Carbon’s Foam Revolution: Reinventing Shoe Midsoles with Printed Structures

In a landscape crowded with additive manufacturing players, Carbon is carving out a unique path by shifting focus from selling printers to delivering structural solutions. As Carbon CEO Phil DeSimone puts it, “I’m not selling a printer. I’m selling a product line.”

To him, true innovation does not come from print resolution or material specs but from solving real-world design problems. “Avoid the 3D printing labs at big companies. That’s where printers go to die,” he said. “You need to go to the design engineers and ask them, ‘What problems do you have that we can solve?’”

Carbon’s strategy centers on embedding itself in product development from the start. This is especially true in performance footwear, where the company works directly with design and engineering teams to create functional structures that competitors cannot replicate.

Midsole Innovation: Replacing Foam with Lattice

The midsole is the most functionally demanding part of a performance shoe. Traditionally, it is made from over a dozen foam components, each with different densities to provide various levels of cushioning, support, and rebound. This method is not only labor-intensive but also limits design flexibility.

Carbon offers a radically different approach using lattice structures. These are custom-designed 3D grids that allow for continuous performance variation within a single printed part.

Lattice, in this context, refers to a parametric mesh framework. It may resemble a honeycomb or scaffold, but every cell is engineered to control softness, compression, and responsiveness. By adjusting geometry rather than materials, Carbon can fine-tune the entire midsole with exceptional precision.

“In a typical running shoe, you’d need 13 different types of foam to achieve what we can do with one printed lattice,” DeSimone explained. “We can deliver all of those compression properties in one part just by changing the design.”

This means brands can create midsoles that transition smoothly from heel to toe without gluing or layering materials. The result is better performance and a more efficient production process.

Footwear Applications Are Already Underway

Carbon’s lattice midsoles are currently being tested in the development pipelines of several athletic brands, particularly in categories such as performance running and training. Their solution provides consistency, durability, and customizable comfort. These attributes make it ideal for brands seeking precise performance differentiation within a single shoe.

One proven case comes from the cycling industry. Carbon collaborated with Specialized on a bike saddle that uses a similar lattice-based approach. “We can produce over two dozen compression zones within a half-inch area,” said DeSimone.

“Some areas need stiffness, others need comfort. The ability to control that in one structure is our biggest differentiator.”

That same level of precision and structure customization is now being translated into footwear midsoles.

A New Model for Footwear Differentiation

Historically, footwear brands have relied on materials, colors, or branding to differentiate their products. Carbon introduces a deeper layer of innovation through performance customization via structure. With lattice design, brands can tailor midsoles to meet specific needs such as long work shifts, endurance runs, or injury prevention. This is all achievable without changing the base material.

Since lattice structures are digitally generated, they are naturally compatible with foot scanning and motion data. This opens up real possibilities for meaningful personalization at scale.

Structure-First Innovation Resets the Market

Carbon’s approach is not just about new technology. It is a new model for market growth. By establishing success in one vertical, such as bike saddles, earning customer trust, and applying that knowledge to other sectors like footwear, Carbon is building a product-driven ecosystem.

Structural printing also streamlines manufacturing. It reduces labor, minimizes material waste, and improves consistency. In a market that increasingly demands sustainability and user-specific performance, this could mark a real shift.

As DeSimone put it, “I’ve seen enough at this point to know we’ve got the winning strategy. Five years from now, people will look back and realize this was the right way to go.”

When the additive manufacturing industry stops chasing specs and starts solving product-level problems, the potential becomes far more real. For footwear, lattice structures offer more than a material upgrade. They offer a way to rethink how midsoles are made, how they perform, and what truly makes one shoe stand apart from another.

Sources: 3dprint.com | carbon3d.com | additivemanufacturingstrategies.com

Images: 3dprint.com