Footwaredesign with 3D technologies

Bhavya, a product designer, discusses the growing use of 3D printing in footwear manufacturing. He highlights the benefits of 3D printing for prototyping and customization, noting that companies like Zellefel in Germany are leading the way. Bhavya explains that 3D printing allows for more sustainable practices, using materials like TPU that are easily recyclable (up to 95%). He mentions that the cost of 3D printing shoes is currently around €70-€160, but expects it to decrease as the technology advances. Bhavya encourages aspiring designers to experiment with 3D printing, suggesting local Fab Labs as accessible resources.

Q: Introduction: Could you briefly introduce yourself and your background in 3D technology?

My name is Bhavya Acharya, and I’m a product designer. I recently graduated in Industrial Product Design from Howest University in Kortrijk. I’ve been working with 3D technologies for the past two to three years, first discovering 3D printing during my university assignments and projects. Most recently, I had the opportunity to explore 3D-printed footwear, which also became the focus of my graduation thesis. Through this work, I gained a deeper understanding of how 3D technology has the potential to completely transform traditional approaches to manufacturing and design.

Q: What do you find most fascinating about 3D printing/scanning in your field?

What fascinates me most about 3D technology is how it closes the gap between imagination and reality. You can have an idea in the morning and be holding a prototype in your hands by the evening. In footwear design, this opens up incredible creative freedom. Traditionally, most shoes follow the same silhouette, with only small variations like color or material. With 3D printing and scanning, however, you can design shoes that are completely unique and tailored to the exact shape of someone’s foot. For me, that’s the exciting part — 3D technology isn’t just a tool, it’s a way to turn creativity into reality.

Q: Can you share a specific example where 3D technology has had a significant impact?

One field I’ve been closely following is footwear design. By combining 3D scanning and printing, it’s now possible to create custom footwear on demand. Traditionally, shoemaking involves cutting, gluing, and discarding large amounts of material, often in overseas factories. With 3D printing, however, we can produce customized soles locally, using flexible recycled plastics, and with almost zero waste. This approach not only reduces environmental impact but also shows how manufacturing can shift from mass production to sustainable, on-demand solutions.

Q: What new careers are emerging in this field, and what skills are essential for them?

As 3D technology becomes more widely adopted, we’re seeing the rise of highly skilled and specialized jobs. For example, we now need CAD designers who can create optimized, printable models for production. We also need materials engineers who are developing sustainable polymers, and technicians who understand 3D printers as reliable production tools, not just for prototyping. These roles show how manufacturing is shifting — it’s no longer just about mass production, but about precision, sustainability, and innovation.

Q: Where do you see 3D technology heading in the next 5-10 years?

In the next five to ten years, I see 3D technology making manufacturing far more decentralized. Instead of relying on complex global supply chains, we’ll have networks of local hubs where products are printed on demand — through print farms, accessible fab labs, and small-scale workshops. Many startups and small-batch producers are already turning to 3D printing as an alternative to traditional mass manufacturing. Processes like injection molding, for example, require very high upfront investment, with molds costing €8,000 to €10,000 each. 3D printing removes those barriers, making manufacturing more flexible, affordable, and accessible to anyone with an idea.

Q: What's a common misconception about 3D technology that you'd like to address? 

A common misconception is that 3D printing is only useful for prototyping. For a long time, it was mainly seen as a tool to test ideas rather than to manufacture real products. But that’s no longer the case. Today, companies in industries like aerospace and automotive are producing certified, end-use parts with 3D printing. Even in footwear, big brands are starting to embrace this shift — Nike, for example, recently released a fully 3D-printed shoe that sold out instantly. These examples show that 3D printing is moving firmly into mainstream manufacturing.