Decathlon’s latest footwear concept features a midsole and outsole produced using HP’s Multi Jet Fusion (MJF) technology and Lonati’s knitted uppers. The 3D printed shoes were showcased at the latest textile trade fair ITMA in Milan.

Shoe production usually requires numerous parts, adhesive materials, and a significant workforce. This often leads Decathlon to handle the mass production of its products in Asia, where multiple parts are assembled. By joining forces, 3D printer manufacturer HP, textile machinery expert Lonati Group, and the sports brand would ensure tighter, local control over manufacturing.

HP’s Jet Fusion 5200 printer is producing both the midsole and outsole of the shoe. To ensure optimal performance, these parts are fabricated using BASF Ultrasint TPU01 material, a versatile thermoplastic polyurethane powder known for its shock absorption and flexibility. Moreover, the use of a single material for the grip and cushion parts enhances the shoe’s recyclability.

With this partnership, the companies are focusing on the advantages of 3D printing and digital knitting for manufacturing at an industrial level, emphasizing customization, circularity and repeatability.

Interestingly, this combination of industrial knitting and 3D printing address another challenge: the manufacturing of uppers.  While 3D printed midsoles have become popular in the consumer goods industry, manufacturers have often relied on foam-like materials and single-print aesthetic to deliver 3D printed shoes. The fact is this approach is not practical enough to produce uppers that might ensure in the end a profitable and reliable production of 3D printed shoes.

Lastly, thanks to a glue-free assembly method, the shoe can easily be repaired when damaged. The cushion and upper parts can be separated, allowing for targeted repairs without the need to discard the entire shoe. This extends the lifespan of the product while reducing waste.

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