On Unveils LightSpray™: a new High Performance Upper technology crafted by a Revolutionary single step Manufacturing Process

LightSpray™ ultralight uppers are sprayed not built, in a process that reduces CO2 emissions, paving the way for a circular future and faster, localized manufacturing ​
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​LightSpray™ is set to revolutionize performance uppers in the same way On CloudTecⓇ transformed midsoles, introducing a completely new design aesthetic and feel

On, the innovative sportswear brand from Switzerland, has introduced LightSpray™, a revolutionary new performance footwear upper technology. Developed at the On Labs in Zurich by an internal team of innovators, this marks a new era of innovation in footwear production and performance. The technology will make its first appearance in the Cloudboom Strike LS (LightSpray™), high- performance running shoe.

LightSpray™ uppers aren’t built like traditional shoe uppers. They’re precision made in a fast, one-step manufacturing process, automated by a robotic arm at the On Labs in Zurich. The result is a one piece upper that is ultra light and provides exceptional fit and support, making it ideal for race day. The ultra-thin and seamless design minimizes distractions and even eliminates the need for laces.

The revolutionary LightSpray one-step manufacturing approach also paves the way for more sustainable manufacturing in the future. The fully automated process reduces waste and produces an upper with 75% fewer carbon emissions than On’s other racing shoes. The process enables faster production of high-performance shoes with less waste, and offers the potential to make shoes closer to the customer. It also creates new opportunities for circular manufacturing and products, thanks to its construction from a single recyclable material and the assembly process that eliminates the need for glue.

“LightSpray™ marks a significant milestone for On, not only in creating high performance products but also the potential it has to move us towards a more sustainable, circular future.” said Marc Maurer, Co-CEO of On.  “Our team is constantly challenging itself to rethink the status quo in terms of the design, development, and manufacturing of performance sportswear. LightSpray™ technology will propel us forward in our mission to be the most premium sportswear brand, rooted in innovation, design and impact.”

On athletes were intimately involved in the design and testing of this technology and shoe. ​ Earlier this year, Hellen Obiri, 4x World Champion runner and winner of the marathons in Boston and New York City, wore a development version of the Cloudboom Strike LS when she won the Marathon in Boston for the second year in a row.

This summer, the automated production unit that makes LightSpray™ technology will be taken on the road for live manufacturing demonstrations. Consumers can watch shoes being made featuring LightSpray™ technology at the On Labs Paris pop-up at 27 Bd Jules Ferry, 75011, Paris from July 27th to August 10th and from August 28th to September 8th. The Cloudboom Strike LS was initially released and made available to the public in April and will be available again in Fall/Winter 2024. Interested consumers can sign up at on.com/lightspray to be notified of the availability of the Cloudboom Strike LS in different markets.

LightSpray™ Manufacturing Process – Top Facts

  • For the first time in its history, On is establishing a fully automated production unit at the On Labs in Zurich, which has been developed in-house. This is where the LightSpray™ upper of the pinnacle high-performance running shoe, the Cloudboom Strike LS, will be manufactured and the final shoe will be assembled.
  • The spark for LightSpray™ came from an unexpected source – a Halloween decoration. A member of the On Innovation Team was inspired by a video that showcased a hot glue gun creating spider webs. Intrigued by the swift creation of fabric onto a complex shape, they saw a shoe as the perfect application for this technology. They started by creating a simple prototype shoe upper with a handheld, modified hot glue gun. They then progressed to developing ​ a unit which produces a continuous filament, forming an engineered structure. This structure eventually became a one-piece upper, sprayed in a single step.
  • For decades, running shoes have been made and developed in the same way, prompting the On Innovation Team to rethink the standard process. Traditional upper manufacturing involves multiple stages, including yarn extrusion and finishing, weaving or knitting, sewing and assembling of parts. In contrast, LightSpray™ uses a robotic arm to create an ultra-light, one-piece shoe upper, fully automated and in just one step. This more efficient process minimizes waste and creates an upper with a 75% reduction in carbon emissions, compared to On’s other racing shoes.
  • An integrated patent pending thermal fusing technology allows LightSpray™ uppers to bond seamlessly to the midsole without the need for glue.
  • With LightSpray™, On has not only revolutionized how a product looks, feels and functions, but also its engineering, design, and development process. The traditional pattern making process is replaced with computational design and robot programming. This allows every part of the LightSpray™ structure to be engineered according to its needs, and facilitates rapid prototyping, transforming ideas into products within hours.
  • Once LightSpray™ uppers are created, branding is added within minutes via a fully automated ink-jet printing process. This method is a more sustainable solution than typical branding processes as it uses a minimal amount of water and allows for high design flexibility.
  • Each shoe is fully assembled in just three minutes
  • The LightSpray™ technology has the potential to revolutionize not only footwear but also all kinds of wearable products in the sportswear industry

Cloudboom Strike LS – Top Facts

  • LightSpray™ is made to optimize athletes’ performance and maximize speed on race day
  • The Cloudboom Strike LS in On’s lightest running shoe. The upper weighs just 30g, while the entire shoe weighs 170g.
  • The ultra-thin LightSpray™ upper is precision-made for support, adaptable to the foot, seamless, and lace-free, resulting in an exceptionally lightweight shoe.
  • This fitted upper eliminates all distractions to fully focus on what really matters: your run, your performance.
  • The midsole features two layers of Helion™ HF hyper foam, On‘s ultra-responsive Pebax® formula made with over 40% bio-based raw materials, providing impact absorption and high energy return.
  • A pre-shaped, stiff carbon Speedboard®, sandwiched between the foam, enables the best propulsion upon each stride
  • Computer-aided engineering leads to an optimized outsole for improved traction and weight reduction while increasing the ground contact area based on runners’ pressure map data.
  • The glueless bonding of LightSpray™ allows for a minimal construction of the CloudBoom Strike LS, which has no sockliner and no strobel in direct contact with the Helion™ HF hyper foam, for minimal energy loss.
  • Weight Men: 170g (size USM8.5)
  • Weight Woman: 158g (size US W7)
  • Heel to toe drop: 4mm
  • Cost 330 USD / 330 EUR / 380 CHF

 

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