From print bed to pavement: How Footwearology leverages flexible filaments

Based in Barcelona, Spain, Footwearology is an innovation lab and academy dedicated to reimagining the future of the footwear industry. Through a mix of research, consulting, and education, the lab equips professionals with the tools and knowledge to embrace advanced manufacturing technologies. From online and in-person training to hands-on prototyping, Footwearology bridges the gap between creative vision and production-ready solutions.

At the heart of its work is a commitment to reshaping the footwear supply chain - connecting technology providers, designers, and digital platforms to drive more sustainable, localized, and customized production models. Its fully equipped lab includes state-of-the-art 3D knitting machines and FDM (Fused Deposition Modeling) 3D printers, providing a platform to explore innovative materials and methods.

One of its core technologies is the UltiMaker Factor 4, a high-performance FDM printer that enables reliable production with flexible materials like TPU. This capability supports Footwearology’s goal of developing recyclable and wearable footwear components that meet both functional and environmental standards.

Advancing footwear manufacturing through material innovation

Footwearology was established with a clear objective: to transform the global footwear supply chain by enabling localized, on-demand production that supports both sustainability and personalization. Recognizing the potential of additive manufacturing early on, the team identified FDM as the most viable technology to meet their requirements for scalability, adaptability, and material efficiency. According to CEO Nicoline van Enter:

FDM allows for affordable production and better sustainability compared to powder or resin-based methods, especially for flexible items. Our materials can be fully recycled or compostable, which is important for us.

Rather than viewing 3D printing solely as a prototyping tool, Footwearology embraces it as a production technology. Its vision centers on a decentralized, “network production” model, where regional manufacturing hubs can produce personalized footwear on a large scale. This approach significantly reduces material waste, transportation emissions, and inventory, while supporting customization based on individual biomechanical profiles.

The role of TPU in performance and sustainability

Footwearology’s material selection is a core part of its strategy. Thermoplastic polyurethane (TPU) has proven to be particularly well-suited to footwear applications due to its durability, flexibility, and recyclability. These qualities enable the team to engineer parts with variable stiffness and cushioning, allowing them to meet specific user needs, such as adjusting support based on body weight or gait.

Footwearology collaborates with 3rd party material manufacturer Recreus to create custom colours for TPU filaments. These filaments come with different properties, with various weights and densities.

The company prioritizes recyclable TPUs to align with its sustainability goals and is actively researching compostable alternatives. This focus on materials science ensures that their products are not only functional and wearable but also designed with circularity in mind. By integrating sustainability at the material level, Footwearology supports the broader transition toward environmentally responsible manufacturing in the footwear industry.

Selecting the UltiMaker Factor 4: Reliability for demanding applications

Following years of experience working with and modifying 3D printers to accommodate flexible materials, Footwearology identified the UltiMaker Factor 4 as an ideal platform for advancing its production capabilities. Having collaborated with UltiMaker during earlier development stages, the team recognized Factor 4’s potential to meet the technical demands of their work, particularly for high-precision printing with soft, complex geometries.

Thanks to its multi-material printing option for flexible materials, we can print an entire shoe using the Factor 4.

Key features such as an enclosed build chamber, consistent thermal management, and dual extrusion capabilities make the Factor 4 especially well-suited for printing flexible materials like TPU.

Factor 4’s dual gripper direct drive extrusion system plays a key role in its ability to handle flexible materials with precision and control. Unlike Bowden-style setups, direct drive extrusion ensures a shorter filament path, reducing the risk of material deformation or clogging, common issues when printing with soft materials like TPU. The dual gripper mechanism adds extra stability and grip, allowing for consistent material flow even during complex or high-speed prints.

These capabilities have enabled Footwearology to produce wear-ready footwear components with high repeatability, dimensional accuracy, and minimal post-processing.

We’ve always valued how easy UltiMaker is to use - especially how effortlessly the print core can be changed.

The integration of UltiMaker’s Digital Factory software has also proven to be a game-changer for Footwearology. The software’s capabilities for profile management have streamlined their production, allowing for better scaling and management of multiple printers.

Another reason we want to keep working with UltiMaker is Digital Factory. The software integrates seamlessly with our workflow,” says Nicoline*

Footwearology’s team can now easily switch between print profiles and print settings, which helps optimize material usage, quality, and speed - something they previously had to manage manually with other 3D printers.

Bridging innovation and industry

As it continues to explore the boundaries of digital manufacturing and material science, Footwearology remains focused on advancing sustainable, scalable solutions for the footwear industry. Its ongoing partnership with UltiMaker and the use of the Factor 4 are integral to achieving this vision - enabling new levels of customization, efficiency, and environmental responsibility in footwear design and production.

Looking to expand your operations and innovate with 3D printing? Talk to UltiMaker experts today.