Huntsman Polyurethanes' unique shoemaking materials are at the core of innovative footwear manufacturing methods that have the potential to change the way footwear is produced worldwide. Spanish company SimplicityWorks, in cooperation with Huntsman Polyurethane Co., Ltd. and DESMA Shoe Machine Company, has created the biggest change in the field of footwear assembly in 40 years, and has developed a revolutionary new method of footwear production. Manufacturers of products closer to customers in Europe and North America offer the possibility to change the rules of the game. In collaboration, the three companies have created a highly automated, cost-effective way to glue two-dimensional components together to form a seamless three-dimensional upper.
Simplicity Works' patented 3D bonding technology is the world's first technology. This process requires no sewing and takes less time, and it only takes a few seconds to connect all parts of the shoe at the same time. Compared with traditional shoemaking technology, this new technology is faster and cheaper, and can be customized according to demand. The technology has proven to be popular among many large-brand footwear companies, as it helps them align local production costs with countries with low labor costs.
This 3D bonding technology uses innovative 3D mold design created by Simplicity Works; injectable materials specially designed by Huntsman Polyurethane Co., Ltd .; and the most advanced DESMA injection molding machine. In the first step, the individual upper components are placed in a mold and placed in slots separated by narrow slot channels, a bit like jigsaw pieces together. After that, each part is pressed into place using a reverse mold. The high-performance polyurethane material developed by Huntsman was then injected into the network of channels between the upper components in one shot. The end result is an upper that is held together by an elastic polyurethane structure, which is both practical and fashionable. In order to obtain a high-quality polyurethane foam structure, to form a durable upper, and a high-definition texture, Simplicity Works and Huntsman have extensively researched new processes and materials. Available in a variety of colors, the texture of bonded polyurethane threads (or strips) can be varied, which means that designers can choose a glossy or matt texture and compare it with many other similar textile Combination of surface processing methods.
3D bonding technology is suitable for a variety of footwear manufacturing and is compatible with a variety of different synthetic and natural materials, which can make footwear manufacturing outside the low labor cost country more cost competitive. Because no seams are required, the labor intensity of the entire production process is lower and production costs are reduced. Since there is no material superimposed part, the material consumption is reduced, and the material cost is reduced. From a consumer perspective, this technology has other advantages. Shoes have no knitting or sewing threads, no material flanging, less friction and pressure points, and they look more like a pair of socks. With no pinholes or permeable seams, shoes are also more waterproof.
With the launch of Simplicity Works' 3D bonding process, the three partners have reached their peak in 6 years of work. They fully believe that this technology can subvert the traditional method of footwear production. "I have worked in the footwear industry for 25 years and have worked in different countries and continents, so I am very familiar with the complexity of traditional footwear production," said Adrian Hernandez, CEO of Simplicity Works and inventor of 3D bonding technology. Six years ago, I realized that there was a way to simplify the manufacturing of footwear. I wanted to be able to correct the geographical balance of the footwear industry in terms of labor costs, so I came up with a new process that would enable footwear production in North America and Europe More cost-effective, while also increasing consumer comfort. With my patented concept, I started looking for partners to make my vision a reality; this led us to work with Huntsman and DESMA Cooperation."
He continued: "In the past six years, our three teams have worked closely to bring together their expertise and expertise to create a process that has the potential to transform the footwear industry. The timing couldn't be better. Currently, An estimated 80% of European footwear imports come from low-cost labor countries. Faced with rising costs in these regions, many footwear companies are looking to shift production back to Europe and North America. Our 3D bonding technology enables them to do this A bit, to create shoes that are more economical than made in Asia, and this has not taken into account the savings in transportation costs. "
Johan van Dyck, Global OEM Business Development Manager for Huntsman Polyurethanes said, "Simplicity Works is demanding, but we like challenges! They want us to develop a reactive, injectable polyurethane system that needs to have excellent adhesion Performance and high product flow. The material must also provide comfort and cushioning, as well as a superb finishing aesthetic. Using our many years of experience, we set out to develop the right technology. This is a long process that requires Various improvements, but we now have a revolutionary technology platform that can perform single-sided or double-sided bonding. Our work on this project has allowed us to expand our long-term partnership with DESMA, and A new alliance with Simplicity Works-Simplicity Works is a business team dedicated to changing the future of footwear manufacturing. "
Christian Decker, CEO of DESMA, said: "We are the technology leader in the global footwear industry and have been providing manufacturers with advanced machinery and molds for more than 70 years. Intelligent, innovative, sustainable, automated footwear production The principle is the core of our business, which makes us naturally become a partner of Simplicity Works. We are very happy to participate in this project and cooperate with the team of Simplicity Works and Huntsman Polyurethanes to provide footwear manufacturers with a workforce A more cost-effective way to make premium footwear in more expensive countries. "
Simplicity Works' 3D bonding technology is very flexible, which means that footwear manufacturers can choose to use it as the main joining technology or combine it with traditional stitching methods for functional or decorative purposes. Simplicity Works has patents on its technology, and engineers use CAD software to design products for customers. Once the product design is complete, Simplicity Works will develop all the tools and molds needed for footwear production. This know-how was then transferred to the manufacturer and worked with Huntsman and Desma to determine mechanical and polyurethane specifications. 3D bonding technology can significantly reduce production costs. Simplicity Works charges a certain percentage of technical use costs. DESMA provides all the necessary mechanical and automated systems. Huntsman provides the best polyurethane materials with 3D bonding technology. in production. "
Simplicity Works' 3D bonding technology is incredibly versatile and has the potential to add value outside the footwear industry. The company is exploring opportunities to use this general manufacturing method to make clothing, accessories and even furniture.