Work

Design and development of sustainable sports shoes using recycled materials in compliance with testing standards

Year: 2026

Type: article

Abstract: The growing environmental impact of conventional athletic footwear manufacturing necessitates sustainable design approaches that reduce carbon emissions while maintaining functional performance. This study presents the design, development and evaluation of a sustainable sports shoe prototype using recycled and bio-based materials. A total of n = 20 male athletes (18–21 years) were included for biomechanical assessment. Digital foot scanning and CAD-based design (Shoemaster®, Version 21.04) were employed to ensure anatomical compatibility. Mechanical and functional performance was evaluated using standardized testing protocols. Results demonstrated adequate abrasion resistance, tear strength, and color fastness. Whole-shoe flexing showed durability up to 100,000 cycles with minor bond opening. Plantar pressure reduction of 20 ± 2% and impact attenuation of 31 ± 3% were observed. The prototype achieved 62–68% recycled material content and reduced carbon footprint (7.8–8.6 kg CO₂-eq/pair) compared to conventional footwear. These findings indicate that sustainability-driven material integration can achieve biomechanical and functional performance suitable for athletic applications.

Source: Discover Applied Sciences

DOI: 10.1007/s42452-026-09113-y

Authors: T. Loganathan, R. Ramakrishnan, M. Akshaya Raman, G. Nallavan, Pandurengan Sakthivel, S. Kamalraj