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How Nike Hyperfuse Based Shoes Are Constructed

High-frequency Hyperfuse.

You know Hyperfuse. That synthetic, plasticky-lookng upper build on an increasingly greater assortment of Nike shoes. You may even own a pair of Hyperfuse based shoes. Now you can get a detailed video look at exactly how the technology is  in this video. It is so detailed, it could almost be training material for factories.

Whoever thought that sneakers are all about stitching is proven wrong here. The upper remains fairly stitch free thanks to other bonding techniques like high-frequency welding, ultra sonic waves and of course fuse.

Nike’s (Hyper)fuse is a new way of constructing shoe uppers through heat pressing (in this case at a temperature of 150°C and pressure of 80 kg for 30 seconds) three or more synthetic layers. This allows for strategic breathabilty, stability and durability.

However, this video also shows that fuse material alone does not make up the whole upper. To prevent skin irritation or chafing, additional lining and padding is added. At the forefoot the shoe has a half-mesh sleeve that is integrated into the tongue.

The illustrated shoe model in the clip shows off the Nike Lunar Sweet Victory training shoe, but the manufacturing process and assembly are an applicable broad look behind one of the Swoosh’s biggest technical pushes over the last few years.



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Comments (9)

leather will always have a place w shoes even if they come out w rocket boosters nothin better than some classic js

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Well said RB i agree.

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Wanted to see the construction and application of the tooling, but it was a neat look into the manufacturing process of the Fuse upper. Even though I’m a fan of the technological advances in production techniques, I still have an appreciation for using fine quality materials, when used selectively and properly.

On another note, I’d really like to see other brands show their processes and technologies, such as adidas’ Puremotion and Under Armor’s MicroG. I don’t think they’d have to reveal too much details that they lose their competitive advantages, but just brief intros like this that educate the interested consumer.

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definitely a great peak into the design process.

it just goes to show that it’s not all about making a shoe look cool, but it’s also about making a shoe, period. though the processes of making shoes have stood the test of time, the innovation in terms of materials, processes and interaction are where design is going.

thanks for sharing!

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The way things are headed.. you wont need a big ass factory in China to make quality shoes anymore.

come on home baby

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@hildred – your country developed the Jedi mindi power that makes the materials and the presonic attachment fly?? awesome!! the day for manual labor comes to an end

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@ Urriah

I doubt it will take 125 people in an assembly line to put those puzzle pieces together and place them in the oven.

Nowadays theres still a gazillion people in factories stitching each pattern piece be piece.

think about it.

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nice post.
but dont you think this will increase the cutting and preparation steps required compared to normal stitched shoes. So the excess labor requirement in cutting and prep might take away from the reduced labor requirement in the stitching/welding process?

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Great to see ultrasonics.

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