How On Makes Spray-On Sneakers In Minutes
In the world of footwear, innovation often comes from subtle tweaks to materials, cushioning, or design. But Swiss running brand On has taken a bold leap with a process that reimagines how a shoe is made in the first place. Their new LightSpray™ technology produces a sneaker upper not by stitching or gluing multiple components together, but by literally spraying it on. What once took factories days or weeks can now be accomplished in as little as six minutes.
This breakthrough could reshape how we think about footwear manufacturing, sustainability, and even the shoes on our feet.
From Fabrics to Filaments
Traditional sneakers are complex constructions. The upper alone — the part that covers the foot — usually requires dozens of fabric pieces, each cut, stitched, or glued into place. The process is labor-intensive, wasteful, and involves shipping materials around the globe. On’s LightSpray turns that process on its head by reducing the upper to a single, continuous sprayed-on material.
The secret is thermoplastic polyurethane (TPU), a versatile, durable plastic commonly used in performance gear. In On’s process, TPU is heated, extruded into a filament, and sprayed in fine, controlled streams. Instead of sewing panels together, the robot sprays TPU directly onto a foot-shaped mold — called a “last” — building the upper layer by layer.
Step by Step: Building a Spray-On Shoe
The process looks futuristic, but it is elegantly simple in concept:
- The foot form (last):
The journey begins with a foot-shaped mold mounted on a robotic arm. This serves as the canvas for the sprayed material. - The spray process:
A robotic nozzle emits a filament of TPU, spiraling and weaving across the last. As the robot rotates the mold, the filament adheres to itself, forming a seamless upper. Unlike traditional assembly, no glue or stitching is needed — the material fuses on contact. - Fine-tuned performance zones:
On can vary how close the nozzle is to the last, or how tightly the filament is layered. A denser weave creates support in areas like the midfoot, while a looser spray pattern allows breathability in zones such as the forefoot. This means the shoe can be customized for stretch, support, and airflow without adding extra parts. - Finishing touches:
Once the upper is complete — a process that takes roughly three minutes — a second robotic arm applies color and finish. The entire sneaker, upper and all, can be built in six minutes flat.
Why It Matters
This innovation is not just a flashy gimmick; it addresses several longstanding challenges in footwear manufacturing:
- Speed:
Traditional sneaker production involves long assembly lines and global supply chains. LightSpray condenses that into a near-instant process. - Sustainability:
Because TPU is sprayed only where it’s needed, waste is drastically reduced. On claims the process cuts the carbon footprint of the upper by about 75% compared to conventional methods. - Simplicity:
Fewer parts mean fewer opportunities for error, less inventory complexity, and shorter transport chains. The shoe is, in essence, printed rather than assembled. - Customization potential:
With a software tweak, the spray pattern could be adjusted to fit different performance needs, foot shapes, or even personalized designs.
A Glimpse of the Future
On’s spray-on shoes still face questions of scale, durability, and consumer acceptance, but the promise is undeniable. Imagine a future where a shoe could be made to order in a store within minutes, tailored to your foot shape and style preferences. Instead of mass-produced, one-size-fits-all models, footwear could become hyper-personalized.
For athletes, this might mean racing shoes fine-tuned for their stride. For everyday wearers, it could reduce the need for mass production and make shoes more sustainable. And for the industry, it represents a radical shift from sewing machines and cutting tables to robotic spraying arms.
The sneaker industry has always thrived on innovation, but On’s spray-on sneakers mark a leap toward a new era of design and manufacturing. By replacing wasteful, complex methods with a precise, robotic spray, On is showing that shoes can be made faster, cleaner, and smarter.
What once sounded like science fiction — a shoe sprayed into existence — is now reality. In just six minutes, the future of footwear takes shape, filament by filament.
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