Traditionally, crafting a single shoe involves up to 300 people along the production line. However, with On’s new LightSpray technology, this task is accomplished by a single robot, revolutionizing the efficiency and speed of production. “The shoe is ready in three minutes,” explained Caspar Coppetti, co-founder of On, highlighting the transformative potential of this technology.
At the heart of this innovation is a robot developed in collaboration with industrial group ABB. The process involves spraying a fine, robust plastic thread in a spiral pattern around a shoe last, directly onto the sole. This creates the shoe’s upper in a single, seamless operation, eliminating the need for seams or glue. The result is a lightweight competition shoe weighing just 170 grams, featuring a futuristic design and reduced production CO2 emissions by 75%.
This cutting-edge shoe can be worn like a sock, with a seamless upper that fits snugly without laces, adapting flexibly to the foot’s shape. Such advancements were showcased at the 2024 Olympic Games in Paris, where On athletes donned the new shoes, and the company presented the technology through a pop-up laboratory in the city center.
Despite its innovative design, the Light Spray shoe currently exists as a single model, priced at CHF360, reflecting its premium positioning and the complexities involved in its production. “The big challenge now is scaling up,” noted Olivier Bernhard, former triathlete and co-founder of On, during an interview with AWP. He emphasized the potential for fully automated production to reduce reliance on traditional manufacturing supply chains, allowing for local and rapid manufacturing.
On’s vision extends beyond a single production facility. The company has plans for additional global production sites, aiming to leverage this technology’s strategic advantages over conventional methods. As the footwear industry looks towards sustainability and innovation, On’s Lightspray technology could set a new standard for manufacturing efficiency and environmental responsibility.
The move represents a bold step into the future of footwear, as On continues to push the boundaries of design and production. As experts and industry insiders watch closely, it remains to be seen how this technology will influence broader manufacturing practices and consumer expectations in the years ahead.
