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Tour a Shoe Last Factory

inside a shoe last factory

Today we are visiting a shoe last factory operated by a good friend of mine, Jackie Huang. The Dongguan Lian Xiang shoe last factory is located on a busy side street in the South China shoemaking town of Houjie. Jackie operates the business and meets with customers while his brother, an accomplished last master, works to shape new lasts.

This small factory makes sample development and production shoe lasts for many top international shoe brands. They have over 25 years of experience making all types of lasts for athletic, fashion, and casual shoes. The factory can make over 50,000 plastic lasts a month and is equipped to make development and custom model lasts one by one. Jackie and his skilled craftsmen can make you a new custom last in just a few hours. Let’s see how they make a new shoe last.

how shoes lasts are made

Inside a shoe last factory:

Inside the last factory you will find a small office, a 3D last scanning machine, a shaping bench, computer controlled high speed last cutting lathes, a finishing area, and a last marking station. You will also find cutting saws, drill presses, hydraulic presses, and plastic extrusion machines.

Getting started on a new shoe last project:

shoe last scanning machineThe last scanner:

The last scanner is a critical piece of equipment in any shoe last factory. The scanner is used to duplicate and record any new lasts that arrive at the shop for adjustments. The scanner is also used to record any handmade modifications.

making a shoe last the last masterThe last shaping bench:

In the last master’s workroom, there will be a workbench specifically designed to hold the last in place while its shape is being refined. While all plastic lasts are cut by the automatic machine, subtle adjustments like adding and removing material are still done by hand.

shoe last cutting machine

Last cutting lathes:

The last cutting lathe machines are the workhorses of the last factory. Able to cut 6 lasts at once, the last cutting lathe can transform “blanks” into lasts in just a few minutes.

Making a new shoe last:

To make a new shoe last, Jackie and his team need a few details. If you know the function of the new shoe, such as running or soccer, Jackie can search his extensive computer files for a suitable last. If you have a photo of a similar style, Jackie can find or create a new last similar to the product shown in your photo. Maybe you have a sample shoe to follow? The factory team can “reverse engineer” a last to duplicate the fitting. Of course, if you a have a last that needs modifications, they can scan and reshape a last per your requirements. Once the last file is found or created, it is simply sent to the cutting machine.

If you require the services of Jackie Huang and his team at The Dongguan Lian Xiang shoe last factory in China, we can put you in touch with an English speaking contact. Send inquiries to Wade@SneakerFactory.net

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The Shoe Material Design Guide – Our newest book!!

Shoe Material Design Guide

Do you want to be a professional shoe designer? You must learn how to select and specify each shoe material correctly. Our newest book, The Shoe Material Design Guide, details all the shoe materials you will need to make modern athletic, classic casuals, and high fashion footwear. You will learn about all the materials used to make shoes.

Each chapter covers a specific shoe material type. You will learn how each material is made, the options available, and how to specify the material correctly. We have chapters on shoe leather, textiles, synthetics, shoelaces, glue, reinforcements, hardware, logos, midsoles, outsoles, a complete shoe materials list and more!

Shoe Material Design GuideWe have included annotated cross sections of over 30 different shoe types. You can see exactly how each shoe materials are used inside real production shoes. Look inside basketball shoes, running shoes, track spikes, hiking boots, work boots, high heels, cowboy boots and many more!

You will also find information on topics such as shoe material testing, sustainable production, exotic materials and more. Written as a companion to our best selling How Shoes Are Made, The Shoe Material Design Guide digs deep into the world of footwear materials and design. Softcover, 330 color photos,  28 chapters, 195 pages.

The Shoe Material Design Guide

 

Chapter 1: Leather for footwearChapter 1: Leather for footwear

How leather is made and how to use leather in your shoe designs.
What materials are shoes made out of? Leather is the most commonly used material for shoemaking. It is durable, flexible, breathable, stretchable and conforms to the wearer like no other material. Study the character, color, grain, thickness, temper and the production steps such as curing, soaking, liming, tanning, etc. Next, we look at the finishing operations, final grading and main types of shoemaking leather like aniline, nubuck, pigmented, top-grain, crazy horse, split leathers, patent leather, action leather and many more. Finally, we cover leather import duty and tariffs, price per square foot and how to specify shoe leather.

  

The Ultimate Shoe Material Textbook

Start with an in-depth study of material types available for modern shoemaking. Learn the technical details of material specifications. 195 pages and 300 color photos.

Buy Now

on sale $39.99
Textiles for Shoes - Shoe Fabrics

Chapter 2: Textiles for Shoes – Shoe Fabrics

Fabric options for footwear. Shoe material types and shoe fabrics such as textiles are tough, lightweight, resistant to the environment, long wearing, and relatively inexpensive. What is the best sneaker material or the best basketball shoe material? Review footwear fabrics such as nylon, polyester, Kevlar, linen, Rayon, wool and their processing, weaves, backing, treatments, and other special features. Study the environmental factors, import duty, lasting and test standards for textiles.
Synthetics for shoes Man-made materials for the modern shoe.

Chapter 3: Synthetics for shoes

Man-made materials for the modern shoe.
Synthetic, synthetic leather, PU leather, pleather, or PU; whatever you call it, this class of shoemaking material offers an immense variety of colors, textures, and features at a range of prices. What are sports shoes and athletic shoes made of? What are basketball shoes made of? Synthetics! What is a synthetic upper? This shoe material can be made to look like natural leather, split leather, textiles, wood, metal or almost anything. Many of the modern icons of basketball shoe design would not be possible without synthetics. When specifying synthetics you have complete control over the outer skin layer and inner backing layers so it is important to understand how it is made and know all your shoemaking material options.
Shoe Stitching Thread Thread and stitching hold it all together.

