How It’s Made Athletic Shoes

Summary

The fascinating journey of athletic shoe production begins with the historical development of rubber soles, which revolutionized footwear. In modern times, crafting a pair of sneakers involves numerous meticulous procedures. From cutting patterns and stamping model numbers to sophisticated stitching and applying thermal resin, each step is vital in shaping the shoe's upper. The process involves high-end machines that streamline tasks like stitching and bonding various parts. Ultimately, a combination of manual dexterity and mechanized precision ensures that these shoes are not only fit for the streets but also for rigorous workouts. It's a whirlwind 21-minute process, epitomizing the intricate and efficient world of shoe making.

Highlights

• Athletic shoes originated with treaded rubber soles, earning the name 'sneakers.' 👟
• The production line involves hydraulic presses, stitching machines, and thermal resin application. 🏭
• Each shoe undergoes a sequence of cutting, strengthening, stitching, and bonding operations to ensure quality. ⚒️
• Reflective logos and intricate embroidery add both functionality and style. 💡
• The finished product is tested and inspected meticulously before it leaves the factory. 🕵️‍♀️

Key Takeaways

• Athletic shoes have evolved significantly since ancient times and gained popularity with rubber soles in the 20th century. 🏃‍♂️
• The shoe-making process involves cutting out patterns and adding structural elements such as leather toe tips. ✂️
• Advanced machines assist with precision tasks like intricate stitching and bonding of shoe components. 🖇️
• The crafting sequence marries both manual and machine operations for a seamless finish. 🤲⚙️
• In just 21 minutes, a pair of sneakers is ready to hit the streets or the track. ⏱️

Overview

Athletic shoes have a rich history, transforming from basic foot coverings to highly-engineered footwear crucial to athletics. The innovative use of rubber soles in the 20th century allowed sneakers to make a quiet yet significant entrance into everyday fashion, spawning a massive industry focused on performance and style.

Manufacturing athletic shoes involves numerous precise stages, each contributing specific features and qualities to the final product. High-tech machinery assists in crafting the perfect shoe, from stamping model numbers to ensuring seamless stitching of various pattern pieces. Leather, resin, and fabric come together in a dance of materials, guided by skilled hands and computerized processes.

Every pair of shoes undergoes rigorous assessment, ensuring they are ready for energetic use, whether jogging down city streets or racing on tracks. The entire process unfolds in a swift 21-minute cycle, highlighting the synchronous ballet of manual craftsmanship and mechanized efficiency. Sneakers reach consumers ready to offer comfort, durability, and style.

Chapters

• 00:00 - 00:30: Introduction to Athletic Shoes Athletic footwear has origins in ancient history, but the modern concept became popular with the invention of treaded rubber soles in the early 20th century. These shoes, known as sneakers for their quiet tread, have evolved in design, increasing their popularity.
• 00:30 - 01:00: Cutting Patterns for the Upper This chapter explains the process of cutting patterns for the upper part of athletic shoes. It highlights how a hydraulic press is used to force a dye through synthetic fabric to create these patterns. Additionally, there is a focus on the punching out of leather toe tips, which are among several cutouts that contribute to the shape and structure of the shoe's synthetic upper.
• 01:00 - 01:30: Stiffening the Toe Tip A worker arranges tip parts on a non-stick tray and places strips of thermal resin onto them. A nonstick sheet is draped over the tray before it's placed into a hot metal press. In the press, the resin melts into the leather to stiffen and strengthen it. Following this, another worker stamps the model number onto the heel cut out.
• 01:30 - 02:30: Sewing Department Operations The chapter titled 'Sewing Department Operations' focuses on the sewing department's role in assembling athletic shoes. It describes how a worker stitches a reflector onto the shoe upper and explains the need for more intricate stitching on accent pieces. The worker uses a computerized platform that automates the movement, ensuring precise stitching that would be challenging to achieve manually.
• 02:30 - 03:30: Assembling the Upper The chapter titled 'Assembling the Upper' details the process of assembling the shoe's upper part. It begins with sewing a reflective logo onto the shoe using computer-guided software. Next, a resin-fortified leather toe tip is attached. Finally, the chapter describes how the collar is pieced together and sewn to the back of the shoe, completing the assembly for this part of the shoe.
• 03:30 - 04:30: Adding Structure to the Shoe The chapter titled 'Adding Structure to the Shoe' describes the process of installing thick foam padding on the inside of a shoe collar. After installing, the collar is turned right side out to neatly tuck the padding inside and hide the seams. Once the collar is in place, any obscured lace holes are cleared using a compressed air punch. Additionally, further down in the production line, computerized needles are used, indicating advanced technology in the shoe manufacturing process.
• 04:30 - 05:30: Bonding Upper to Sole This chapter describes the process of assembling an athletic shoe, specifically focusing on the sewing of brand information onto the tongue panels, adding liners and padding, and stitching a fabric base onto the shoe. The sequence emphasizes working inside out to conceal seams.
• 05:30 - 06:30: Final Assembly and Inspection In the chapter titled 'Final Assembly and Inspection,' the process of assembling the shoe is detailed. A piece of rigid plastic is applied to the heel of the shoe to provide structure and support. This is followed by the shoe being placed on a foot form called a 'last,' which helps shape the shoe. Heat is applied to make the shoe malleable, allowing a machine to mold it to the shape of the last. Additionally, nozzles apply cement to the shoe for gluing purposes.
• 06:30 - 07:00: Feedback and Suggestions The chapter discusses the process of bonding the upper part of a shoe to the rubber sole. Initially, heat is applied to both the upper and the rubber sole, activating the glue on the sole and preparing the upper for bonding. Manual force is initially used to press the two components together. Following this, the shoe is placed in a machine where mechanized pressure is applied via an expanding rubber bladder to ensure a secure bond.

