Shoe manufacturing is a labor-intensive, multi-step, and manual production process. The process requires a number of highly specialized machines and workers to produce different pieces and then arrange them together to create the final product.

Keeping these things in mind, the manufacturers are now looking for innovative manufacturing process optimization methods. With 3D printing, shoe companies are now streamlining some shoe components, such as shoe soles.

Different from the conventional manufacturing process, it doesn’t require any additional tooling for part making. This process involves creating 3D models and parts for the build platform using resins or filaments. A software application is used to automatically guides the printing process based on the design. That means the shoed production can be streamlined while lowering the involvement of manual labor.

All most all the significant shoemakers are now using 3D printing for molding and rapid prototyping applications. Besides, sine some few years, 3D printing is extensively used to create functional footwear components.

For example, manufacturing parts for sneakers are some successful footwear applications for 3D printing in the footwear industry. Some brands are using this advanced additive manufacturing technology to produce sneaker 3d printed shoe soles and midsoles, and some are experimenting with 3D-printed sneaker upper and sandal parts.

How is 3D printing helping companies?

1. Faster time to launch your products

One of the massive challenges in developing footwear is the cost and time required to produce sole unit molds. As you know, each shoe size needs a separate mold; developing a new mold will cost thousands of dollars. Besides, mold manufacturing is a lengthy process and can take a month. On the other hand, the communication gap between the factories and the brand can be influential.

Now, coming to 3D printing, it doesn’t require any molds. Here, shoe parts can be developed by processing a digital design file, letting shoemakers develop new shoes to market. For example, the combination of automation, localized production, and 3D printing have enabled Adidas to launch new products to the market four times faster than conventional production.

2. More innovative designs

3D printing technology has enabled brands to implement new shoe design features. For example, the midsoles. Previously they were used to be made as a solid piece. Now, with 3D printing, the performance of shoes can be significantly improved. Now, you can use lattice structures to create midsoles. What’s more? You can now design the structure to achieve the desired densities for the midsole. By tuning the areas, you can correctly optimize the level of cushioning in the shoe.

3. A significant level of customization

The choice can vary from one customer to another. You can’t say that a single design will be perfect for all. With 3D printing, you can manufacture shoes designed to the feet of the user. How? To create a custom pair of sports shoes, shoe manufacturers generally use 3D scanners to measure the wearers’ feet.

Taking the scanned data, the designers can produce a perfect design of different shoe components, such as insoles and midsoles, that will perfectly meet the customers’ particularities. After that, the design is sent to the printed to produce the 3D object.

3D printed midsoles are the first consumer products that are mass-produced utilizing 3D printing. On the other hand, insoles are the first footwear products to be mass-customized.

These two significant trends, i.e., customization and production, combining with the explosive implementation of 3D printing in mold production and prototyping, will be the key factors to drive the global 3D printed footwear industry.

1.1, What is the original production process of shoes

Talking about the original shoe production process, to understand this, first, you need to know about the shoe sole making process. Shoe soles are made of rubber material. It is a combination of different rubber components. Based on the rubber outsole’s performance requirements, synthetic and natural rubbers are appropriately combined with the curing agents, like peroxide and sulfur.

However, for this, the shoe industry should thank Charles Goodyear. Why? After years of experiments, in 1844, Goodyear managed to invent the processes to heat natural rubber, combining sulfur to produce shoe rubber. He named the process “Vulcanization.” The same process is now used to produce shoe rubber.

Most famous brands, such as Adidas, Yeezy, Nike, Jordan, and more, use this process. You can use gum rubber, crystal rubber, and black rubber for this. Crystal rubber is 100 percent synthetic; black rubber has a sufficient amount of carbon and gum rubber, combining synthetic and natural rubber elements.

After getting the right rubber material, it’s time to prepare the frame. The logo color is inserted inside the sole frame or mold by hand. Once done, the logo background color is added. Then raw rubber material is added to the primary side of the wall mold. When heat is applied, the rubber will start to expand. After that, the net plate of the mold is closed correctly.

Now, the structure is placed into the heated press. It is heated for around 3 to 5 minutes. After that, the maker removes the middle plate and clean up the “flash.” Now, heal color and forefoot rubber is applied. Again, the mold plate is closed and is hot-pressed. This will perfectly combine the sides and bottom.

Once done, the uppers and outsoles are sent to the assembly line. The workers apply different types of glue and primer to every part. It may be noted that the outsole needs a different primer that can produce a robust bond. Once the cement and primer are dry, the parts are ready to be assembled. The workers choose the correct size outsole and upper and press them together manually.

They carefully align them and make sure that they are centered. After that, they flip the shoe and attach the heel into the right position. The cement is tacky, so it may get repositioned. A metal tool is used to ensure the midsole perfectly follows the glue line. After that, shoes are sent through a chilling tunnel.