Chapter 4: Shoe Stitching Thread

Thread and stitching hold it all together.
Shoe stitching thread is also an important shoe designing material. As a design element, the thread color choice and specification are important to the look of the shoe. You may choose matching stitching for your sneaker materials list to help conceal poor alignment, or bright contrast stitching to highlight exceptional craftsmanship and your shoe print fabric. Are you making a waterproof shoe with as few stitches as possible or a hyper-modern design with all the stitching hidden inside? Learn about this tiny component that holds it all together.
Footwear Reinforcements How to create, support, and fix the shape of shoes.

Chapter 5: Footwear Reinforcements

How to create, support, and fix the shape of shoes.
The internal reinforcements you select will allow your shoe to hold its shape, protect the foot, provide support, and stay together. Reinforcements are a significant factor in your shoes’ performance, comfort, durability, and suitability for its designated task. Look at heel counters, heat-molded plastic sheets, vulcanized rubber, backing materials and outsole reinforcements.
Shoelaces Options for shoe closure systems. Shoelaces hold the shoe onto your foot and provide some style

Chapter 6: Shoelaces

Options for shoe closure systems.
Shoelaces hold the shoe onto your foot and provide some style. Study the construction, materials, lacing systems. The “correct” shoelace depends on the function of your shoe. The same lace that works for a fine leather office shoe will not be suitable for hunting boots or ballerina slippers.
Shoe glue The use and application of adhesives in shoes. Almost every part of a modern shoe is glued or laminated in place.

Chapter 7: Shoe glue

The use and application of adhesives in shoes.
Almost every part of a modern shoe is glued or laminated in place. It is critical to specify a glue that will not saturate, stain, or melt the material you are bonding. It is also important to nd the bonding process suitable for each material type.
Hardware for shoes Metal and plastic parts for shoes. Functional parts such as eyelets, speed hooks, or buckles will have specific performance requirements.

Chapter 8: Hardware for shoes

Metal and plastic parts for shoes.
Functional parts such as eyelets, speed hooks, or buckles will have specific performance requirements. When specifying and designing hardware parts for your shoes, there are many factors to consider such as material selection, setup costs, unit costs, MOQ (Minimum Order Quantity), finishing effects, testing, and attachment methods.
Logo applications for shoes Techniques for branding shoes.

Chapter 9: Logo applications for shoes

Techniques for branding shoes.
A new shoe design is not complete until you have detailed its logos. We will review the most common types of logos found on sports shoes like die cuts, screen printing, embossed, embroidery, woven labels, molded logos, PVC gel bubbles and discuss what the logo parts cost, the setup charges, and designer tips.
Foam for shoes How to specify foam. What is foam? The modern sports shoe will have several types of foam inside.

Chapter 10: Foam for shoes

How to specify foam. What is foam? The modern sports shoe will have several types of foam inside. It is important to know what foam is appropriate for the shoe upper and what is appropriate for cushioning the shoe outsole. When specifying foam, it is critical to understand the performance attributes such as density, durometer, compression set, impact resistance, energy return conformability, breathability, and more.
Midsole cushioning systems A review of 14 different midsole types.

Chapter 11: Midsole cushioning systems

A review of 14 different midsole types. The midsole provides cushioning support, and heel lift. Not every shoe type has a midsole, and some sole designs have the cushioning system integrated into the outsole components. We cover various types such as Cup, cut, and buff sole, injection molded EVA, airbags, and Polyurethane foam, advising the tooling cost and unit price for these and many more.

Shoemaking Material Kit

All the hard find parts for your DIY shoemaking project are here in one place. Lasting board, strobel material, lining mesh B&W, collar foam and all the reinforcing parts you need for one pair.
Learn more
On sale $39.99

Outsoles for footwear A study of 8 different outsole constructions.

Chapter 12: Outsoles for footwear

A study of 8 different outsole constructions.
The shoe outsole is one of the most expensive parts of the shoe and a set of outsole tooling is by far the most expensive equipment needed to produce a shoe. Rubber cupsoles, compression molded EVA soles, injection molded outsoles and 5 others are uncovered and analyzed.
Waterproof constructions An overview of waterproof construction techniques.

Chapter 13: Waterproof constructions

An overview of waterproof construction techniques.
Making high-quality waterproof shoes and boots can be a difficult technical challenge. See inside a waterproof boot. The shoe pattern, material selection, specific waterproof construction techniques, and conscientious testing must all come together to make it work.
Footbeds Picking the right footbed, ten options to study. Footbeds come in all shapes, sizes, and materials.

Chapter 14: Footbeds

Picking the right footbed, ten options to study.
Footbeds come in all shapes, sizes, and materials. They may be customizable, removable, or glued in. It is important to select a footbed which will compliment your shoe design. Will it be molded or die cut? Multi-density, hybrid, or crystallized PU?  What material will cover it, what other features will you need for your shoe?
Webbing For Shoes Options and uses of webbing.

Chapter 15: Webbing For Shoes

Options and uses of webbing.
Its light weight and high strength make webbing perfect for use as lace loops, tongue pulls, back pull tabs, tongue anchors, and reinforcements. Webbing for footwear is usually made of nylon, polyester, polypropylene, or cotton. It can be knit with colors or dyed and comes in various widths, thicknesses, and even 3D features such as ribs or logos.
Plastic parts A quick study of plastic molding for shoe parts. Almost every part of a modern athletic shoe is made of plastic,

Chapter 16: Plastic parts

A quick study of plastic molding for shoe parts.
Almost every part of a modern athletic shoe is made of plastic, we will look at injection, compression, and blow molded plastic parts for footwear. Technically speaking, textiles are woven from plastic fibers, foam is made of blown plastic, and synthetics are actually sheets of plastic with plastic fiber backings. We are going to focus on the plastic accessory parts which give shoes their special functionality.
Footwear Packing Specifications How to design and specify packing materials for shoes.

