At the ITMA 2023 textile machinery show in Milan, a new shoe manufacturing concept was demonstrated by Italy’s Lonati Group, in partnership with digital printing specialist HP and Decathlon, the world’s largest sports goods retailer.

Traditionally, shoe production requires numerous parts and adhesive materials  which can be significantly reduced by the new process which combines shoe uppers of single or double-layer fabrics produced on Santoni and Lonati knitting machines and 3D printed midsoles and outsoles made with HP’s Jet Fusion 5200 printer.

The components are manufactured using BASF Ultrasint TPU01 – a versatile thermoplastic polyurethane powder known for its exceptional shock absorption, and flexibility.

By combining 3D printing and digital knitting for manufacturing at an industrial level, new Decathlon sports shoes can be highly customisable, enabling consumers to personalise their footwear to suit preferences and needs.

Due to the glue-free assembly method, the shoes can also be easily repaired when damaged. The cushion and upper parts can be separated, allowing for targeted repairs without the need to discard an entire shoe. This not only extends the lifespan of the product but also reduces waste. In addition, the use of a single material, TPU (thermoplastic polyurethane), for the grip and cushion parts, enhances recyclability.

In addition, by leveraging 3D printing, the shoes can be produced locally, reducing transportation and supporting local economies and the manufacturing process allows for stock lifetime optimisation and enables on-demand production, further reducing waste.

“We are thrilled to collaborate with HP’s personalisation and 3D printing business and Lonati Group on this project that exemplifies our commitment to sustainability,” said Phillipe Seille, exploration leader at Decathlon. “By leveraging the potential of 3D printing, we are revolutionising the shoe manufacturing process by offering consumers customised, recyclable and locally produced footwear.”

www.santoni.com

www.lonati.com

www.hp.com