New Balance, a global leader in athletic shoes, has announced a specialized process for 3D printed shoes, focused on their high performance products for athletes. Elite athletes can now have their spike plates customized to individual specifications and created using 3D printing.

“With 3D printing we are able to pursue performance customization at a new level to help our elite NB athletes and eventually all athletes. We believe this is the future of performance footwear and we are excited to bring this to consumers,” said New Balance President and CEO Robert DeMartini. “As the only major athletic brand to manufacture shoes in the U.S., we are proud to invest in American workers.    Developing our printing capabilities could ultimately help us further invest in the American worker by adding highly technical positions to our already skilled labor force in Massachusetts and Maine.”

More from the New Balance press release.

New Balance has developed a proprietary process for utilizing a runner’s individual biomechanical data to create hyper-customized spike plates designed to improve performance.  The process requires race simulation biomechanical data which the New Balance Sports Research Lab collects using a force plate, in-shoe sensors and a motion capture system.   Advanced algorithms and software are then applied to translate this data into custom 3D printed spike designs.

For the production of the custom plates, New Balance uses selective laser sintering (SLS) to convert powder materials into solid cross-sections, layer by layer using a laser.  SLS printing enables the customization process by allowing for complex designs that could not be achieved through traditional manufacturing methods.  Additionally, SLS printing greatly accelerates the turnaround time from design to functional part.

NB Athletes involved in the development of this process included: 2008 and 2012 US Olympic Athlete and current 1500m World Champion gold medalist Jenny Barringer Simpson, 2012 US Olympic Athlete Kim Conley, 2012 Great Britain Olympic Athlete Barbara Parker and 4 time All-American runner in the 800m, 1500m and the Mile Jack Bolas. These athletes provided key feedback in order to develop spike plates that spoke to each individual athlete’s personal preference, biomechanics and specific race needs.

“Utilizing our Team New Balance Athletes to develop the customization process was extremely helpful”, said Sean Murphy, New Balance’s Senior Manager of Innovation and Engineering.   “We are impressed with their precise ability to identify and speak to the differences in the custom options provided.  They are acutely aware of what is happening in their shoes”.

In addition to printing semi-rigid parts like spike plates for track runners, New Balance is working on softer SLS printed components that mimic the cushioning properties of foam midsoles.  This initiative will be critical to bringing the customization process to a broader audience of athletes .

At the New Balance Games in January 2013, Team New Balance athlete, Jack Bolas, became the first ever track athlete to compete in customized, 3D printed plates.

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A roundup of the top news On 3D Printing brought you from July 9 to July 15.

Monday, July 9

• Shapeways Friday Finds: Anvil Cufflinks, Ceramic Ducks

Tuesday, July 10

• Designed to Win: 3D Printing Could Help Athletes Break World Records
• Moddler is Making the Market in High-End 3D Printing [Video]

Wednesday, July 11

• Enter the 3D4D Challenge to Win $100K and Change the World

Thursday, July 12

• 3D Printing Presents Long-Term Threat to Otherwise Healthy Toy Stocks

Friday, July 13

• 3D Printing Architecture From the Cloud with 3D Model-To-Print Service
• Bring Children’s Books Alive: 3D Printing The Very Hungry Caterpillar

Will 3D printing make a difference at the next Olympics?

French designer Luc Fusaro has developed a new technique for custom-fitted track shoes using 3D printing. His project, called “Designed to Win”, produces the lightest sprint footwear ever made at just 96 grams and is fitted to match the physical properties of the runner’s foot.

3D printing is the only way to create shoes this light and with such a perfect, custom fit.

Fusaro’s approach utilises a similar approach using bespoke manufacturing processes. Following 3D scanning of the athlete’s feet, a “one shot” full sprint shoe is produced, complete with traction elements and shoelace features, and is the very first sprint shoe fully made with additive manufacturing. The SLS (selective laser sintering) process, known for being ideal for a constantly changing design process, is also one of the strongest in the range of additive manufacturing.

Fusaro claims that the shoes can improve running performance up to 3.5%, which should enable top athletes to break world records in track.

The video below shows how the shoes are made and depicts athletes testing the shoes.

Via Luc Fusaro and PSFK.