Chapter 17: Footwear Packing Specifications

How to design and specify packing materials for shoes.
Shoe packaging is a significant part of your product marketing presentation. It is also important to consider where and how your products will be sold. The shoe box for your average sports shoe may cost anywhere from $0.75 to $10 for high-end packaging. Learn how the corrugated board is specified by the weight of the skin papers and the size of the flute pattern and get the details on inner box vs. case box, graphics effects, die lines, etc.
Shoe material specifications How to create a footwear specification.

Chapter 18: Shoe material specifications

How to create a footwear specification.
A detailed specification sheet is absolutely critical to your success. We will describe the requirements for your specification sheet, material maps, header details, how to specify the outsole unit and we will show you samples. The best materials used in basketball shoes.
Shoe material testing Testing requirements for shoes and shoe materials.

Chapter 19: Shoe material testing

Testing requirements for shoes and shoe materials.
Physical testing and lab testing of materials and the finished product are required to ensure your shoes work. We will review five types of testing including tests for waterproof shoes and bonding trials. How is a waterproof shoe made? Shoe designing materials and shoe fabric review.
Local market shoe materials Using locally available stock materials.

Chapter 20: Local market shoe materials

Using locally available stock materials.
Local markets are storefronts large and small with every type of shoe material, shoe component, and manufacturing equipment available to buy. What will you find and how can you get the most out of your visit? Also, you must be careful when purchasing shoe materials from the local market. The supply factory’s contact information may not always be available, and there may not be material physical test data reports ready.
Material vendor relations How to get the most from your material vendors.

Chapter 21: Material vendor relations

How to get the most from your material vendors.
Your shoe material suppliers can be your best partners as you design and develop your shoe lines. How to find suppliers, develop materials, and what it means to nominate a supplier. Shoe material vendors and shoe material suppliers uncovered.
Material costing and consumption How to calculate the cost of shoe components. Pattern consumption, cutting loss, labor, overhead, and profit and currency conversion are all important factors which make up the cost of a shoe.

Chapter 22: Material costing and consumption

How to calculate the cost of shoe components.
Pattern consumption, cutting loss, labor, overhead, and profit and currency conversion are all important factors which make up the cost of a shoe. See our infographic on the cost breakdown of the materials and a sample costing sheet. What are women’s shoes made of? See what sneakers are made out of? What are men’s shoes made of? We’ll break down the costs.
Shoe material supply chain The challenges of sourcing footwear materials.

Chapter 23: Shoe material supply chain

The challenges of sourcing footwear materials.
When looking at the supply chain for a specific material, there are four main factors to consider which include the country of origin and the vendor purchase terms. These factors along with others will be different for every material you specify. What are the materials used to make shoes?  Shoe fabrics, shoe leather, synthetic mesh, what materials are basketball shoes made of, and more. Remember, even a simple shoe can have materials from over a dozen different shoe material suppliers.
Exotic and illegal materials How to know if rare materials are safe and legal to use.

Chapter 24: Exotic and illegal materials

How to know if rare materials are safe and legal to use.
Exotic animal hides like snake, ostrich, alligator, and even elephant are used in footwear to create drama, luxury, mystique and a feeling of exclusivity. What do they cost and how do you work with them?
Building a shoe material library Tips and techniques for collecting material swatch books.

Chapter 25: Building a shoe material library

Tips and techniques for collecting material swatch books.
It is critical to build a library of relevant material swatches and sample books. Having materials on hand allows you to communicate what the new design will look like to product managers, sales managers, or customers. How to get the most from shoe material vendors, shoe material suppliers, and shoe material manufacturers.
Sustainable shoe production How to reduce the environmental impact of your shoes.

Chapter 26: Sustainable shoe production

How to reduce the environmental impact of your shoes.
Footwear designers, shoe developers, product managers, and factories can make choices to help reduce the negative environmental and social impacts of shoe production. We will consider different aspects of shoe production that can make your shoes more or less environmentally sustainable.
Shoe dissections Cross section views of popular shoe styles. The best way to understand how materials are used is to see for yourself!

Chapter 27: Shoe dissections

Cross section views of popular shoe styles. The best way to understand how materials are used is to see for yourself! We have saved you some time, effort, and money by collecting 35 different shoe models for you to study. Each shoe has been photographed, opened up, and labeled to expose and review its internal construction.  See what Nike Shoes are made out of, what Vans shoes are made out of, what women’s shoes are made out of, how a running shoe is made, what are the best materials for shoes,  what hiking boots are made out of, how a basketball shoe is made and more. You’re going to love this!
shoe materials supplier sneaker materials list Shoe material vendor list

Chapter 28: Shoe material vendor list

Where to find top quality shoe materials. A listing of our favorites and their websites. Shoe material makers. Shoe material vendors. Shoe material suppliers. Shoe materials supplier information and sneaker materials list are listed in detail.

New Online Course
How to Select Shoe Materials

14 Shoe Material lessons. Over 4 hours of video instruction. In-depth study of leather, textiles, synthetics, and plastics for footwear. Material Design Guide Textbook included.
Course Details
enroll now $399

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Shoe Dissection: Inside the Nike Kobe XI Elite Low

see inside the Nike Kobe Elite XI, How are shoes constructed? Types of shoe construction

Shoe Dissection: See Inside Nike Kobe XI Elite Low

Today we have a pair of the Nike™ Kobe XI Elite Lows in the Sneaker factory teardown lab. The color is Hyper Grape, Black with a clear gel sole. Sorry to all you Nike and Kobe Fans but we are cutting this shoe apart right now! If you like the youtube channel The Sneaker Chop you will like this.

