You’ve seen the lattice. That weird, pale green, resin-looking mesh sitting at the bottom of a sneaker in a glass case at the mall. It looks like something pulled out of a sci-fi lab or a high-end architectural model. Most people just walk by and think it’s a gimmick. Honestly? I used to think the same thing.
But Adidas 3D printing isn't just a visual flex. It’s a radical shift in how we actually build things for the human body.
For decades, sneaker midsoles were basically just slabs of foam. We’re talking about EVA (ethylene-vinyl acetate)—the stuff in your flip-flops and your running shoes. To change how a shoe felt, designers had to change the chemical density of the foam. It was a blunt instrument. If you wanted it softer, you made the foam airier. If you wanted it stiffer, you made it denser. But with 3D printing, or more specifically, Digital Light Synthesis (DLS), Adidas stopped using foam entirely. They started using light and oxygen to grow shoes from a pool of liquid resin.
The Carbon Partnership: Not Your Average Desktop Printer
If you’re picturing a slow nozzle spitting out lines of plastic like a hobbyist's Ender 3, stop. That’s not how this works. Adidas partnered with a Silicon Valley company called Carbon back in 2017. They use a process called Continuous Liquid Interface Production (CLIP).
It’s fast. Like, incredibly fast compared to traditional additive manufacturing.
Essentially, a digital projector shines UV light through an oxygen-permeable window into a vat of liquid polyurethane resin. The light solidifies the resin into a specific shape, while the oxygen prevents it from sticking to the glass. It looks like the shoe is being pulled out of a liquid puddle, T-1000 style. This is why the Adidas 4D midsole is one solid piece of material with no weak points or layers.
Why the Lattice Matters
Why go through all that trouble? Why not just stick to foam?
The answer is tunability.
Think about a standard foam midsole. It has the same physical properties from the heel to the toe because it's one uniform material. But your foot doesn't work that way. When you run, your heel strikes with massive force. Your midfoot needs stability. Your forefoot needs "spring" to push off.
With the Adidas 4D lattice, engineers can program 20,000 individual struts. They can make the heel struts thin and flexible for cushioning, and the midfoot struts thick and rigid for support. All in one single, seamless piece of material. This isn't just marketing fluff; it’s high-level mechanical engineering.
Real-World Performance: The Futurecraft 4D Legacy
The first real breakthrough was the Futurecraft 4D. When it launched, it was a collector's item. It was expensive. It was heavy. Let’s be real: those early 4D models felt like bricks compared to the ultra-light Boost foam that dominated the market.
But Adidas kept iterating.
They looked at 17 years of athlete data. We’re talking about millions of data points on how feet move, where they sweat, and where they need the most pressure relief. They fed this into their design software to create the 4DFWD.
This shoe was a turning point. Instead of just bouncing up and down, the lattice in the 4DFWD is angled. When you step down, the lattice compresses forward. It literally converts vertical impact into horizontal motion. Most shoes just absorb energy. This one tries to use it.
Does it actually work?
Studies from the University of Calgary and Adidas' own internal testing suggest that this forward-motion lattice reduces braking force by up to 15%. That sounds like a small number. It’s not. For a marathoner, that’s thousands of tiny "brakes" being removed from their stride.
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However, we have to acknowledge the elephant in the room: weight.
3D-printed resins are generally heavier than the nitrogen-infused foams used in "super shoes" like the Adizero Adios Pro. If you are looking for a feather-light racing flat to break a world record, a 3D-printed shoe might not be your first choice yet. It’s currently better suited for daily training, stability, and high-impact protection.
The Sustainability and Waste Problem
The footwear industry is a nightmare for the planet.
Traditionally, you take a big sheet of foam, you die-cut the shapes you need, and you throw away the scraps. It’s wasteful. Adidas 3D printing changes the math. You only use the resin you need. There is almost zero "off-cut" waste because the object is grown to its exact dimensions.
Also, look at the STRUNG upper.
While not a 3D-printed sole, it’s a 3D-printed upper. Adidas uses a robotic arm to thread a single continuous strand of material exactly where it’s needed. No overlays. No glue. No extra fabric. It’s a data-driven cocoon for your foot. When you combine a DLS midsole with a STRUNG upper, you’re looking at a shoe that is almost entirely "additive."
Why Mass Personalization is the End Game
Right now, you buy a size 10. I buy a size 10. We get the exact same shoe.
But your gait is different from mine. You might overpronate. I might strike on my midfoot. In the very near future—and Adidas has already toyed with this in select flagship stores—you’ll walk on a pressure-sensing treadmill, and the 3D printer will generate a lattice specifically tuned to your weight and your stride.
This isn't just about comfort. It’s about injury prevention.
Medical professionals like Dr. Kevin Maggs, a running gait specialist, often point out that footwear can't "fix" a runner's form, but it can certainly manage the loads placed on specific tissues. A 3D-printed shoe that is stiffened in the exact spot where a runner has a history of stress fractures? That’s a game-changer.
The Hurdles
It hasn't been all sunshine and roses. The cost of resin is still higher than the cost of foam. The printing time, while fast for 3D printing, is still slower than a traditional injection mold that can pop out hundreds of soles an hour.
There's also the "dirt" factor. If you've ever worn a pair of 4D shoes on a muddy trail, you know the pain. That beautiful lattice is a magnet for pebbles, mud, and dog... well, you get it. Cleaning them requires a pressure washer or a very patient person with a toothbrush.
Moving Beyond the Hype
The "hypebeast" era of 3D printing is mostly over. We’ve moved into the utility phase.
We are seeing the technology bleed into other areas of sports. Adidas used 3D printing for the Riddell Axiom football helmet, creating a custom-fit internal liner that absorbs impact better than traditional foam pads. This is the real value of the tech: it goes where foam can't.
What You Should Do Next
If you’re thinking about diving into the world of Adidas 3D printing, don't just buy the first pair you see on sale.
- Check the Model: The older Alphaedge 4D is quite stiff. It’s great for the gym or lifestyle wear, but it’s not a great running shoe.
- Look for 4DFWD: If you actually intend to run, look specifically for the 4DFWD or 4DFWD 2 models. The lattice geometry is significantly more advanced for forward motion.
- Mind the Surface: Stick to pavement or tracks. Avoid loose gravel or mud unless you enjoy digging stones out of your soles with a screwdriver.
- Size Up: Many 4D models have a very snug, "sock-like" upper. If you have a wider foot, you’ll likely want to go up half a size.
The tech is finally catching up to the vision. We’re moving away from shoes that are "made" and toward shoes that are "coded." It’s a weird transition, but once you feel that lattice compress under your heel, it’s hard to go back to a boring block of foam.
Stop thinking of these as just sneakers. They are data-driven mechanical structures that just happen to fit on your feet. The next time you see that green mesh, remember: it’s not just a design choice. It’s the sound of the traditional manufacturing industry being disrupted, one strut at a time.