(506) 2240-6804
New balance 3d printed shoe
New Balance's Latest Shoes Come With 3D-Printed Soles
If you currently own a pair of running shoes, the odds are that the midsole—the shock-absorbing layer in between the inner and outer soles—is made from molded ethylene vinyl acetate (EVA), which is squishy, resilient foam.
As a cushioning material, EVA foam isn’t bad. It’s elastic, affordable, and can be dyed a variety of colors. But an EVA midsole offers the same degree of support throughout the shoe, and what you really want is different levels of support across different parts of the foot. Also, EVA breaks down and compresses with repeated use, and this degradation is the reason many runners replace their shoes every few hundred miles. For these reasons, shoe companies have been actively experimenting with materials to replace EVA.
Two years ago, running shoe giant New Balance teamed up with Somerville, Massachusetts–based 3D-printing company Formlabs to develop a new type of sole. Now the duo are debuting TripleCell, a footbed technology whose components are made of a proprietary photopolymer called Rebound Resin.
For its first shoe in this lineup, New Balance is re-releasing its classic 990 Sport with a TripleCell heel. The $185 runner is lighter, more supportive, and more durable than the EVA version. Two more performance-oriented models with TripleCell components will be arriving within the next year.
Rough and Tough
3D-printed shoes aren’t precisely a new idea. For example, Adidas has also begun developing similar automated 3D-printing facilities that might allow customers to order digitally printed, personalized products.
But rather than focusing on the shoe's appearance, New Balance decided to find ways to improve its performance. The company gave Formlabs a formidable list of properties the new material would be required to have.
“What you don’t think a lot about with footwear is the demand that we put on this midsole material,” says Katherine Petrecca, general manager of New Balance’s Innovation Design Studio, in a phone interview.
“It has to last for several hundred miles of repeated impacts,” she says.
“It has to work for a 110-pound female runner like Jenny Simpson and a 230-pound basketball player like Kawhi Leonard. These things are going to be outside, it has to be stable for UV and hydrolysis … It has to be able to withstand heat tunnels in the manufacturing process and bond to all these other materials."
Formlabs chief product officer Dávid Lakatos and his team went through hundreds of iterations with the formula to achieve the final product. Besides printability, two of the most important properties of the material were energy return and elasticity.
“[The design] has to be able to give back energy, to have a good feel when you’re using them to run and walk,” Lakatos said in a phone interview. “[It] also has a 330 percent elongation before it breaks … We’ve learned more about how the dynamics of human anatomy work when walking on the surfaces than in almost any other industry.”
Formlabs has pioneered the use of pliable, resilient photopolymers in 3D printing, via a process called low force stereolithography (LFS).
Once a design is uploaded, the company's Form printers draw highly intricate patterns in liquid Rebound Resin, which cures when the light hits it, resulting in a hardened 3D shape.
New Balance and Formlabs reveal TripleCell sneaker with upgraded 3D printed forefoot
0Shares
Multinational footwear maker New Balance is updating its TripleCell 3D printing platform with the addition of a new sneaker: the FuelCell Echo Triple.
Launching on September 27th with an expected retail value of $175, the shoe features a forefoot (part under the ball of the feet) 3D printed using Formlabs technology. It is a new take on the standard FuelCell Echo, and follows the release of the revamped New Balance 990 Sport in June 2019.
“TripleCell will deliver the industry’s pinnacle expression of data to design with seamless transitions between variable properties underfoot,” explains Katherine Petrecca, New Balance General Manager, Innovation Design Studio. “This new, cutting edge, digitally manufactured technology is now scaling exclusively within New Balance factories in the U.
S. further establishing us as a leader in 3D printing and domestic manufacturing.”
The Formlabs New Balance FuelCell Echo Triple. Photo via Formlabs.“Formlabs has been an integral partner to bring this to life. We’re really going to be able to disrupt the industry not only in performance, but also in athlete customization and speed to market”
New Balance and Formlabs
The relationship between New Balance and Massachusetts-based 3D printer OEM Formlabs was first revealed in 2017. Both companies announced an exclusive partnership to develop high-performance materials and hardware while developing a manufacturing process for athletic footwear.