To ensure perfect bonding between the upper and outsole, the shoe will move through three pressing operations types. These are the side press, toe & heel press, and downward press.

This is the process of how shoes are made manually. As you can see, the entire process is carried out manually and can a lot of time. In fact, some shoes may take a month to come to the market. However, the introduction of 3D printers in the shoemaking industry has made production faster. Have a look at how it is influencing the industry.

1.2, What processes can 3d printers replace?

From design to the final product, producing perfect shoe molds is a crucial part of shoemaking. And the process of making molds for shoes, from manual at the earlier period to 3D printing to CNC engraving, the cost and time related to manufacturing a pair of shoes have reduced. Traditionally, the material is carved with wood, and that takes more time.

On the other hand, it ultimately depends on the craftsman’s skills. When the CNC machines were introduced, the material was replaced by a wood-like material. But there are some drawbacks to this. For example, the process produces dust pollution, and it is quite challenging to engrave the intricate pattern.

However, it is the time of Industry 4.0, and 3D printing is now changing the production process. With 3D printing, you can now quickly print shoe molds and models. On the other hand, the material used to create molds and mode is resin.

How are molds created?

1. The molds for shoes are first designed using a CAD software tool, for example, Fusion 360 and AutoCAD.
2. Once done, the design is saved in a format that the printer can read. The most common format is the STL file format. After that, the digital design is sliced into G-code.
3. Then, the file is sent to the 3D printer, and it starts printing the molds layer by layer.

These molds are then attached with shoe uppers to create the final product. Compared to the manual process of mold making, you can make mold within a few hours and use different materials. For example, ABS or though or flexible resin. As you are making shoes, you need to make sure that the molds have a great detail level. That’s why experts suggest using an LCD 3D printer that processes resins to create molds.

Another thing that 3D printing is replacing in the shoe production process is design. Now there is no need to draw out a design on paper. You can directly create the design using 3D printing software. Your design will be very accurate, and you can also change it whenever you want, without drawing the entire object again.

On the other hand, if you are making a customized pair of shoes for your customers, you can use a 3D scanner device to collect accurate measurements of the customer’s feet. So, 3D printing makes the process comfortable and easier for you, and you should take maximum advantage of it.

1.3, What’s the changes after the intervention of 3d printers

Shoe 3D printing was the first application to propel the imagination of a massive demographic of people, envisioning the idea to wear stylish and trendy 3D-printed products. Started by Janne Kyttanen, artists, designers, and visionaries worldwide have experimented with footwears that have been 3D printed. On the other hand, the utilization of 3d printer for making shoes for shoe prototyping is an ideal practice for the global footwear industry.

It has been used to produce patterns, molds, and shoe parts. As discussed above, mass production of mid-soles and mass-customization of in-soles are the two crucial things that propel the growth of 3D printing. Some experts have projected that 3D printing will cross US 400 billion marks very soon in the global footwear market.

As per the data, in the year 2018, the global footwear industry witnessed around USD 260 billion revenue, and it is projected to reach USD 4000 billion by the end of 2029. The market is expected to grow at a Compound Annual Growth Rate of 4 percent. So, 3D printing technology is expected to play a crucial role on multiple fronts, such as indirect manufacturing, prototyping, and more.

The evolution of shoe materials

Earlier, shoe mid-soles were produced from a rubber material, and the durability level was not right. Now, 3D printing technology has introduced new materials that can be used to produce different parts of shoes. Here, the ideal example can be TPU. In general, models printed using Thermoplastic Polyurethane come with some advanced properties.

As a result, you will get flexible, strong, and durable parts. Besides, you can add some extra features to your shoes by using such materials as energy return, shock absorption, and a high level of elasticity. On the other hand, if you want to create complex parts and flexible lattices, this material will work great.

Additive manufacturing in the fashion industry allows designers like you to unleash their creativity significantly. You can get some collections that will be personalized, unique, and surprise others with the products’ geometries and shapes.

In the footwear industry also, 3D printing is gradually creating a perfect place. From sports shoes to futuristic footwear, 3D printing has simplified the process. It may be noted that not just shoes, the midsoles, and outsoles can also be 3D printed using a 3D printer. Let’s know how major shoe manufacturers are using this technology.

1. Adidas

Adidas uses 3D printing for the first time in the year 2018. Well, that got a lot of attention from the competitors and other industries. Adidas proved that 3D printing could be used for series production, apart from prototyping. In 2018, Adidas manufactured 100,000 pairs of shoes named Futurecraft 4D using a 3D printer and Carbon’s CLIP method.

Taking about the CLIP, it functions by projecting U.V. images produced by a DLP through a U.V. transparent window below a liquid resin bath. The process looks quite similar to SLA- Stereolithography. The company informed that it helps them to attain a maximum level of flexibility. Adidas also has released the Alphaedge 4D 3D printed sneaker.

