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From Patent to Possibility: Nike's Fabric-Integrated 3D Printing Technology

In February 2025, Nike was granted a U.S. patent US-12226973-B2 for a novel 3D printing method that could reshape the future of footwear manufacturing. Rather than announcing a new shoe, this patent reflects Nike's ongoing investment in research and innovation within additive manufacturing. Nearly three months since its approval, the implications of this technique are becoming clearer, especially as sustainability and customization remain high priorities in the industry.



A New Approach to 3D Printing Footwear

The patented method centers on a two-stage 3D printing process. First, Nike proposes printing digital patterns directly onto a flat piece of knitted, woven, or nonwoven fabric, forming the shoe's upper. This is followed by 3D printing the sole directly onto that same fabric layer, eliminating the need for gluing, stitching, or bonding multiple components together. The materials involved include resins, thermoplastics, polymers, or acrylics, which are deposited and then UV-cured to ensure strong adhesion and durability.


What distinguishes this method is its capacity for advanced customization.

Designers can strategically vary the material properties, adjusting support, flexibility, abrasion resistance, and rigidity, depending on the needs of specific foot zones. This opens the door to personalized performance gear, tailored to athletes or consumers based on biometric or usage data.


A Decade of Additive Manufacturing at Nike

Nike's involvement in 3D printing is not new. Back in 2013, the brand unveiled the Vapor Laser Talon football cleat, which used SLS technology for a lightweight footplate. In 2016, the brand partnered with HP to explore Multi Jet Fusion (MJF) capabilities and introduced the Zoom Superfly Flyknit for sprinter Allyson Felix.

These early efforts focused on prototyping and material experimentation.


The shift toward commercial application began with the Flyprint upper, launched with marathon runner Eliud Kipchoge in 2018. The Flyprint material was lighter than Flyknit and marked Nike's transition from experimentation to performance-grade product delivery. In 2024, Nike deepened this trajectory with the Zellerfeld-collaborated Air Max 1000, its first near-fully 3D printed sneaker.



Implications for the Footwear Industry

The fabric-integrated 3D printing approach presents several potential advantages. First, it dramatically reduces manufacturing steps, cutting down on labor and time. Second, by eliminating adhesives and overlapping materials, the final product is lighter and potentially more recyclable. Third, localized production becomes more feasible, especially when paired with digital customization tools.


Nike’s inventors on the patent, David P. Jones and Ryan R. Larson, are deeply involved in the brand’s additive and digital manufacturing initiatives. Their work suggests that Nike sees this technique not just as a concept, but as a viable direction for scaling future product lines.


As of May 2025, Nike has not yet commercialized this exact patent method. However, its existence highlights the brand’s continued pursuit of efficiency, personalization, and sustainability. Competitors like Adidas, Reebok, and Hilos are also exploring AI-assisted design and 3D production, so Nike’s method may serve as both a technical roadmap and strategic signal. Whether this technique evolves into a flagship product or remains a research milestone, it reinforces Nike’s commitment to shaping the next era of footwear design and manufacturing.


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