FOOTWEAR DEVELOPMENT
Shoe Development Process | From Concept to Production
Our shoe development process follows seven main stages, from style requirements and last development to trial fitting, sole construction and final finishing.
PROCESS OVERVIEW
Seven Steps to Developing Shoes
Each stage builds on the previous one. The upper is developed and formed around the last before a trial shoe is reviewed. Only after fit and appearance are confirmed does the shoe move into final sole construction and finishing.
01
Style & Requirements
02
Shoe Last Development
03
Pattern & Materials
04
Upper Making
05
Trial Shoe & Fitting
06
Shoe Construction
07
Finishing & Inspection
STEP 01
Define the Shoe Style and Product Requirements
The process begins by reviewing the intended shoe design, reference sample, drawings, size requirements, target use and other development information required for the project.
Input
Output
STEP 02
Build the Shape and Fit of the Shoe
The shoe last defines the three-dimensional form of the footwear and influences toe shape, width, instep, heel fit, proportion and overall fitting characteristics.
Controls
Output
STEP 03
Develop the Upper Pattern and Select Materials
Patterns are developed around the approved last and shoe design. Upper materials, linings, reinforcement components and other materials are then selected according to the intended appearance and performance.
01
02
STEP 04
Build the Upper and Shape It Around the Last
Cut upper components are stitched together with lining, reinforcements and decorative elements. Once the upper is completed, it is placed over the shoe last, shaped and secured so the footwear takes on its intended three-dimensional form.
01
Upper Cutting
Upper components are cut according to the developed pattern.
02
Lining & Trimming
Linings, reinforcements and decorative components are added.
03
Upper Stitching
Individual upper components are stitched into a complete upper.
04
Place Upper on Last
The completed upper is positioned around the shoe last.
05
Shape & Secure
The upper is shaped and fixed to establish the intended shoe form.
STEP 05
Review the Shoe Before Final Production
The trial shoe is reviewed before moving into final production. This gives the customer an opportunity to check the overall appearance, fit and comfort and request changes where necessary.
01
Review Overall Appearance
02
Check Fit & Comfort
03
Identify Problems
04
Make Necessary Adjustments
05
Customer Approval
Customer Communication
Mass Production
STEP 06
Join the Approved Upper and Sole
After the trial shoe has been approved, the shoe moves into final construction. The required sole construction is carried out according to the selected footwear style and construction method.
01
Approved Trial Shoe
02
Prepare Bottom Construction
03
Prepare the Sole
04
Attach or Stitch Sole to Upper
05
Complete Shoe Construction
STEP 07
Complete the Final Appearance and Quality Check
After construction, the last is removed and the finished shoes move through cleaning, trimming, surface finishing and final appearance inspection before packing.
01
Remove the Shoe Last
02
Trim & Clean
03
Install Sock Liner
04
Surface Finishing / Polishing
05
Final Quality Check
Finished Product Quality Inspection