The Kobe XI Elite Low is made by force lasting or stobel lasting. This is the most common construction technique for Air Jordan and Nike basketball shoes. One unique thing about the Kobe XI Elite bottom unit is the clear rubber sole and clear stobel sock. These allow you to see through the bottom and into the shoe. The assembly process for the Kobe XI is conventional except the shoe cement must be clear and have a UV stabilizer to prevent the sole from yellowing. The glue is carefully applied to maximize the see-through effect.

Kobe XI Elite low outsole with clear rubber and stobel
Kobe XI Elite low outsole with clear rubber and stobel

The rubber sole part is made by conventional rubber compression, but the tooling has some special features. The inside of the Kobe IX bottom tooling has a smooth polished finish instead of rough texture designed for maximum bonding. During disassembly we found this did cost Nike some bonding strength, the Strobel was easy to pull off – the bond was not to the standard 4KG per square cm.

The Strobel sock material is a blue-tinted clear nylon plastic sheet. This is a unique Strobel material, most shoes have stitch bonded polyester fabric. The Strobel stitching thread is clear nylon mono cord thread. Mono cord thread is much like fishing line.

Kobe XI Elite low drop midsole  the sneaker chop
Kobe XI Elite low drop midsole the sneaker chop

The Kobe XI Elite Low also features a drop in combination midsole/footbed. Rather than trapping the midsole between the Strobel sock and the rubber outsole, the midsole is molded with footbed contours on top. The stated benefit is that this allows the foot to be closer to the floor. The downside is the midsole and footbed are now a single density of the foam. In this case, the standing surface has a higher density than a conventionally made basketball shoe. The cost is a reduced “try on” comfort in stores.

The Nike Kobe XI Elite upper is 4K computer knit fabric. The fabric is reinforced with a welded TPU eyestay and non-woven internal eyestay. The tongue lining, internal gussets, and the toe lining are constructed with 3mm air mesh.

If you want to see more check out the book Shoe Material Design Guide 

Shoe Material Design GuideDo you want to be a professional shoe designer? You must learn how to select and specify shoe materials correctly. Our newest book, the Shoe Material Design Guide, details all the shoe materials you will need to make modern athletic, classic casual, and high fashion footwear.
Each chapter covers a specific shoe material type. You will learn how each material is made, the options available, and how to specify the material correctly. We have chapters on shoe leather, textiles, synthetics, shoelaces, glue, reinforcements, hardware, logos, midsoles, outsoles, and more!

 The Sneaker Chop
Shoe Material Design Guide

We have included annotated cross sections of over 30 different shoe types. You can see exactly how each material is used inside real production shoes. See inside basketball shoes, running shoes, track spikes, hiking boots, work boots, high heels, cowboy boots, and many more!
Do you want to see sneaker chops?

You will also find information on topics such as material testing, sustainable production, exotic materials, and more. Written as a companion to our best selling How Shoes Are Made, the Shoe Material Design Guide digs deeper into the world of footwear materials and design. Softcover, 330 color photos,  28 chapters, 195 pages.

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10 Best Shoemaking Blogs

First pullover shoe making blog

Are you interested in learning more about various stages of the shoemaking process? Perhaps you’d like to see inside bespoke shoe factories?  If you want to start your own shoe brand and learn more about how shoes are made and what materials, equipment, and tools are used to make shoes, this is the place to start. We have assembled a list of our 10 favorite “go to” shoemaking blogs.

Visit these shoemaking blogs

shoemaking blogs, shoe bloggerCarréducker
James Ducker and Deborah Carré are British shoemakers who studied under John Lobb. Their footwear blog has lots of great pictures of the handmade shoemaking process, shoe school, and shoe tools.
http://carreducker.blogspot.com

The Shoemakers Academyshoemaking blog has lots of great pictures of the shoemaking process, shoe school, and shoe tools. – I wish this site and these design and development tools were around 20 years ago when I was new to the trade. Great practical information to read or purchase.  Blog and books written by Wade Motawi and various veteran shoe dogs cover everything you need to succeed in the shoe business. Check out their books, How Shoes are Made, How To Start Your Own Shoe Company, and Shoe Material Design Guide.
https://ShoemakersAcademy.com

Shoes and Craftfootwear blog
Run by Marcell Mrsan of the Koronya shoemaking company. Similar to Carréducker, but with more emphasis on the business side of things and with the added charm of broken English. Shoemaking videos and courses in Savannah, Georgia (USA).
https://shoesandcraft.com

Making Shoes
Online shoemaking blog with step by step tutorials on how to make your own shoes. YouTube channel with video tutorials, online shoemaking courses, great tips and free shoemaking guides.  https://www.shoemakingcoursesonline.com

Top Ten shoe Blogs
The Shoe Snob Blog
Justin FitzPatrick, originally from Seattle, WA now a shoemaking blogger and business owner in the Soho area of London. See his blog The Shoe Snob Accessories and J.FitzPatrick Footwear range here. Shoe care videos and informative blog and boutique for shoes and accessories.
www.theshoesnobblog.com  and www.jfitzpatrickfootwear.com

First pullover shoe making blog

First Pullover Footwear Blog
Footwear design blog and resource with many videos such as Aluminum Last Making, How to Make a Last, How a Football Boot is Made, Leather Tanning, Footwear Photoshop Rendering Tutorial, How to prepare rubber,  Sketching Exercise, etc.
http://www.firstpullover.com