2. New Balance

New Balance, in 2015 partnered with 3D System to create a midsole using 3D printing. The company has named it DuraForm Flex 3d printed shoe soles. These are made of thermoplastic elastomer material using SLS 3D printing technology. The significant features of them are better flexibility and an excellent level of strength. As per the company, it has managed to produce complex structures that can offer better shock absorption. Besides, the company also has partnered with Formlabs to launch FuelCell Echo Triple trainers.

3. Reebok

Reebok has implemented 3D printing to create different types of soles for sports shoes in its manufacturing process. While all the parts are created using traditional manufacturing methods, the sole, called Liquid Speed, is developed through 3D printing. For the development, Reebok partnered with BASF and used the liquid polyurethane material for the soles production. The sole offers the shoes more durability and more excellent performance.

4. ECCO

ECCO, in 2019 introduced QUANT-U service for footwear customization. It has a 3D scanning process that the users can access, and using the data, the company produces 3D printed durable midsoles that will perfectly fit the users. The midsoles are 3D printing shoes parts made from silicone to produce a greater level of performance and cushioning.

This way, the company has managed to serve more people than before, as everyone now can get a perfect pair of shoes. The experimental concept store of ECCO’s W-21 is now harnessing the real power of 3D printing to offer walk-in customers tailored shoes within a few hours. This is a three-step process. First, the customer’s data is collected by 3D scanning.

That data will include foot length, volume, width, arch contours, toe spacing, and more. Once done, the collected data is then translated into a design file that a 3D printer can process. The digital design file is then sent to a 3D printer that will produce the object using silicone material. After that, the midsoles are used in the company’s Flexure shoes so that the customers can get a perfect fit.

5. Prevolve

The company has been founded to offer minimalist shoes that can let the users walk and run naturally, and the shoes will support the moves. The producer utilized BioFusion Technology to manufacture 3D printed shoes that are custom-fit and flexible. After getting data off your feet, the company sends the data to the printer to produce the shoe with a sole having 7 to 14mm of thickness. The shoes are recyclable.

6. Iris Van Herpen

Herpen is a well-known 3D printing designer. In fact, she is the one who uses 3D printing to design the entire collection, from shoes to dress. The piece, which is quite popular, is developed in collaboration with Rem D Koolhaas, United Nude’s founder. The designer’s 3D printing design is inspired by the Banyan trees and made by using Stratasys’s PolyJet 3D printer.

7. Nike

Nike is using 3D printing technology to iterate the functional parts much quicker. For example, Nike Vapor Laser Talon. This is the world’s first football cleat create through 3D printing. Then the company developed the Nike Vapor High Agility cleat. As per the company, 3D printing, the company create, iterate, and test shapes that are not possible with traditional manufacturing.

For this, the company used the SLS- Selective Laser Sintering process. Nike is also famous for producing good quality upper shoe components. Talking about an upper, this component covers the toes, the heel, the foot’s side, and the top of the foot. Traditionally, they are made of textile, which is challenging for 3D printers to create.

But 3D printers now produce better uppers using flexible resins or filaments. For example, Nike the Nike Flyprint. It is created using TPU filament through SDM- Solid Deposit Modeling. It offers a better level of durability than woven uppers. Here, the layers are perfectly fused together to avoid frictional resistance.

Creating new opportunities in the industry

With the introduction of digital manufacturing and new material, 3D printing technology is now opening doors for many new and innovative footwear products. Currently, the technology is greatly facilitating the manufacturing of customized sandals and high-performance sports shoes. This enables the brands to speed up the time to market while trying out new designs and gifting their customers better customization options.

Rethink your production process

Like other industries, the 3D printing method can be utilized to create an innovative manufacturing process. It will offer more opportunities and possibilities for all companies. For instance, Feetz. This American startup unit manufacturers are stylish and comfortable to wear custom shoes. Besides, the company’s work is not affecting the environment.

The company developed its own 3D printer, with the FFF- Fused Filament Fabrication method and their in-house produced 3D printing material, a polymer. To make the manufacturing process sustainable, they changed the manufacturing process. The company uses recycled and recyclable materials.

There is no water consumption, which has helped the company reduce the carbon footprint by around 60 percent. So, it clearly proves that by choosing 3d printing for shoes, you can change your existing manufacturing process and make it much better.

Are 3D printed footwears for everyone?

Well, if you consider the current situation, the answer will be yes. You can quickly get 3D printed shoes online. Shoe manufacturers are now collaborating with 3D printing service providers to come up with new designs using new materials. Apart from shoes, there are sneakers and slides for everyone. Some companies let you send your 3D printed foot size. So, both technologies and manufacturers are evolving.