New system for shoe manufacturing

Considered one of the biggest changes in the last 40 years for the footwear production, the Spanish company SIMPLICITY WORKS has made available to the market its innovative 3D BONDING TECHNOLOGY manufacturing system. It has the collaboration of HUNTSMAN Polyurethanes and DESMA, both leading brands in the field of chemicals and polyurethanes products, and technology for injection.

The joint work of the three companies has created a highly automated and cost-effective way of joining two-dimensional components, in a single operation, to form a seamless three-dimensional upper part.

The 3D BONDING technology, patented by SIMPLICITY WORKS, is the only one in the world, which does not require seams and adhesives, and the process simultaneously joins all footwear pieces in just a few seconds.

Faster and cheaper than conventional shoe manufacturing techniques, the new technology can be customized to meet the requirements and is already being implemented in several footwear companies of greater brands, helping them align local production overhead with countries of lower labor cost.

Process description

3D BONDING technology uses a set of 3D molds created by SIMPLICITY WORKS, different from direct injection, in which the parts are introduced inside. An injectable material with adhesive functions, specifically designed by HUNTSMAN Polyurethanes and a state-of-the-art DESMA injection molding machine.

In the first step, the individual upper components of the uppers are placed in the mold, in slots separated by narrow channels, similar to the assembly of a puzzle. A countermould presses each piece in its place. Through the network of channels between the upper components, the high-performance adhesive polymer is injected, all at once. The end result is an upper part of the shoe joined by a polyurethane flexible skeleton, which is functional and elegant. Various materials such as leather, textiles, synthetics, rubbers, wood, metals, etc. can be joined.

The technology is flexible, which means that shoe manufacturers can choose to use it as the main joining technique or combine it with traditional sewing methods for functional or decorative purposes.

Lower costs and greater comfort

With this technology, all types of footwear can be created and makes it possible for productions outside countries with low labor costs to be much more competitive.

With no seams to perform, the overall production process requires less labor, which reduces overhead. Material costs are also lower since there are no overlapping areas and much less waste. From the consumer perspective, there are additional benefits. Without knitting or seams lines, and without overlaying materials, shoes have fewer friction and pressure points, and behave more like a pair of socks. Shoes are also more waterproof since there are no needle holes or permeable seam lines.

To meet the new needs of the market

The launch of the 3D SIMPLICITY WORKS joining process culminated six years of work between the three companies, who passionately believe in the ability of technology to supplant conventional forms of footwear production.

Adrián Hernández, CEO of SIMPLICITY WORKS and inventor of 3D BONDING TECHNOLOGY, said: “I have worked in the footwear industry for 25 years, in different countries and continents, so I am very familiar with the complexities involved in the conventional footwear production. Six years ago, I realized that there was a way to simplify shoe manufacturing. Desiring to correct the geographical balance in the footwear industry in terms of labor costs, I came up with a new radical process that can make footwear production in America and Europe more profitable, while increasing comfort for consumers.”

“Working closely together for the past six years, our three teams have combined knowledge and experience to create a process with the potential to renew the footwear sector. The timing could not be better. Currently, it is estimated that 80% of European footwear imports come from countries with low labor costs. Given the increase in costs in these territories, many shoe companies seek to move their productions to Europe and America. Our 3D BONDING technology allows them to do exactly that, produce cheaper shoes than in Asia, in addition to taking into account the savings in transportation costs.”

Partner opinions

HUNTSMAN

Johan van Dyck, Global OEM Business Development Manager at HUNTSMAN Polyurethanes, said: “The SIMPLICITY WORKS requirement was demanding, but we liked the challenge! They wanted us to develop an injectable polyurethane reagent system, which combine excellent adhesion properties with an extreme flow capacity of the product. The material also had to offer comfort and damping, along with excellent finishing aesthetics. Using our many years of experience in solutions, we set out to develop appropriate technology. It was a long process, with several necessary revisions along the way, but now we have a revolutionary platform for the union of one or two shots. Our work on this project has allowed us to extend our long-standing relationship with DESMA and forge a new alliance with SIMPLICITY WORKS, a business team committed to changing the future of footwear manufacturing.”

DESMA

Christian Decker, CEO of DESMA, said: “We are a technological leader in the global footwear industry and we have been providing advanced machinery and mold to manufacturers for more than 70 years. The principles of smart, innovative, sustainable and automated footwear production are at the heart of our business, which makes us a natural partner for SIMPLICITY WORKS. We are delighted to participate in this project, working with two renowned partners, to provide producers with a means to manufacture highly sophisticated footwear, in countries with high labor costs, in a more economical way.”