New Balance steps up the game with 3D printed soles

Sporting goods manufacturer, New Balance will be launching the first running shoe with a 3D printed midsole.

Through an exclusive collaboration with 3D Systems and its newly developed elastomeric powder, DuraForm® Flex TPU, New Balance says it has made significant advancements in the performance of printed parts for running shoes.

According to the company, the new midsoles leverage the benefits of 3D printing and breakthroughs in materials science to achieve an optimal balance of flexibility, strength, weight and durability.

New Balance 3D Printed Performance Running Shoe Midsole
New Balance 3D Printed Performance Running Shoe Midsole

This limited edition, advanced running shoe will launch first in Boston in April 2016 and then in select New Balance retail locations around the globe.

The shoes will also be on display and in use by employees in the 3D Systems booth at the 2016 Consumer Electronics Show (CES) in January.

The latest designs of the 3D printed midsole are based on underfoot pressure data from heel strikers with more cushioning elements in areas of higher average pressure.

For midsole production, New Balance uses selective laser sintering (SLS), a process which converts new powder materials into solid cross-sections, layer by layer, using a laser.

DuraForm® Flex TPU powder gives the resulting parts a previously unavailable combination of strength and elasticity that is ideal for performance running shoes.

Want to learn more about 3D printing for manufacturing?

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“This project represents an unprecedented technical collaboration in footwear”, says Sean Murphy New Balance Senior Manager of Innovation and Engineering.

“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. These are the types of collaborations that will drive footwear design and manufacturing in the future.”

New Balance Football Athlete Aaron Ramsey Reviewing Data with Pedro Rodrigues from the New Balance Sports Research Lab
New Balance Football Athlete Aaron Ramsey Reviewing Data with Pedro Rodrigues from the New Balance Sports Research Lab

In 2013 New Balance was the first athletic brand to have a track athlete, middle distance runner Jack Bolas, compete with data-customised, 3D printed spike plates.

Since then Team New Balance athletes have continued to compete in custom, printed spikes including US Olympic Athlete Kim Conley at the 2014 USATF Outdoor National Championships where she came in first in the 10,000m.

Beyond Track & Field New Balance has also created customized soccer cleats and baseball spikes for its elite athletes. New Balance soccer star Aaron Ramsey wore a bespoke boot with printed plates in the FA Cup Final on May 30, 2015.

“In 2013 we said this was the future of footwear manufacturing and today we are proud to bring the future to consumers with a fully 3D printed midsole,” says New Balance President and CEO Robert DeMartini.

“With 3D printing we are able to pursue performance customisation at a whole new level. The New Balance Innovation Team is showcasing the latest in performance running and these advancements signify an important step forward to becoming one of the world’s top athletic brands.”