How It’s Made Athletic Shoes Transcription

• 00:00 - 00:30 athletic footwear dates back to ancient times but the concept gained traction with the development of treaded rubber soles in the early part of the 20th century these represent abell and hit the ground quietly earning them the name sneakers design improvements have broaden the appeal of athletic shoes
• 00:30 - 01:00 people wear them everywhere the athletic shoe has definitely gone Main Street using a hydraulic press this employee forces a dye through synthetic fabric to cut out patterns for the upper part of the shoe at the next station he punches out leather toe tips the toe tip is one of numerous cutouts that adds shape and structure to the synthetic upper
• 01:00 - 01:30 after arranging the tip parts on a non-stick tray this worker places strips of thermal resin onto them she drapes a nonstick sheet over the tray then slides it into a hot metal press the resin melts into the leather to stiffen and strengthen it another worker stamps the model number on to the heel cut out then it's over to
• 01:30 - 02:00 the sewing Department where a worker stitches a reflector on to the athletic shoe upper other accent pieces call for more intricate stitching so she arranged 'as the parts on a computerized platform the platform moves back and forth allowing the needle to do a perfect job of stitching the accent pieces to the upper this stitching would be difficult to execute manually
• 02:00 - 02:30 once some of the more substantial pieces have been applied to the shoe it's time to sew on a reflective logo and the needle is once again guided by computer software this athletic shoe upper is now ready for its resin fortified leather toe tip she stitches it in place and then pieces together the caller and sews it to the back of the shoe
• 02:30 - 03:00 she installs thick foam padding on the inside of the collar and then turns it right side out to tuck the padding neatly inside and hide the scene putting on the collar has obscured the top lace holes so she clears them with a compressed air punch down the line more computerized needles
• 03:00 - 03:30 embroider brand information onto the tongue panels the next worker shows a liner and padding to the panel again working inside out to hide the scene another worker then stitches a fabric base on to the athletic shoe
• 03:30 - 04:00 she applies a piece of rigid plastic to the heel which adds structure and support to the back part of the shoe further down the production line a worker tugs the shoe onto a foot form called a last they heat it to make it malleable enough for this machine to pull it to the shape of the last at the same time nozzles apply cement to glue
• 04:00 - 04:30 the overlap to the fabric base then a machine heats both the upper and a rubber sole the heat activates glue applied to the sole earlier and also prepares the upper for bonding to that soul they initially use manual force to press the two together and then the shoe is subjected to mechanized pressure inside this machine a rubber bladder expands to force the two together for a
• 04:30 - 05:00 complete seal the shoe then gets a foam insole with an arch support the worker laces it partially and then pairs it up with the other shoe an inspector examines the pair for defense it has taken about 21 minutes to make this pair of athletic shoes and they should be able to take a real workout if
• 05:00 - 05:30 you have any comments about the show or if you'd like to suggest topics for future shows drop us a line at wwc oh it's made calm