The Honourable Cordwainers’ Company Blog The Honourable Cordwainers’ Company (H.C.C.)
The Honourable Cordwainers’ Company (H.C.C.) is a non-profit 501c(3) educational organization, incorporated in 1987 in Virginia, the home of America’s first English shoemakers. Founded in 1984 by a small group of shoemakers and historians, the H.C.C. is dedicated to promoting the study, practice, interpretation, and preservation of historical and traditional shoemaking and allied trades. They provide a forum for the exchange of technical expertise, research, training and material needs.
http://www.thehcc.org

Lord Point Shoe Blog
This is an interesting website with lots of dress shoe tips. Shoemaking walkthroughs, leather, shoe dissections.  Shoe diagrams and drawings.
www.lordpoint.wordpress.com

Old Leather Shoe
Glen Tippetts discusses all things related to men’s leather dress and business shoes in this blog. How to care for shoes, how to shop for shoes, shoe terminology, and more.

Nathalie Mornu Sandal Blog
Technically, she makes sandals. This shoemaking blog has lots of interesting information and is helpful if you are looking to source lasts.
https://nathaliemornu.wordpress.com

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Pantone Colors for Shoe Designers

shoe design color Book

The Pantone Color Book:  The Shoe Designers Must Have Tool.

Your new shoe is ready to be manufactured, how do you explain the perfect shade of red you have in mind to the sample maker in China or Italy?
You could collect material swatches and cut color chips from around your office, attach these to your spec sheets, and Fed-Ex them to China. For unique materials or textures, this is a great idea. But, if you have 20 different shoes to spec with multi-color logos, this is not practical. You also need to consider what happens inside the factory.   Your color swatch will have to be chopped up into a dozen pieces.  One piece will go to the rubber factory, one piece to the mesh factory, one piece to the leather factory, one piece to the print shop, one piece to the shoelace factory, etc…etc… and the main shoe factory also needs to keep a piece to confirm the other factories get the color right. This is not practical for all the subcontractors.
To save time and money, professional shoe designers will use a color matching system. There are several systems, Toyo (from Japan), Ral (from Germany), and Pantone (from the USA).  Don’t waste your time with anything else – PANTONE is it, period.

Tools every shoe designer will need Pantone booksPantone Colors for Shoes

A Pantone color specification book is required for every shoe designer and developer. You will need to have a Pantone book to communicate with the shoe factory and your customers exactly what color you want. The Pantone corporation color books are the industry standard for color matching. You will find that every shoe factory has a Pantone book and it’s easy for you to reference a color.

How to use the Pantone System:

There are many Pantone books and chip sets. The basic color fans on paper cost about $150.00.  The two fan set includes coated (glossy) and uncoated (matte) finishes. The coated book is great for plastic, mesh, molded rubber, and PU leather.  The uncoated book is best for cut EVA, synthetic nu-buck, canvas, or any other matte finish item.
Pantone Chip Orange 021CIt’s so simple!  Just add the color number to your specification sheet.
This is nice bright orange, # 021 C.
“021” is the color name.
“C” means it’s from the coated book.
There are several other books. The “U” (uncoated book) and the “TP” (textile color book), etc. It’s not a bad idea to also note the page number.
learn how to design shoes shoe design

Types of Pantone Books:

The colors are also available in a tear out chip book.
The Pantone company makes the same color books in cotton, nylon, and plastic chips sets. If you work for a big office, go for it! You will see that these are very expensive books. Pantone also makes an electronic color sensing system and many other color specifying products.
A final note on Pantone Books:  When you get to the factory, have a look at their Pantone books. I was having trouble getting colors matched correctly at one factory. During a factory visit, I found the printing department was using the oldest, dirtiest, worn out Pantone book. AH HA!
The manager was very angry when I took his book and threw it into the trash, but he was very happy when I gave him a fresh new one.
Without the Pantone book, it is almost impossible to match colors correctly with your overseas factories. The books are expensive but your entire office can easily share one. This is a must-have shoe designers tool. You can order Pantone books from Amazon.com
I would start with Pantone Set GP1501, then GG1504 if you need pastels and neon colors.
FGP200 has a deeper selection of earth tones if you are leaning that direction.

The Ultimate Shoe Material Textbook

Start with an in-depth study of material types available for modern shoemaking. Learn the technical details of material specifications. 195 pages and 300 color photos.

Buy Now

on sale $39.99

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How Shoe Lasts are Made

How shoes lasts are Made

How Shoe Lasts are Made shutterstock_111577298The shoe last is the starting point for any shoe design project and is critical to the shape and function of all types of footwear. The last is used by the shoe factory to determine the shape of the shoe. The last also determines the fit, performance, ergonomics, and style of a shoe. Round toes, pointed toes, low heels, or high heels, these attributes are all determined by the shoe last. These attributes are what make different shoes suitable for running, basketball, hiking, or high fashion.

With the shoe last in hand, the pattern master creates the shoe pattern to fit the last tightly. Once the design is confirmed, the patterns are graded following the last to make each shoe size.  Shoe lasts can be made from injection molded plastic, carved wood, or cast aluminum.

last making school How shoes lasts are Made When discussing the attributes of a last, you will need to know the common terms. The majority of measurements are volume rather than the traditional length and width associated with shoe fit.
Click here to see How Shoe Lasts are Measured 

Last making is an art form. A skilled last-maker will have many years of experience and may have gone to last-making school. When making a last, the anatomy of the foot must be considered, especially how the foot shape changes when flexing.  When a last is designed for custom shoes, every dimension of the customer’s foot and the desired style must be considered.

