4 things you need to know about the adidas 4DFWD

adidas tested 5 million 3D printed mesh combinations to design its latest running shoe

A few years ago, the idea of ​​being able to «print» a solid object seemed like something out of Star Trek. But here we are in 2021, and 3D printing, or additive manufacturing, has given people the freedom to turn their ideas into reality, to create customized materials and objects on demand.

adidas is already known for finding ways to combine a deep understanding of the sport with innovations in technology and design. Inspired by the creative freedom offered by 3D printing, adidas chose to create its new running shoe using this technology: the 4DFWD.

What makes it different is that the 3D printed midsole was designed precisely to improve running performance, whether you are an avid runner or just a casual runner.

Below we take a look at four of the key technology, design and performance options used by adidas.

Designed to give you a boost when you run

The 4DFWD midsole, 3D printed, was designed in such a way as to give a boost to the run. How is this result achieved? Essentially, when your heel hits the ground, whether you’re on the pavement or treadmill, the intelligent midsole takes the vertical impact braking forces felt by the foot and converts them into forward horizontal motion. According to adidas, those who tested the 4DFWD said it made them feel like they were «gliding» instead of running.

adidas worked with the University of Calgary to conduct biomechanical testing to refine the design, analyzing the shoe’s motion, braking forces and running economy to optimize performance. The 4DFWD can push up to three times harder, helping to provide a supported, controlled ride that feels like a glide.

Data-driven design

This unique experience could be developed by introducing the optimal 3D printing technique and cell structure.

The 4DFWD’s insole is made up of 3D butterfly cells made from 40% bio-based materials, woven together in a mesh structure.

Over 17 years of studied data on running, propulsion and how your feet touch the ground are behind this design. The adidas team also explored over five million possible mesh shapes to identify the best midsole design to support maximum performance.

They then commissioned the company 3D Carbon to build the midsole. Carbon took all the data from adidas and used a digital light synthesis process to deliver high-precision 3D printed midsoles that help depending on the angle at which the wearer walks every second.

Comfortable coverage

adidas built the entire 4DFWD with the idea of ​​making the most of the 3D printed midsole and used historical mapping data from years of product development and prototypes to customize the perfectly crafted upper with adidas’ soft and supportive Primeknit+ material.

This section of the shoe is tight and very light, «feels like you’re wearing a sock» – a quality that some of the other shoes in the 4D range are known for.

Total training partner

While the 3D printed midsole brings style and innovation, the outsole at the bottom of the shoe offers exceptional traction on a variety of running surfaces and while the midsole features the latest 3D printing techniques and structures, the upper is comfortable and breathable.

The 4DFWD is the expression of extensive research and extensive testing: a shoe that can help runners of all types achieve peak performance.

Conclusion

The monumental effort by Adidas in testing 5 million 3D-printed mesh combinations to design its latest running shoe serves as a powerful testament to how additive manufacturing (3D printing) has fundamentally revolutionized product development, moving beyond simple prototyping into mass customization and performance optimization. The ability to rapidly and affordably iterate through such a vast number of complex, custom geometries would be impossible with traditional molding or manufacturing techniques.

This extensive testing allows Adidas to engineer a shoe sole that is precisely tuned for specific athletic needs, controlling variables like cushioning, energy return, and stability at an unprecedented level of detail. The result is a footwear product that embodies the core promise of 3D printing: the freedom to turn complex digital ideas into physical reality, creating highly customized materials and objects on demand. The successful integration of this technology confirms that 3D printing, once a futuristic concept, is now a crucial tool driving innovation in high-performance consumer goods.