Decathlon and partners put 3D-printed shoe idea on display at ITMA

Sports group Decathlon has worked with printing technology provider HP and with textile machinery developer Lonati Group on a new footwear project. The companies involved say they have used “the power of 3D printing” to develop a new sports shoe.
The shoe they have developed combines a sock knitted on Lonati machines with a midsole and outsole produced using HP’s 3D print technology. The partners have said the integrated upper offers comfort, lightness, performance and quality.
Thermoplastic polyurethane (TPU) powder from BASF is the material used to print the midsole and outsole of the shoe. HP used its Jet Fusion 5200 printer to turn the powder into the footwear components.
Advantages the technology providers and Decathlon have pointed to include customisation, flexibility and local production.
They have also said the shoe is in keeping with circularity and repairability. U glue-free assembly method will make the product easier to repair if any damage occurs, they said. The cushion and upper parts can be separated, allowing for targeted repairs without the need to discard the entire shoe.
This will extend the lifespan of the product and reduce waste, they said. Moreover, the use of a single material, TPU, for the grip and cushion parts enhances recyclability.
Philippe Seille, who leads on ‘value chain exploration’ for Decathlon said: “By leveraging the potential of 3D printing, we are revolutionising the shoe manufacturing process, offering consumers customised, recyclable and locally produced footwear.”
The companies arranged a joint exhibition boot at the ITMA exhibition in Milan and invited customers and other interested parties to see at first hand a demonstration of the system.