One of the results of this partnership has been the creation of a proprietary photopolymer called Rebound Resin. The material is designed to create springy, resilient lattice structures with the durability, reliability, and longevity expected from an injection molded thermoplastic. In early 2019, the Rebound Resin was previewed during the Digital Factory Conference and the Formlabs User Summit events in Boston.
Katherine Petrecca, General Manager at New Balance Athletics and her team demonstrated various 3D printed structures made from the previously unnamed resin.
Lattice structures made from Rebound Resin were used to form the heel of the redesigned 990 Sport, helping to maintain the cushioning experience found in the classic style while being 10% lighter than the New Balance 990v5. This basis has now been further enhanced in the FuelCell Echo Triple shoe.
The reimagined New Balance 990 Sport with a 3D printed heel. Photo via New Balance.Developing forefoot technology using Formlabs 3D printing
The standard FuelCell Echo sneaker was first released for New Balance’s FuelCell platform, which is dedicated to forefoot running shoes. Looking to update the shoe’s forefoot technology with 3D printing, New Balance integrated the sneaker within its TripleCell platform as well, resulting in the FuelCell Echo Triple iteration.
The experience and knowledge gained from the original launch of the FuelCell platform helped to inform the creation of the new TripleCell sneaker.
The design of the FuelCell Echo Triple consists of hundreds of precisely shaped and mapped out design elements. It is engineered to deliver long-lasting high rebound and cushioning to improve running performance.
TripleCell technology can be found in the lattice structure at the forefoot of the FuelCell Echo Triple, located at the front of the sneaker. It is 3D printed using Formlabs machines. One of the notable benefits of applying 3D printing to make this component is that it eliminates the use of molds, which can lengthen and create extra cost in the product development process. According to Dávid Lakatos, Chief Product Officer of Formlabs, “3D printing is changing how companies approach manufacturing, with this announcement New Balance is pioneering localized manufacturing.”
“By eliminating the dependence on molds and direct printing for both prototyping and production,” Lakatos adds, “their team shifts from months to hours in the development and production cycles.
”
“We’re moving towards a world where design cycles are closing in on the whim of the consumer and it’s exciting to be on the frontlines of this with New Balance.”
Subscribe to the 3D Printing Industry newsletter for the latest news in additive manufacturing. You can also stay connected by following us on Twitter and liking us on Facebook.
Looking for a career in additive manufacturing? Visit 3D Printing Jobs for a selection of roles in the industry.
Featured image shows the Formlabs New Balance FuelCell Echo Triple. Photo via Formlabs.
Tags Dávid Lakatos Formlabs FuelCell Echo FuelCell Echo Triple Katherine Petrecca New Balance TripleCell
Anas Essop
Anas Essop is an English and Film graduate, who loves writing about the advancement of technology.
New Balance launches line of 3D-printed
sneakersTechnologies 3D printing new balance Lifestyle
New Balance launches a line of 3D printed sneakers
Georgy Lyamin —
The sports shoe manufacturer is mass-producing its latest technological innovation: a 3D-printed range with unique cushioning properties.
The initiative started in 2017, at which time New Balance partnered with leading 3D printing experts Formlabs.
Based in Massachusetts, Formlabs develops and sells high quality materials, equipment and manufacturing processes to create competitive athletic footwear. The technology, co-developed with New Balance, is called TripleCell and will be used in the 990 Sport and FuelCell Echo models.
