New industrial process for footwear manufacturing using 3D Bonding

Project Information

3D Bonding

Grant agreement ID: 190199097

DOI

10.3030/190199097

Project closed

EC signature date 27 July 2022

Start date 1 August 2022

End date 31 July 2024

Funded under

• The European Innovation Council (EIC)

Total cost

€ 1 843 318,54

EU contribution

€ 1 290 322,00

Coordinated by

SIMPLICITY WORKS EUROPE SL
Spain

Periodic Reporting for period 2 - 3D Bonding (New industrial process for footwear manufacturing using 3D Bonding)

Reporting period: 2023-08-01 to 2024-07-31

Summary of the context and overall objectives of the project

The innovative 3D BONDING solution offers substantial benefits by enabling large companies to embrace CIRCULARITY within a traditionally linear industry. This is achieved through material conservation, reduced electricity consumption, and the reutilization of molds to create fresh designs. Notably, our approach empowers these companies to engage in small-scale production runs, mitigating the need for stockpiling necessitated by previous large-scale economies. As a result, both manufacturers and major corporations can enhance their competitiveness, fostering a transformative shift in the industry landscape. The 3D BONDING technology is rapid, modular, and automated manufacturing (utilizing cobots (collaborative robots), interchangeable molds, and on-demand production) without minimum order requirements, significantly shortening delivery times (shaving off months), facilitating swift adaptation to market and Fashion Trends. Other benefits of the use of this expertise in the selected footwear area can be emphasised:

● Footwear is designed for comfort (seamless construction).
● Superior quality footwear (enhanced product performance by 30 %).
● Environmentally friendly footwear (13 % decrease in carbon footprint compared to conventional shoes, equating to 7.6 kg CO2 per pair).
● Attractive and affordable footwear choice.
● Substantial savings in labour, materials, and waste (achieving a 75 % reduction).
● Appealing and affordable footwear options for customers (large enterprises can introduce 3D Bonding footwear while upholding quality and customer loyalty).
● Integration of 3D Bonding Technology into their factories empowers them to manufacture quality footwear competitively, paving the way for a transition to a more CIRCULAR BUSINESS model.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The project has successfully achieved its objectives, outcomes, and milestones within the first year. In summary, the project has met its technical goals, with the:

- Design and construct of a Smart Production Line machinery for footwear manufacturing through 3D Bonding process. Conducting comprehensive work related to technology implementation (mechanical design, element dimensions, assembly construction, shoe design, and scaling) and determining optimal conditions for footwear production.
- Smart Production Line enabling the design, testing, and production of manufactured shoes (100 pairs/day) during this initial funding period.
- Performed an in-depth analysis of the shoes, studying their durability, comfort, usability, and resistance, among other factors, in accordance with regulations, confirming the high-quality standard of the produced footwear.
- To effectively administer the work plan and to ensure completion of tasks, WPs and the project, maintaining the schedule regarding the deliverables and milestones.
- To engage with various stakeholders, including potential collaborators and customers.
- To ensure compliance with the 'ethics requirements'.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

Traditional footwear technologies base their production on stitched seams, which is a labour-intensive technique to join diverse materials such as fabric, leather, or textile. The process is complex and involves many steps which has led the industry to move production to low labour cost locations (Asia). The assembly and production also imply high waste generation.

3D Bonding technologies enable footwear manufacturers, in the EU:

- Agile, modular and automated manufacturing (cobots, interchangeable moulds, production on demand) that does not require minimum order quantities and that is delivered faster (saving months) which enables a faster adaptation to market and fashion trends.
- Attractive and affordable footwear choice
- Substantial savings in labour, materials, and waste (achieving a 75 % reduction).
- Lower CO2 footprint (13% less, 7.6 kg CO2 per pair) to comply with regulations and/or apply for compensation.
- Desirable and affordable footwear for customers (large companies can introduce 3D bonding footwear while maintaining quality and customer base).
- Implementation of 3D bonding can make them able to produce quality footwear at competitive prices and transition towards a more circular business model.
- European production - no Asia dependency.