Shoe Last Types:

Depending on the style of shoe that is being made the last will need some special features to allow the shoe to release the last.  The standard athletic shoe with a floating lace-up tongue can use a solid last. Loafers, Oxfords, and boots will require a last that can articulate so the shoes are not damaged during the de-lasting processes.

Solid Shoe lasts:  The most common type of shoe lasts, the solid last can be made of plastic, aluminum, or wood.

Hinged Shoe Last:  The hinged last is often used for making fine leather shoes. The last can adjust, allowing easy removal.

Scoop Last: In the scoop last, the instep is removable, allowing a cone of the shoe to be shaped.

Telescoping Last:  Used for high boots, the telescope last separates into parts allowing easy removal.









The Classic Sneaker Last

Stop searching! The classic Sneaker last is instock. Ready for your DIY shoe making projects. We have your size and bottoms that fit.
Learn more
On sale $79.99

The Wood Shoe Last

The wood shoe last can be made by copy lathe turning, CNC milling, and even hand carving

Pros: Great for handmade, custom one-off, or bespoke shoemaking.  Easy to customize with hand tools and can be made for a specific customer. Wood surface accepts nails and tacks required for custom-made shoe construction.  Perfect for the handmade high-dollar shoe or the handmade fit testing last. The wood last can be made of solid, hinged, scoop, and telescope last styles.

Cons:  Wood lasts are expensive, fragile, and susceptible to warping and rot if damp. They do not agree with heat tunnels or vulcanizing ovens. Wood lasts are not acceptable for modern mass production.

The Plastic  Last:

The modern plastic shoe last is made of high-density polyethylene plastic (HMW-HDPE), which allows for many tack holes before needing repair. 

The plastic last is made by first injecting a plastic “blank” that is roughly shaped by each size. These plastic blanks are then turned (or cut) by a computer-controlled cutting machine (or lathe). In the turning process, the lasts are rough cut at high speed, then moved to another machine for the final shaping cuts.  After turning, the toe and heel are trimmed with a saw and then sanded into the final shape.

Pros:  The plastic shoe last is the state of the art for modern shoemaking.  Easy to reshape for fitting tests, the lasts can be machined, sanded, and filed.  Computer-turned plastic lasts can be highly accurate for precision fitting.  Easy to mass produce, impervious to heat and moisture. The plastic shoe last is the workhorse of the modern, high-quality sneaker factory.  The plastic last can be made of solid, hinged, scoop, and telescoping styles.

Cons:  Plastic shoe lasts can be expensive.  They are very durable but they can be chipped, dented, and scratched if subjected to rough handling. Large sizes of plastic lasts for boots can be heavy and difficult for workers to handle. Plastic lasts cannot be used in vulcanizing ovens. They can be more expensive to recycle as they must be chipped and remelted.

















The Aluminum Last

Very common for shoe production, the cast aluminum last is easy to handle in large sizes. Often used for snow boots and for making wellington style rubber boots. Mass-produced in rather primitive casting factories, the cast aluminum lasts are made hollow in sand casting molds.

Pros:  The cast aluminum shoe last is cheap, easy to mass produce, and impervious to heat and moisture.  The metal last is required for vulcanized shoe production.  It is perfect for short production runs, easy to recycle, and made of lightweight aluminum.  Cast aluminum is also very durable.

Cons:  Shape is not as accurate as wood or plastic. It is not so easy to keep clean. Quality can be suspect.  Variations between sizes must be watched. Rough surfaces can damage linings.

























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How Rubber Shoe Soles are Made

Outsole mold with locater pins

We can thank Charles Goodyear for his perseverance. In 1844, after years of experimentation, Charles Goodyear finally invented the process of heating natural rubber mixed with sulfur to create shoe rubber.
He called it vulcanization, and this is still how we make shoe rubber today. With the right combination of mixing, heat, and curing agents, sticky natural rubber is transformed into tough and colorful rubber shoe bottoms.

Vulcanization is how all the big shoe brands like Nike, Adidas, Yeezy, Vibram, Margom, and Jordan made outsoles. The molds and processes are all about the same. Black rubber, crystal rubber, or gum rubber is all a matter of the recipe. Black outsole rubber is loaded with carbon, Crystal rubber is 100% synthetic, while Gum rubber is a mixture of natural and synthetic rubber compounds.

How Rubber Soles are Made for Shoes

To make a rubber outsole you need a sole design, metal outsole tooling, a heated hydraulic press, and rubber compound.  


The rubber pressing operations for shoe soles are usually sub-contracted to a factory that specializes in the compounding and pressing of the rubber parts. The rubber mixing operations are messy and pressing rooms are uncomfortably hot, making it best done outside of the shoe factory.
Also, the rubber pressing factory will have many customers, allowing the presses to run higher volume efficiently.

See a rubber pressing factory
The rubber pressing operation begins with the mixing of the rubber components. Depending on the performance requirements of the rubber outsole, natural and synthetic rubbers are combined with curing agents such as sulfur or peroxide.

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How Adidas Makes Shoes

How Adidas Makes Shoes

Great video by Adidas showing how the Hyper Boost is made.

What is the process used to make Adidas Shoes? Most Adidas shoes are made by cold cement construction. Cold cement is the modern updated style of shoe construction. It is the opposite of the classic, high heat, vulcanized shoe construction found in Vans and Converse shoes.
Cold Cement shoe construction allows the use of modern lightweight plastic, foam, and mesh materials due to the low temperatures required for bonding the upper to the shoe sole. Every modern high-performance athletic shoe manufactured by Adidas for running, basketball, etc. is made by this cold cement process.
Every Adidas shoe from the Samba to the New Adidas Ultra Boost is made by the cold cement process. This is how Adidas makes all of its performance athletic shoes.

