Going against the usual bottom-up manufacturing process implemented by the footwear industry, Swiss company On opts for a different approaches, including one that goes from the top down.
One of their latest innovations is called 'LightSpray' technology, an ultralight, one-piece upper that is sprayed onto the shoe by a robotic arm.
Through this technology, On has reached breakthroughs for both running performance and sustainability.
Image source: On
Automation meets Athleticism
LightSpray is made in a fast, one-step manufacturing process, all done by a robotic arm. It's ultra-thin, adaptable to the foot, seamless and lace-free. Most importantly, each shoe upper is fully assembled in just three minutes.
This fast approach is not only efficient but also plays a key role in enhancing the sustainability of On's products. For instance, this technology allows for glueless bonding, cutting out all unnecessary excess and processes, like yarn and textile formation, conventional colouration or increased water consumption. The result is less waste and fewer parts, with a 75% reduction in CO2 emissions compared to other racing uppers.
Image source: On
Additionally, no laces means no distractions, which is why this design is revolutionising running performance.
This shoe upper is the lightest yet, weighing only 30 grams, with a second-skin fit that reduces chafing to improve focus. Paired with a propulsive bottom unit, On created the Cloudboom Strike LS, which features a carbon-fibre Speedboard between two layers of Helion HF hyper foam for high energy return and impact absorption. A shoe which has already been seen on podiums in Boston, Paris, and New York, proving the success of this new technology.
Image source: On
A new chapter in Performance footwear
In the long run, On’s approach could signal a shift for the entire industry. By using robotic systems that can work anywhere, they could decentralise production, reducing transportation emissions and allowing for more adaptive, on-demand manufacturing.
With its blend of speed, sustainability, and sleek design, the Cloudboom Strike LS is more than just a fast shoe. It’s a symbol of what happens when cutting-edge technology meets ecological urgency. In an industry more than often driven by tradition and convenience, On has once again proved that responsible innovation can lead the pack.
Discover more about the brand On and its sustainable practices here.
What is LightSpray?
LightSpray is an innovative manufacturing process developed by On that uses a robotic arm to spray an ultralight, seamless upper directly onto the shoe. This one-step method replaces traditional, multi-part assembly, making the production faster, more sustainable, and more precise.
How is LightSpray more sustainable than traditional methods?
LightSpray eliminates excess materials and processes such as textile weaving, dyeing, and gluing. It reduces CO₂ emissions by up to 75% compared to conventional racing shoe uppers and cuts water usage.
