The new LightSpray Cloudmonster 3 Hyper is a performance running shoe from Swiss brand On that uses robotic manufacturing to form its upper in a continuous process. A robotic arm sprays a single filament of material onto a foot-shaped mold, creating a seamless upper in about three minutes without seams, laces, or glue and bonding it directly to the midsole through thermal fusing. The shoe is constructed from just eight components, a significant reduction compared with typical running shoes that are assembled from dozens of pieces.
The design pairs the sprayed upper with a thick Helion HF hyper-foam midsole set on CloudTec cushioning geometry to provide light support for long runs. Weighing about 205 grams for a men’s size US 8.5, the shoe is lighter than the standard Cloudmonster 3 model.
Image Credit: On
Why This Trend Is Growing
- Robotic Spray Manufacturing
- Robotic arms that spray continuous filaments onto molds are enabling rapid, low-waste production of complex soft goods with precise material placement.
- Seamless Single-piece Uppers
- A move toward one-piece, seam-free uppers bonded directly to midsoles is reducing part counts and altering traditional assembly workflows in performance footwear.
- Component Minimalism in Footwear
- Designs that pare shoes down to a handful of multifunctional components are simplifying supply chains and shifting value toward material and process innovation.
Industries Being Reshaped
- Athletic Footwear
- Performance shoe brands are positioned to benefit from manufacturing methods that deliver lighter, more integrated designs and shorter production lead times.
- Apparel Manufacturing
- Clothing and soft-goods producers can leverage spray-based fabrication to create seamless garments and accessories with novel material properties.
- Industrial Robotics
- Manufacturing robotics providers can expand into specialized end-effectors and process control systems tailored to precise deposition of polymer filaments onto three-dimensional forms.