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Cold Cement Shoe Assembly Process:

This is how Adidas makes shoes In the cold cement process, the shoe upper can be prepared with the Strobel bottom. For this running shoe, the outsole covers the edge upper so a Strobel bottom can be used to make the shoe lighter and more flexible.

The shoe upper is steamed to soften the materials, and the last is inserted and pulled tight. Once the last is tight inside the upper, a second lasting machine pulls the heel edge. Once the last is secured inside the upper and temporary shoelaces are pulled tight, the upper is cooled to shrink the upper tight to the last.

The shoe may have a plastic or fabric part installed on top of the tongue to protect the surface from damage and drift during the lasting operations.

While the upper is being lasted, the sole unit is being prepared. In this case, a rubber sheet sole is combined with the EVA foam cushioning component cemented inside. This is done in a separate process that’s called stock fitting.

Primer and Cement

Once the upper has lasted tightly, and the outside unit is complete, the two pieces come together. The rubber sole unit will receive a coating of primer and cement. The outsole will get its own special primer designed for EVA and rubber. The shoe upper is also prepared with its own special primer and cement.

After the contact cement and primer are completely dried in the heating tunnels, the two pieces are joined together by hand. A skilled worker aligns the upper and outsole together then places the shoe in a hydraulic press.

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Pressing

The shoe will have 3 pressing operations, usually all done with one machine. A vertical press, toe and heel press, and side pressing. This ensures there is full contact between the upper and outsole. Once the shoe is pressed together, it is often put in the cooling tunnel to set the glue.

After the cooling tunnel, a shoe de-lasting machine is used to push the last out of the shoe without wrinkling the upper.

Now the sneaker is complete. At this point, you can insert the footbed. The footbed may be molded EVA with a fabric cover or flat sheet cut foam. The flat die-cut footbed is usually cemented inside the shoe, while molded footbeds are most often removable.
The new sneaker is ready for a final QC inspection, a quick check for any loose threads, cleaning, and packing.

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4D Knit Flyknit™ Shoe Construction

how to make nike flyknit

nike flyknit shoe materials Introduced in 2012, Nike™ Flyknit™ technology, also called 4D knitting is changing the way athletic shoes are made.
A one-piece upper design is produced by a CNC knitting machine then assembled with the tongue, lining materials, and reinforcements. This knitting technology once found only on expensive shoes is rapidly expanding to lower-priced shoes.  You can find running shoes made by Nike™, Tubular X Knit Soccer shoes, Hyper Boost™ from Adidas™, and even Chinese local market casual shoes are now being made with 4D knitting technology.  In the major shoemaking areas of China, the CNC kitting machine is becoming a common sight.
shoe making machine flyknit factory

Flyknit Construction

To construct the one-piece upper, the knitting machine is loaded with polyester, nylon, or spandex fibers. The newest knitting machines can handle a mix of fibers and up to 10 colors at one time. The machine can be programmed to knit one upper at a time or 3 uppers with a maximum width of 90cm.
Depending on the programming and fibers selected, the upper can be thin and stretchable or thick and stretch resistant. The design opportunities are nearly infinite with fiber options, colors choices, knit densities, and openings configurations.
shoe making machine flyknit factory

4D Knitting Cost

The cost depends on the number of colors and fiber types. A single color polyester fiber design may cost $2.50, while a multi-color, polyester spandex combination can cost $7.50 per upper.
Flyknit_shoe_construction3
MOQ (Minimum Order Quantity) is around 1000 pairs, with a setup fee per design of $300. Sample development is fast – just 7 to 10 days, this may take longer if custom color fibers are required. Once the design is confirmed the automated production can run around the clock. 1000 parts can be done in 7 to 10 days, less depending on how many knitting machines are deployed.

Flyknit Construction and Design

While these shoes look like they are entirely constructed with the knit material, the internal linings, reinforcements, and padding are exactly what you will find on a conventionally cut and stitched shoe.

There are many firms in China that now offer one piece knit shoe uppers.

Guoyao Technology Co., Ltd.
Prima Knit
nike flyknit shoe materials Introduced in 2012, Nike™ Flyknit™ technology, also called 4D knitting is changing the way athletic shoes are made.
A one-piece upper design is produced by a CNC knitting machine then assembled with the tongue, lining materials, and reinforcements. This knitting technology once found only on expensive shoes is rapidly expanding to lower-priced shoes.  You can find running shoes made by Nike™, Tubular X Knit Soccer shoes, Hyper Boost™ from Adidas™, and even Chinese local market casual shoes are now being made with 4D knitting technology.  In the major shoemaking areas of China, the CNC kitting machine is becoming a common sight.
shoe making machine flyknit factory

How to Pick Shoe Materials

Start with In-depth reviews of material types available in modern shoemaking. Learn the Technical details of shoe material specification. 195 pages or 300 color photos.

Learn more

on sale $39.99

Flyknit Construction

To construct the one-piece upper, the knitting machine is loaded with polyester, nylon, or spandex fibers. The newest knitting machines can handle a mix of fibers and up to 10 colors at one time. The machine can be programmed to knit one upper at a time or 3 uppers with a maximum width of 90cm.
Depending on the programming and fibers selected, the upper can be thin and stretchable or thick and stretch resistant. The design opportunities are nearly infinite with fiber options, colors choices, knit densities, and openings configurations.
shoe making machine flyknit factory

4D Knitting Cost

The cost depends on the number of colors and fiber types. A single color polyester fiber design may cost $2.50, while a multi-color, polyester spandex combination can cost $7.50 per upper.

How to Pick Shoe Materials

Start with In-depth reviews of material types available in modern shoemaking. Learn the Technical details of shoe material specification. 195 pages or 300 color photos.