“TripleCell is best suited for design with variable properties. This new, advanced digitally produced technology is currently only used in New Balance factories in the US, making us the leader in 3D printing in the local market. Formlabs has become our indispensable partner. We will be able to disrupt the industry not only with performance, but also with a high speed to market.” - Kathryn Petrekka, New Balance CEO, Innovation Design Studio
The Made in USA 990 Sport with TripleCell technology goes on sale today for $185, while the FuelCell Echo hits stores September 15 for $175.
iGuides on Telegram — t.me/igmedia
iGuides in Yandex.Zen — zen.yandex.ru/iguides.ru
Source:
Hypebeast
Buy advertising
Recommendations
- USB-C was supposed to make our lives easier, but it ended up confusing everything
- Ozon has changed the way it receives orders
- Whatsapp has a cool new feature.
There is no such thing anywhere, even in Telegram - Ozon warned of a possible default. What will happen now?
Recommendations
USB-C was supposed to make our lives easier, but it ended up confusing everything
Ozon has changed the way it receives orders
Whatsapp has a cool new feature. There is no such thing anywhere, even in Telegram
Ozon warned of a possible default.
What will happen now?
Buy advertising
See also
XiaomiSmartphones
Macs with M1 and M2 chips can now run Windows 11 through VMware Fusion 13
Apple Mac Windows 11
How to Add a Safari Downloads Folder to Your iPhone Desktop and No Longer Find It in Files
Safari iPhone Guides
New Balance and Formlabs Collaboration
In 2017, New Balance partnered with Formlabs to create a 3D printed production line, opening up new innovative exterior design possibilities with endless freedom to create streamlined designs, with the promise of custom components at an affordable price in the required scale, as well as a wide scope in the choice of materials.
This summer, the company announced its vision with the introduction of TripleCell technology: 3D printers equipped with Formlabs stereolithography (SLA) printing system and a brand new material, Rebound Resin photopolymer.
TripleCell will allow us to break new ground in using data to control every millimeter of a product. Formlabs has become our integral partner in this initiative. We will be able to disrupt the industry not only with performance, but also with customization, as well as high speed to market.”
Kathryn Petrekka, CEO at New Balance, Innovation Design Studio
New Balance has already started a small production in Lawrence, Massachusetts with the limited edition 990S TripleCell to be followed by the FuelCell toe , made with TripleCell technology, in the fall of 2019, as well as the first models of high-tech running shoes in 2020.
Learn more about the TripleCell 3D printing materials and process, and the approach that enables New Balance to deliver high-tech manufacturing.
Complex supply chain - customization possibilities
Shoes are definitely a complex product. The production of footwear requires a large amount of inventory, a large-scale business, and a lot of manual labor and skill. New Balance introduces thousands of designs each year, each with hundreds of color and size references, with components made using a variety of materials and assistive programs.
Due to the growing demand for customization, it is becoming more and more difficult to manage these processes. The modern shopper demands customized products that can be ordered from anywhere, on any device, and delivered in the shortest possible time.
Until now, many companies have only been able to offer highly customized, one-of-a-kind pieces, using 3D printing to create and manufacture shoes for professional athletes. For the first time, the athlete competed in 3D printed shoes in 2013. Athletes from the track, football, baseball, etc. followed.
The first 3D printed cleat game was played in Major League Baseball in April 2017, where pitcher Corey Kluber played in cleats with specially designed traction plates.
Along with these changes, 3D printing technology has continued to evolve. In 2012, Formlabs introduced the Form 1, aiming to create powerful, reliable stereolithography (SLA) technology that is technically and financially affordable and scalable. The Form 2 followed in 2015. Since then, over 40 million parts have been printed by users. Now the Form 3 and Form 3L are opening the door to further opportunities for 3D printed products, including large parts.
Today, 3D printing is well on its way to making mass customization for businesses a reality, with examples such as Gillette's Razor Maker™ platform delivering printed, ready-to-use parts directly to the consumer.
Building shoes from the inside faster than ever
In addition to collaborating with professional athletes, New Balance has also long used 3D printing to develop prototypes. Today, the company produces thousands of 3D printed prototypes every year. The development and growth of the 3D printing market has been closely monitored.
