On is shaking up sneaker manufacturing with LightSpray, a fully automated, low-emission production process. And it all starts in Zurich.

Powered by robots and precision, this new facility is taking another look at what performance footwear can be.

A LightSpray Revolution

Zurich isn’t just the home of watches and chocolate anymore. Now it's the epicentre of a footwear revolution. Swiss running brand On has officially opened its LightSpray factory, a robotic production facility that swaps human assembly lines for high-tech automation.

Located at the company’s Zurich West headquarters, the factory marks the world’s first robot-operated sneaker facility. Instead of 200+ production steps and hundreds of workers, four robot arms now do the job, creating each shoe upper in just three minutes.

This is LightSpray, a game-changing production method. It uses a 1.5 km-long plastic filament, sprayed by robotic arms in a spiralling motion to form a seamless, lace-free upper. Without using glue or stitching. Just one smooth, sock-like fit. And, according to On, the process cuts CO₂ emissions by 75% compared to their conventional racing shoes. Fewer materials also mean it's easier to recycle once the shoe reaches the end of its life.

Built For Performance

The new shoe weighs just 170 grams, making it perfect for elite performance. It’s already made its Olympic debut, worn by On athletes at the 2024 Paris Games, where the company also hosted a public demo lab in the city centre.

While there’s currently only one model available, On is aiming higher with plans to open more robot-powered facilities in New York, Paris, and Tokyo. The company sees this as a way to localise production and minimise reliance on overseas supply chains.

“We can now manufacture locally and quickly,” says Olivier Bernhard, co-founder and former triathlete. “Robots allow us to scale without the traditional constraints.”

Right now, the Zurich robots can produce around 350,000 pairs annually, which is just a fraction of On’s 2 million shoes sold each year. But this is just the beginning.

With automated production that reduces costs, carbon footprint, and time, On’s LightSpray model points toward a more sustainable, decentralised future for performance footwear.

Curious to learn more about innovations in the footwear industry? Check out Reflawn's news page for the latest breakthroughs.

All Images: Logan Swney