Let’s take a look at the shoe manufacturing process and understand how shoes are made through various stages. When it comes to producing sneakers as the standard, there are several processes involved. In this discussion, we will focus on key processes and provide a basic overview of each.
Shoe Manufacturing Process
The shoe manufacturing process can be broadly divided into two main parts: Upper and Bottom. The Upper manufacturing process consists of Lamination, Cutting, Preparation for Sewing, and Sewing. On the other hand, the Bottom manufacturing process includes Midsole production, Outsole production, and Insole production. Please refer to the diagram below:
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| shoe manufacturing process |
In the diagram above, we have listed the essential processes in shoe manufacturing. However, there are many hidden processes that are equally important. For example, in models where the No-Sew technique is applied instead of sewing, equipment like No-Sew machines is used. Additionally, processes such as printing and creating pellets for production are also significant.
We will explore the major processes and related equipment in detail in subsequent updates. For now, let’s focus on the key aspects of the shoe manufacturing process.
Upper Manufacturing Process:Shoe Manufacturing Process
Lamination:
Lamination involves the bonding of multiple layers of materials to create the material for the shoe’s upper. Different materials are combined to form the upper material, depending on the shoe’s design. This process is carried out using laminating machines, and it can be categorized into methods like water-based lamination, film lamination, and sticker lamination.
Cutting:
Cutting is the process of cutting individual pieces from the laminated material according to the shoe’s design. The components of a shoe, such as the toe cap, vamp, quarter, eyestay, and tongue, consist of many separate parts. This step prepares these parts for assembly. Cutting machines are used for this process, including traditional traveling head cutting machines, swing arm cutting machines, laser cutting machines, and oscillating blade cutting machines.
Pre-Stitching
In the preparation for sewing process, the individual cut pieces are prepared for stitching. This step may include tasks like edge painting and buffing to refine the appearance and quality of the shoe’s upper.
Sewing(Stitching):
Sewing is the process where the prepared pieces are stitched together to form the upper part of the shoe. This is a crucial step that requires skilled manual labor. Various types of sewing machines are employed, such as flatbed sewing machines, post-bed sewing machines, zigzag sewing machines, twin-needle sewing machines, and computerized sewing machines.
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| Shoe Component |
Bottom Manufacturing Process:Shoe Manufacturing Process
The Bottom of the shoe consists of three main parts: Midsole, Outsole, and Insole. The quality control in these processes significantly impacts the comfort and durability of the shoe.
Midsole Production:
Midsoles are traditionally categorized into three types: Phylon, Injection Preform (IP), and Polyurethane (PU). Each type has its own production methods based on chemical properties. Phylon involves a process of compression molding and cooling on hot and cold plates. IP is made by melting the raw material and injecting it into molds. PU production is similar to making waffles, where liquid material is poured into molds and allowed to solidify. The finished midsole components are then sent to the preparation process.
Outsole Production:
The outsole is the rubber sole that forms the bottom of the shoe. While it may seem simple, the outsole production process is intricate. It involves various machines and processes, including mixing rolls, calendering machines, cutting, and outsole pressing. The outsoles are molded into specific shapes and patterns during the pressing stage.
Insole Production:
The insole, often referred to as the shoe’s inner sole or footbed, undergoes a complex manufacturing process. Thick EVA foam is expanded using a press, and then it goes through skiving to achieve the desired thickness. Fabric is added to the top, adhered, shaped, and cut to create the final insole.
StockFit:Shoe Manufacturing Process
The StockFit process involves adhering the midsole and outsole together. Primers and bonding agents are applied to both the midsole and outsole, dried, and then pressed to form the shoe’s bottom or sole.
Assembly Process
The Manufacturing process involves the final assembly of the completed upper and bottom parts. Shoes are manufactured using a combination of heat, cold, curing times, and chemical adhesives. The upper is completed, and then primer and bonding agents are applied to both the upper and sole. They are dried, pressed together, and shaped in chambers. Quality checks are performed at various stages, and after passing inspection, the shoes are ready for shipment.
This overview provides a glimpse into the complex and detailed process of shoe manufacturing. Each step requires careful attention to materials, machinery, and quality control to produce high-quality footwear.
Taking another look at the overall process of making shoes from the beginning will be even more helpful for better understanding.
