Charles R. Goulding and Preeti Sulibhavi discuss Zellerfeld’s intricate 3D printed designs.
The sneaker industry has long been dominated by big names like Nike, Adidas, and New Balance. But a small startup based in Los Angeles called Zellerfeld is making jumping hurdles with its unique 3D printed sneaker designs that are attracting attention from top fashion houses and A-list celebrities.
Zellerfeld was founded in 2018 by entrepreneur Micah Zellerfeld, who saw an opportunity to disrupt the sneaker market using 3D printing technology. The company focuses on creating one-of-a-kind sneaker designs with intricate details and textures that would be difficult or impossible to manufacture using traditional methods.
What sets Zellerfeld’s sneakers apart is the 3D printing process that allows for completely custom and complex designs. Using advanced 3D modeling software and industrial-grade 3D printers, the company can “print” sneakers with intricate lattice structures, customizable support features, and designs not possible with cut-and-sew methods. For example, their HERON01 model features a unique “exoskeleton” design with support struts throughout the midsole, providing a level of structurally-integrated cushioning impossible in normal manufacturing.
The materials are also integral to achieving these complex designs. Zellerfeld sneakers are printed from BASF industrial resins which are durable, flexible and provide critical support exactly where needed. This allows the creation of open air meshes and lattice designs that look amazing but still provide support and structure to the sneaker.
Zellerfeld’s innovative approach has captured the attention of the fashion world, including luxury brand LVMH. In 2021, Nicolas Ghesquière, Louis Vuitton’s creative director of Women’s collections, collaborated with Zellerfeld on a 3D printed boot design for the brand’s Fall/Winter 2021 runway show. We have covered the fashion footwear brand ROOTS3D that displayed similar lattice-based designs.
Celebrities have also taken note of the trendy and technology-forward brand. Pop superstar Justin Bieber caused a frenzy on social media when he was spotted wearing a pair of Zellerfeld’s HERON01 sneakers featuring the signature exoskeleton cage design. Other celebrity fans include NBA player LeBron James and DJ Steve Aoki.
One of Zellerfeld’s most unique designs is the Heel Your Sole model. Featuring a complex honeycomb lattice design along the length of the shoe, the Heel Your Sole almost looks like a prop from a sci-fi film. But reviews from testers confirm the radical design provides amazing comfort and support thanks to the ability to finely tune the lattices to provide structure and flex precisely where needed. The pair tested by SneakerFreaker magazine received a 9 out of 10 score, with the reviewers raving about the “space age comfort.”
The Research & Development Tax Credit
The now permanent Research and Development (R&D) Tax Credit is available for companies developing new or improved products, processes and/or software.
3D printing can help boost a company’s R&D Tax Credits. Wages for technical employees creating, testing and revising 3D printed prototypes can be included as a percentage of eligible time spent for the R&D Tax Credit. Similarly, when used as a method of improving a process, time spent integrating 3D printing hardware and software counts as an eligible activity. Lastly, when used for modeling and preproduction, the costs of filaments consumed during the development process may also be recovered.
Whether it is used for creating and testing prototypes or for final production, 3D printing is a great indicator that R&D Credit eligible activities are taking place. Companies implementing this technology at any point should consider taking advantage of R&D Tax Credits.
Conclusion
By leveraging cutting-edge 3D printing technology and innovative design, Zellerfeld is proving that the future of sneaker manufacturing and high fashion may rely on additive manufacturing. As Micah Zellerfeld said in an interview with HypeBeast, “3D printing gives us almost unlimited freedom to create structures previously unimaginable in footwear design. We’re just beginning to scratch the surface of what’s possible.” With major brands and celebrities now taking notice, Zellerfeld’s 3D printed designs seem poised to disrupt and revolutionize the world of sneaker fashion.
