A Dutch design team has developed shoes made entirely from thermoplastic polyurethane (TPU). Using processes such as 3D printing, knitting techniques and high-frequency welding, a prototype was created that does not require adhesives. This project, Welded Loop, shows how a mono-material can be used in shoe manufacturing to facilitate recycling processes.
Designers Suzanne Oude Hengel and Joris de Groot, who both specialize in different aspects of material processing, worked together to realize the concept. Oude Hengel, founder of Knit in Motion, focuses on innovative textile designs, while de Groot uses high-frequency welding for plastic materials. They realized that TPU yarn is suitable for both textiles and 3D-printed components, which formed the basis for their approach.
Traditionally manufactured shoes are usually made from a variety of materials such as leather, rubber, textiles and adhesives. This variety of materials makes recycling considerably more difficult. Shoes made from a single, fully recyclable material such as TPU could offer a sustainable alternative.
The first prototypes were presented at the Dutch Design Week. Production begins with the processing of TPU yarn into a knitted textile. 3D-printed eyelets are welded on before the textile is thermoformed on a mold to create the shoe upper. The sole is printed separately from TPU filament and then welded to the upper.
The project is currently in an experimental phase. In addition to shoes, the designers would also like to explore other products made from monomaterial.
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