Whereas most midsoles are made from foam through injection molding-a manufacturing technique that is both expensive and wasteful-New Balance has partnered with 3D Systems to access their SLS 3D printing technology, using laser sintering to fuse a proprietary elastomer powder into a cohesive material for the midsole, that will be both lightweight and extremely durable.
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In 2013, New Balance became the first athletic brand to sponsor a track athlete, middle distance runner Jack Bolas, competing in data-customized, 3D printed spike plates.
Adidas recently announced that they’re going to be using 3D printing to manufacture custom-fit shoes for their customers, and today, New Balance stated that in April 2016, they will be releasing a limited edition high performance running shoe with a 3D printed midsole. But instead of gluing a traditional foam midsole into the shoe, the new shoe will incorporate a 3-D printed midsole. The sneaker features a 3D printer-made midsole whose materials will improve the experience of runners due to the balance of weight, durability, and flexibility.
New Balance also added that it is hopeful of offering customizable 3-D printed shoes at a few select locations by 2017.
New Balance has already tested out its 3-D printing technology in a few of the biggest competitions in the world.
Sean Murphy New Balance Senior Manager of Innovation and Engineering explains more about the revolutionary design of the running shoe.
Detailing the technology, New Balance says it utilized selective cross-sections that were laid down one layer at a time using a laser. “To deliver this level of performance with a 3D printed component, we paired experts in running and biomechanics with leaders in plastics engineering, material development and generative design”.
The as-yet unnamed shoes will make their first public appearance at the 2016 Consumer Electronics Show in January. DuraForm® Flex TPU powder gives the resulting parts a previously unavailable combination of strength and elasticity that is ideal for performance running shoes. “With 3D printing we are able to pursue performance customization at a whole new level”.
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New Balance has been working on 3-D-printed midsoles for several years.