“By learning about innovations in 3D printers and materials used to print, we envisioned a future where they come together in consumer products,” says Ms. Petrekka. “When you can use 3D printing technologies to move to a more in-demand production model, it becomes a turning point. This benefits both the consumer and New Balance as a manufacturer. Compared to molding, there are significantly more opportunities to develop and manufacture a product. This allows us to produce better quality parts than we currently have with plastic and foam.”
Today, most of the foam components in shoes are produced by injection or compression molding, which greatly limits the design possibilities. The move to 3D printing for both prototyping and manufacturing provides creative possibilities unthinkable in a traditional product manufacturing process.
“What we have been able to do now is to design the outer part of the shoe and rely on the original properties of the material to achieve the desired performance results.
What used to be considered customization was pieces of foam glued or molded together followed by a multi-step assembly process, says Dan Dempsey, senior additive manufacturing engineer at New Balance. “By applying additive manufacturing technologies, we can significantly change the lattice structure in order to change local properties within a single mold, thus allowing us to make changes throughout the entire volume of the product. We can create a system from within.”
3D production allows for a complete part design with structure "beyond" foam. New Balance's TripleCell products will be the industry's epitome of data-to-design with seamless transitions between different shoe elements.
This new way of design takes performance possibilities to a whole new level. TripleCell allows for seamless work across the entire piece, providing a seamless transition from soft to high stability within a single design and one material.
Prototyping and 3D printed parts are transforming the entire development process, reducing time to market.
“Traditionally, the product cycle, starting with documentary preparation and ending with the introduction to the market, is 15-18 months. When we create tools and expect to receive foam or resin parts, we allow 4-6 weeks for delivery. says Ms. Petrekka. “By getting rid of molding, we can save months on the development process. TripleCell technology makes it easy to produce multiple designs at the same time, reimagining the traditional iterative testing approach. We had the opportunity to shape and modify thousands of variations before settling on the performance and running focused designs you see today.
Development of Rebound Resin and Seamless 3D Printing Manufacturing System
At the start of the project, the New Balance team knew they needed a special material that did not really exist in the additive industry, as well as a large partner who could help implement the entire system. In 2017, the company announced a collaboration with Formlabs, introducing large-scale 3D printing technology at a manufacturing facility in Massachusetts.
Following an R&D program and bypassing hundreds of research formulations to create Rebound Resin, Formlabs worked closely with New Balance to create a manufacturing system that brings TripleCell technology to life and its potential.
Formlabs worked closely with New Balance throughout the project. Teams from both companies have collaborated from pre-R&D and iteration through hundreds of experimental formulations to development of the manufacturing cycle, including customized programming features, field support, and a dedicated supply chain.
“Everything starts and ends with the properties you can get out of what you create. You can run the world's fastest printer or have a million dollar printer, but it doesn't matter if the material properties can't withstand the product's intended use.” . says Ms. Dempsey.
New Balance and Formlabs have developed a custom material from the ground up for New Balance that can withstand the required industrial and consumer use.
The result of the joint work was the polymer Rebound Resin. Designed to create a springy, resilient lattice structure, this material delivers much more energy, tear resistance, and tensile strength than any other SLA material from Formlabs.
"3D-printed TripleCell components provide more responsive, spring-like cushioning than foam and can be made on request at our Massachusetts facility." - said Ms. Petrekka.
Rebound Resin is engineered to create a resilient, springy lattice structure and has greater tear strength and tensile strength than any other Formlabs SLA material.
“Everything starts and ends with the properties you can get from what you create. You can run the world's fastest printer or have a million-dollar printer, but it doesn't matter if the material properties can't withstand the product's intended use."
Dan Dempsey, Senior Engineer, New Balance Additive Manufacturing.
Pushing the boundaries of shoe design and manufacturing
The TripleCell collaboration will have a major impact on the expansion of 3D printing applications from prototyping to scalable manufacturing.
