How a Running Shoe Is Made – From a Piece of Mesh to the Finished Shoe

“The fit of a running shoe is crucial,“ says Andre Kriwet, running shoe developer and co-founder of True Motion. It’s what most runners love about their favorite shoe. If a shoe doesn’t fit well, it will ultimately not be purchased.

Before a recognizable running shoe is created from the individual parts, a die-cut shape is used to cut out the upper from the mesh material used.

In the next step, the workers sew the tongue of the shoe – and apply the label. Later, the finished tongue is attached to the upper. To prevent the tongue from slipping when running, it is stitched to the upper material with elastic elements.

Before that, the eyestay is adhered to the upper, and the matching holes for the laces are punched. Oval elastic laces prevent the tied laces from coming undone when running.

The upper is then shaped into a recognizable shoe shape for the first time. With the help of a kind of shoehorn, the workers manually last the shoe. The design of the shoe can be anticipated for the first time.

During the next steps, the running shoe remains on its last. First, the workers thread the laces. The shoe is clamped in the toe area.

At the same time, the midsole is pressed. That’s where True Motion’s unique horseshoe-shaped U is located. The patented U-TECH™ technology centers the forces generated during running and thus reduces the risk of running-related injuries.

Next, the upper and the midsole are bonded together. The workers coat the bottom of the upper with adhesive and glue the upper material to the midsole.

Before the midsole is firmly bonded to the upper, the workers adjust the midsole with the help of a spatula-like tool. If the result is right, it is finally heat-bonded to the upper.

Once all 50 or so individual parts have been assembled, stitched, and stockfitted together, the final inspection takes place. The workers carefully check whether all parts fit properly. If this is the case, they place the running shoes in shoe paper and pack them in boxes. From there, they are sent to True Motion’s warehouse in larger outer boxes.