On Unveils LightSpray™, A Revolutionary Spray-On Sneaker Technology Transforming Sustainable Footwear

Swiss performance brand On has introduced a groundbreaking new footwear innovation called LightSpray™, a robotic spray-on manufacturing process that creates a seamless, ultra-light shoe upper in a single step.  This new approach has the potential to significantly reduce waste, simplify production and reshape how running shoes are made.

LightSpray™ replaces many traditional steps used to construct sneaker uppers, such as knitting fabric, cutting multiple pieces, stitching panels together and applying glue. Instead, a robotic arm sprays the upper material directly onto the shoe last, forming a one-piece, precision-moulded structure. The first shoe built using this process is the Cloudboom Strike LS, On’s new race-day model that weighs just 170 grams.

One of the most important aspects of LightSpray™ is its sustainability impact.  On reports that this method can reduce the carbon emissions associated with the upper by up to 75% compared with conventional production.  Because the upper is produced in a single piece, there is also minimal material waste, eliminating the offcuts and scraps that occur in cut-and-sew manufacturing.  The bonding process uses thermal fusion rather than adhesives, reducing the need for chemical glues and simplifying end-of-life material separation.

LightSpray™ could also play a role in improving localisation and production agility.  On recently opened the world’s first LightSpray production facility in Zurich, signalling the potential for future decentralised production where shoes can be made closer to consumer demand.  This could lead to shorter supply chains, lower transport emissions and more responsive manufacturing.

The Cloudboom Strike LS is the first commercially available shoe featuring this technology, showcasing a sleek, layered aesthetic that highlights the sprayed upper. While currently used in a performance context, LightSpray™ could eventually influence broader categories of footwear and inspire new approaches to sustainable design.

For those interested in exploring the technology further, On’s official LightSpray information page offers detailed visuals and additional insights:
https://www.on.com/en-se/lightspray