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How a Running Shoe Is Made – From a Piece of Mesh to the Finished Shoe

6th March 2022

Building a running shoe is true craftsmanship. Workers assemble, sew, and glue together dozens of smaller and larger individual parts. At True Motion, there are about 50 such parts per pair. We will show you how a finished running shoe is made from a piece of mesh fabric and foam.

Content:

  1. Die-cutting the upper mesh

  2. Stitching the tongue

  3. No-sewing the eyestay

  4. Lasting the shoe

  5. Threading the laces

  6. Pressing the midsole

  7. Stockfitting the midsole

  8. Adjusting the midsole

  9. Packaging the running shoe

“The fit of a running shoe is crucial,“ says Andre Kriwet, running shoe developer and co-founder of True Motion. It’s what most runners love about their favorite shoe. If a shoe doesn’t fit well, it will ultimately not be purchased.

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“The fit is mainly determined by the last,“ explains expert Andre Kriwet. The plastic foot mold determines length, volume, all proportions, and the instep of a running shoe. Not surprisingly, the last is the sanctuary of running shoe brands.

This is true for True Motion as well. “We analyzed thousands of runners’ feet,“ the running shoe developer says. “From the results, we eventually created our current last.“ And that’s exactly what every running shoe at True Motion starts with – like the U-TECH Nevos next gen.

Die-cutting the upper mesh

01

Before a recognizable running shoe is created from the individual parts, a die-cut shape is used to cut out the upper from the mesh material used.

Stitching the tongue

02

In the next step, the workers sew the tongue of the shoe – and apply the label. Later, the finished tongue is attached to the upper. To prevent the tongue from slipping when running, it is stitched to the upper material with elastic elements.

No-sewing the eyestay

03

Before that, the eyestay is adhered to the upper, and the matching holes for the laces are punched. Oval elastic laces prevent the tied laces from coming undone when running.

Lasting the shoe

04

The upper is then shaped into a recognizable shoe shape for the first time. With the help of a kind of shoehorn, the workers manually last the shoe. The design of the shoe can be anticipated for the first time.

Threading the laces

05

During the next steps, the running shoe remains on its last. First, the workers thread the laces. The shoe is clamped in the toe area.

Pressing the midsole

05-01

At the same time, the midsole is pressed. That’s where True Motion’s unique horseshoe-shaped U is located. The patented U-TECH™ technology centers the forces generated during running and thus reduces the risk of running-related injuries.

Stockfitting the midsole

06

Next, the upper and the midsole are bonded together. The workers coat the bottom of the upper with adhesive and glue the upper material to the midsole.

Adjusting the midsole

07

Before the midsole is firmly bonded to the upper, the workers adjust the midsole with the help of a spatula-like tool. If the result is right, it is finally heat-bonded to the upper.

Packaging the running shoe

08

Once all 50 or so individual parts have been assembled, stitched, and stockfitted together, the final inspection takes place. The workers carefully check whether all parts fit properly. If this is the case, they place the running shoes in shoe paper and pack them in boxes. From there, they are sent to True Motion’s warehouse in larger outer boxes.

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