3D printing (also known as additive manufacturing) is a revolutionary manufacturing method that creates products layer by layer. Unlike traditional manufacturing methods, which needs molds, cutting, or assembly of various components. While 3D printing allows for precise, customized, and efficient results with minimal waste.
There are other multiple types of 3D printing technology, however the two most widely used ones are:
1. Fused Deposition Modelling (FDM).
FDM is one of the most popular 3D printing technologies among amateurs and small-scale manufacturers. It operates by extruding heated thermoplastic filament via a nozzle, depositing material layer by layer until the end result is complete.
Advantages of FDM:
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Reduced cost of printers and materials
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Ideal for basic prototyping and home use.
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Works with a variety of thermoplastics, including PLA, ABS, and PETG.
Limitations of FDM:
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Longer print times for detailed objects
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Lower resolution and surface finish when compared to other methods
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Limited material properties for high-performance applications.
2. Stereolithography (SLA) and resin printing
SLA, a resin-based 3D printing technique, employs a laser or light source to cure liquid photopolymer resin into solid layers. This produces high-resolution prints with fine details and excellent surface quality.
Advantages of SLAs:
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Extremely precise and smooth surface finish.
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Ideal for intricate designs and complex geometries.
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More durable and adaptable material options
Limitations of SLAs:
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Costly printers
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Requires post-processing (washing, overcoming).
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More specialized equipment is needed.
Why Autrion Uses SLA 3D Printing
We are reinventing the way our shoes are made with innovative SLA 3D printing technology. Here's why.
1. Completely 3D-printed construction.
Unlike traditional footwear manufacturing, which involves cutting and assembling multiple parts, our shoes are intended to be printed as a single seamless unit. This approach reduces material waste, improves structural integrity, and enables precise cushion customization. While also allowing us to create footwear that was previously thought impossible like our world's first 3D printed DuckBoot.
2. Extremely Comfortable Lattice Cushioning System
SLA printing allows us to create a sophisticated lattice structure that provides precise cushioning and support. Unlike traditional foam midsoles, which may gradually lose their comfort due to material compression (also known as bottoming out), our lattice cushioning is designed to maintain its integrity for longer.
Foam shoes frequently experience:
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Material Compression: As foam compress over time, it may lose its ability to provide the same level of cushioning as when they were new.
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Uneven Pressure Distribution: Foam midsoles may concentrate pressure in specific areas, potentially causing discomfort and foot fatigue.
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Limited Longevity: Traditional foam midsoles can degrade more quickly, lowering its useful lifespan.
In contrast to our lattice system:
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Evenly Distributes Pressure: Designed to reduce strain on specific areas of the foot while providing consistent support.
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Maintains Structural Integrity: Designed to provide long-term cushioning without significant compression.
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Improved Durability: Constructed to offer better longevity compared to traditional foam materials, based on internal testing and research.
3. High-Speed SLA Printing for Efficiency.
Our production process uses high-speed SLA printing, which is engineered to enable efficient footwear manufacturing while maintaining precision and quality.
4. Sustainability and Ethical Manufacturing
Sustainability is a key component of Autrion's innovation strategy. Our manufacturing approach aims to reduce both material waste and energy consumption. Unlike traditional footwear production, which can result in excessive material waste and inefficient energy consumption, our 3D printing process is intended to maximize material usage. Our shoes are also printed from bio-based TPE.
Cloud-Controlled Printing Process
Here is how it works:
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Remote-Controlled Factory: The SLA printing facility is designed to run autonomously, allowing for 24/7 production without the need for continuous on-site personnel.
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Cloud-Based Manufacturing: A cloud computing system is used to monitor and optimize production in real-time, ensuring consistency in quality and efficiency.
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Minimal Waste and Sustainable Practices: By printing only what is required, material waste is greatly reduced while maximizing resource efficiency.
Performance-Driven Material
Our innovative footwear is designed to perform well, not just look good. According to material testing and research, bio-based TPE has shown:
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Fatigue Resistance: Designed to retain shape and integrity after extended use.
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High Resilience: Designed to return to its original shape following compression.
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Tear Resistance: The product has been tested for wear and tear resistance
- Optimal hardness: 77 Shore A, which is intended to balance softness and durability.
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Tensile strength: 20 MPa ensures flexibility and stretchability.
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Elongation at Break: 250%, which allows for a soft and stretchy upper.
- Flexural Endurance: Over 200,000 cycles, according to testing for long-term wear.
Using a bio-based TPE was additionally chosen for these key factors:
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Water resistance
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Hypoallergenic properties
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Resistance to odors
- Soft surface finish
At Autrion, we think that innovation, sustainability, and technology are the keys to the footwear industry's future. We hope to bring in a new era of comfortable, high-performance, and environmentally conscious shoes by utilizing high-speed SLA 3D printing and an automated production system.
Are you ready to take a step into the future? Explore Autrion's 3D-printed footwear here.