On, the Swiss sportswear brand, has recently revealed a pioneering technology known as LightSpray, described as a revolutionary new performance footwear upper technology. Developed at the On Labs in Zurich, the new upper will make its debut in the Cloudboom Strike LS (LightSpray), designed for high-performance running.
The LightSpray uppers, according to On, are not constructed like traditional shoe uppers. They are precision-made in a rapid, one-step manufacturing process, which is automated by a robotic arm at the On Labs in Zurich. The result is a one-piece upper that is ultra-light, provides exceptional fit and support, and is ideal for race day. The sleek, seamless design minimises distractions and eliminates the need for laces.
In terms of sustainability, the LightSpray one-step manufacturing approach is a step forward. It reduces waste and produces an upper with 75% fewer carbon emissions than On’s other racing shoes. This process enables faster production of high-performance shoes with less waste, while also offering the potential to make shoes closer to the customer. The use of a single recyclable material and an assembly process that eliminates the need for glue opens up new opportunities for circular manufacturing and products.
Marc Maurer, Co-CEO of On, stated, “LightSpray marks a significant milestone for On, not only in creating high-performance products but also in moving towards a more sustainable, circular future.” The technology has potential to contribute to the brand’s mission of being a premium sportswear brand rooted in innovation, design and impact.
On athletes were closely involved in the design and testing of the LightSpray technology and shoe. Earlier this year, Hellen Obiri, 4x world champion runner and winner of marathons in Boston and New York City, wore a development version of the Cloudboom Strike LS when she won the Boston Marathon for the second year in a row.
Starting this summer, the automated production unit that makes LightSpray technology will be showcased for live manufacturing demonstrations. Consumers can witness shoes being made featuring LightSpray technology at the On Labs Paris pop-up.
For the first time, On is establishing a fully automated production unit at the On Labs in Zurich, where the LightSpray upper of the Cloudboom Strike LS will be manufactured and the final shoe will be assembled.
The idea for LightSpray originated from an unexpected source – a Halloween decoration. A member of the On Innovation Team was inspired by a video showcasing a hot glue gun creating spider webs. This led to the development of a fully automated, one-step shoe upper manufacturing process.
Traditionally, running shoes are made and developed in a similar way, involving multiple stages and the use of glue. On’s LightSpray approach, however, uses a robotic arm to create an ultra-light, one-piece shoe upper, fully automated and in just one step. An integrated patent-pending thermal fusing technology allows light spray uppers to bond seamlessly to the midsole without the need for glue. Computational design and robot programming replace traditional pattern making, allowing for rapid prototyping and faster transformation of ideas into products. Additionally, branding is added within minutes via a fully automated ink-jet printing process, an eco-friendly alternative to typical branding processes.
On mentions that each shoe is fully assembled in just three minutes, emphasizing that the LightSpray technology has the potential to revolutionise not only footwear but also all kinds of wearable products in the sportswear industry.
The Cloudboom Strike LS was initially released to the public in April and will be available again in autumn/winter 2024. Interested consumers can sign up on the website to be notified of the availability of the Cloudboom Strike LS in different markets.
This is truly an exciting advancement in the world of sports footwear, and it’s just the beginning of what’s possible with On’s innovative LightSpray technology.