Global technology leader HP joined forces with Decathlon and Lonati Group, one of the world’s largest sports companies, to introduce a game-changing production concept at the ITMA fair in Milan. Together, all three brands offer an innovative and sustainable approach to shoe production that will reshape the industry. Leveraging the power of advanced technologies such as HP’s Multi Jet Fusion technology and Lonati’s shoe knitting machines, this collaboration paves the way for the future of sustainable shoe manufacturing.Traditionally, shoemaking required a large number of parts, adhesive materials, and significant labor. But HP, Lonati Group and Decathlon are revolutionizing this process by harnessing the power of 3D printing. In their latest innovation, they have developed a sneaker that represents the future of shoe manufacturing.
This groundbreaking shoe combines Lonati’s meticulously crafted sock with an innovative midsole and outsole manufactured using HP’s cutting-edge 3D printer. Lonati’s XT-MACHINE and Double Cylinder E1530XS knitting machines enable the production of the upper (the visible side of the shoe, excluding the sole) of a single or double layer fabric, resulting in an integrated upper that offers unmatched comfort, lightness, performance and quality.
HP’s Jet Fusion 5200 printer showcases the cutting-edge capabilities of 3D printing technology, producing both the midsole and outsole of the shoe. To ensure optimum performance, these components are manufactured using BASF Ultrasint TPU01 material, a versatile thermoplastic polyurethane powder known for its exceptional shock absorption and flexibility. By integrating these advanced materials and technologies, Decathlon and HP are revolutionizing the sneaker industry and paving the way for innovative designs that deliver unmatched comfort, durability and performance.
With this partnership, the companies shared a key message focused on the advantages of 3D printing and digital knitting for industrial-grade manufacturing, highlighting the following key points:
- Customization: Footwear is highly customizable and allows consumers to customize their shoes to suit their preferences and needs.
- Circularity and Repairability: A glueless assembly method is used and can be easily repaired if the shoe is damaged. By separating the cushion and upper parts, targeted repairs can be made without the need to throw the entire shoe away. This not only prolongs the life of the product, but also reduces waste. Also, the use of a single material, TPU (thermoplastic polyurethane) for the grip and cushion parts, increases the recyclability of the shoe. All this contributes to a more sustainable and environmentally friendly product lifecycle.
- Local Production: By utilizing 3D printing, shoes can be produced locally, shipping reduces emissions and supports local economies.
- Flexibility: The manufacturing process allows for stock life optimization and reduces waste by enabling production on demand.
Decathlon Discovery Leader Phillipe Seille expressed his excitement at the collaboration, saying: “We are excited to be collaborating with HP’s Personalization and 3D Printing unit and the Lonati Group on this project that exemplifies our commitment to sustainability. Leveraging the potential of 3D printing to revolutionize the shoe manufacturing process, we offer consumers customized, recyclable and locally produced shoes.”
Don Albert, Head of Customization and 3D Printing Footwear and Sports, HP added: “HP’s Multi Jet Fusion Technology is enabling a new era of sustainable and innovative manufacturing. We are proud to contribute to a more sustainable approach to manufacturing and to partner with Decathlon to showcase the enormous potential of 3D printing. Lonati Group’s expertise in footwear technology aligns perfectly with our shared values of sustainability. Working together is truly inspiring.”
Together, Decathlon, Lonati Group and HP, reshaping the future of sustainable footwear manufacturing, invite industry professionals, media representatives and ITMA exhibitors to witness this groundbreaking collaboration firsthand at their joint exhibition stands (Hall 4, C201).
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