Changing the way shoes are made and materialized for athletic use dates back centuries. Spiked leather running shoes for track and cross-country appeared in the late 1800s, Keds introduced canvas sneakers over a hundred years ago and the Nike Waffle Trainer debuted a cushioned outsole five decades ago.

Modern advancements in material science have ushered in lighter, faster, better performing footwear introducing upper materials engineered to enhance breathability and comfort; midsole foam formulations with hyper-responsive energy return benefits; more durable plant-based alternative leathers; and production methods automated for speed and customization. And this year readies for the next big leap in shoe design and development. Circular fabrics compete with conventional yarns, scalable solutions for regenerative fiber developments are coming of age, categories widen for textile experimentation with cycling and climbing shoes making strides in fit, form and functionality. Most significantly, AI is now in the hunt for the holy grail of performance footwear.

When asked about game-changing textile trends over the past 25 years, Larry O’Brien, key accounts sales manager for OrthoLite highlighted the importance of knit/woven uppers. “This process for designing and manufacturing uppers has been an industry revolution allowing for unlimited upper designs, colors and patterns. It created a clean, rich look that was unachievable from single panel stitch and turn designs of the past. It also opened the door for a multitude of color applications, improved durability, breathability and helped eliminate waste!”

O’Brien also emphasized On’s proprietary LightSpray upper technology as a key textile development. He states, “the spraying of a polymer which forms into an upper has been a brilliant innovation using robots in the application process. Less waste, extremely lightweight and no variance in the upper which you see in cutting and stitching. It greatly reduces the large volume of people touching the shoe and the speed to market is remarkable! The use of robots may make mass production challenging to scale.”

THE PAST

Manmade Fibers Step Up

Nike Air Terra ACG debuted as an original multi-purpose shoe designed for the hazards of trail running. New in Spring ‘91, the Air Terra ACG lightweight, low-cut shoe employed synthetic materials suitable for stability on rugged terrain. A review in the September 1990 issue of Outside Business magazine featured the shoe’s “low profile polyurethane forefoot, a Phylon heel collar and a uniquely patterned solid rubber outsole that was inspired by the tread of a mountain bike tire.”

Reebok Liquid Speed launched in 2016 using 3D tech to create and assemble shoes in the company’s “Liquid Factory,” with a manufacturing process that optimized modern software and robotics. In collaboration with Reebok, chemical company BASF developed a urethane-based liquid to help eliminate molds. The liquid is drawn on the entire shoe as the outsole, resulting in a three-dimensional fit.

KEEN Uneek features an unconventional hybrid sneaker-sandal with woven-cord upper made from two cords and a sole. Launched in 2013, the model highlights that unlike 2-dimensional sheets of material, the new construction technique is highly adaptable to different foot shapes.

THE PRESENT

Functional Foams & Carbon Plates

Norda Abyss 001A upper is seamlessly constructed with bio-circular Dyneema, an exceptionally strong and extremely light, sustainable fiber noted for high durability and abrasion resistance. Bio-circular Dyneema means the raw material comes from a sustainable mass-balance approach and is Bluesign approved and ISCC certified. Carbitex materials possess the unique ability to precisely tailor flex to match the athlete’s needs.

Brooks Glycerin Flex utilizes technology that blends flexibility with max cushioning. The nitrogen-infused DNA-tuned cushion is seamlessly crafted into one midsole without added layers. Strategic cutouts in the midsole foam combined with asymmetrical flex grooves creates a more grounded underfoot feel and overall more natural movement experience.

Nike ACG Zegama arrived 35 years after the original ACG Air Terra with premium upgrades in cushioning, protection and traction. The new iteration incorporates trail-tuned ZoomX foam and dynamic energy return with Cushion 3.0 and improved Vibram Megagrip outsole.

THE FUTURE

Design Simplicity & Next-Gen Solutions

SIDI Genius X WYVE cycling shoe has a breathable lightweight mesh upper with TPU reinforcements for enhanced foot stability. Dual NUUN aluminum dials are for precise, fast, and aerodynamic tension control. The Fit system functions seamlessly even when the lever is closed, ensuring consistent, micro-adjustable fit with every turn.

Notace Yama T1 includes a neutral heel-to-toe platform supporting natural gait mechanics and healthy posture, as well as an engineered eTPU midsole that delivers an ideal balance of flexibility, cushioning and ground feel. The 3mm lugs are angled in three different directions for unparalleled traction and grip.

La Sportiva Skwama Lite climbing shoe blends precision and adaptability with a soft microfiber upper, updated heel construction, and a dynamic closure system that delivers a secure, responsive fit. A 4mm FriXion Black sole provides reliable grip and sensitivity ideal for modern gyms, techy boulders, and outdoor leads.