Learn more

on sale $39.99
Flyknit_shoe_construction3
MOQ (Minimum Order Quantity) is around 1000 pairs, with a setup fee per design of $300. Sample development is fast – just 7 to 10 days, this may take longer if custom color fibers are required. Once the design is confirmed the automated production can run around the clock. 1000 parts can be done in 7 to 10 days, less depending on how many knitting machines are deployed.

Flyknit Construction and Design

While these shoes look like they are entirely constructed with the knit material, the internal linings, reinforcements, and padding are exactly what you will find on a conventionally cut and stitched shoe.


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How to Select Shoe Materials

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Over 4 1/2 hours of video instruction.
In-depth study of leather, textiles, synthetics and plastics.
Material Design Guide Text Book included.

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Starting a New Shoe Company : FAQ

How to start your own shoe company

What does it take to really start a shoe company?
How to start a shoe business?

Shoe Company FAQ’s

At the Sneaker Factory, we are often asked for advice on how to start a new shoe company.  Here we will answer the most common questions from people around the world.

How to start a shoe business with no money?

Well, this is a tough one. The answer is – you can’t.  Just about everything you need to get started is going to cost some money.  Selling permits, trademark registration, shoe designs, and samples all cost money. Maybe a better question would be – How much money do I need to put into my shoe company to attract investors or launch a Kickstarter™ campaign? You can try to launch a Kickstarter campaign without any actual sample shoes but this will make funding very difficult.

So, how much will it cost to get samples made for a Kickstarter campaign?  If you have your own designs and are using an existing outsole from the factory, $1,000 to $2,500.  If you need an outsole tool made you can add $2,000 to $4,000 depending on the complexity of the molds required. Add another $2,000 to $3,000 if you need professional designs.

(This process and more detailed cost information are covered in full detail in chapter six of our book How to Start Your Own Shoe Company.)

How much does it cost to start a shoe company?

The cost depends on the complexity of your product line. The minimum cost can be only $1,000 to $2,000 if you buy “off the shelf” shoe designs and use stock outsoles and materials. In this case, the start-up costs will include the cost of buying the shoes from the factory and importing them.  Also, you can assume the factory will require a minimum order of 500 pairs.

(This is covered in more detail in chapter six of our book, How to Start Your Own Shoe Company. )

Can I start a shoe business online?

Many people ask me if it is possible to have a factory in China make custom shoes, one-by-one, and have the shoes shipped directly to the customers. Yes, this is possible but very difficult. Factories charge close to double the price for a “one-off shoe”, then there’s the extra expense for air shipping one pair of shoes from China to the USA or Europe which makes the shoes very expensive.  Also, a customer color picker internet interface will be fairly expensive to develop.

What about buying shoes in bulk and selling them online? Yes, this is a fine idea. If you can get paying customers to your website it is possible to make good profit margins this way.

(In the book How to Start Your Own Shoe Company we discuss in detail the costing models and distribution models for internet shoe businesses.)

Can you help me make my shoe business plan?

You will need a detailed business plan and Sneaker Factory is here to assist.  Without a solid plan, your shoe company dream will become a nightmare! Your master plan needs many smaller plans. It is easier to make a comprehensive plan by breaking it down into many smaller parts. Your plan needs to include your brand identity, product plan, financial calculations, sourcing supply chain, sales plan, distribution plan, and marketing plans.

(Shoe company business plans are discussed in chapter 1 of How to Start Your Own Shoe Company and the entire book is your guide to making a complete plan.)

How to start a shoe line from scratch

While this relates to the question “How to start a shoe business without any money?”  The most important idea is to make a shoe LINE.  The work required to make your shoe company is wasted if you only make one shoe design and it fails to sell. You should start with a small product line, 2 or 3 styles in a few colors.  Making more shoes will increase your startup expenses but it will also increase your chance for success. In the trade, we call this small line a merchandise assortment.

(In the book How to Start Your Own Shoe Company we discuss designing your product line in chapter 3.)

How to start a shoe business from home?

Yes! You can run your small shoe brand entirely from your home. You can have a business selling thousands of shoes without renting office space. This is a fully “virtual” operations plan. Hire out all the services your company requires: design, marketing, warehousing, etc. These can all be done by someone else, someplace else.

(Operational models from traditional to hybrid to virtual are all reviewed in chapter 9 of the book How to Start Your Own Shoe Company.)

How to start a shoe manufacturing company

Many people think Nike™ makes millions of pairs of shoes. The truth is that Nike itself does not make the shoes. Nike, along with the majority of other mega brands, does not own the shoe factories they use. The shoes are developed by Nike in partnership with the factory and Nike lets the factory manufacture the shoes. Nike sets the standards and has an army of inspectors and technicians, but Nike employees do not actually MAKE the shoes.

Starting a shoe manufacturing factory is a totally different question. A new factory requires space, equipment, and workers. Space and equipment are easy to find and buy. Staffing a factory with experienced pattern makers, developers, technicians, and stitchers is a huge challenge.

How much money do I need to start my own shoe brand?

This one is easy. ZERO. Get your brand started with just a pencil and a pad of paper. Write down your ideas, draw your shoes, and sketch your logos. Solve a footwear problem that no one else has solved. Create a design that no one has ever seen.  Build a sneaker which will increase performance on the field, court, or workplace. Your new shoe brand starts in your mind and once you put your ideas down on paper you can begin to build and share them with others.

How To Start Your Own Shoe Company PDFLearn how to start a shoe business: Your next step

Check out our book:  How to Start Your Own Shoe Company
Read these articles:  Can I start a shoe company and Finding a Shoe Sourcing Agent. 
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