Adidas has created custom 3D printed soccer cleats for Philadelphia Union winger Cavan Sullivan, according to a report by The Athletic.
The footwear was produced through Adidas's Project RAP platform, which launched in March to build athlete-specific boots using a rapid liquid printing station.
The process allows designers to iterate without traditional molds or factory production delays.
How the Cleats Were Made
Adidas designers visited Sullivan during the summer break to collect gait analysis, pressure mapping, and high-speed motion camera data using portable scanning equipment.
Nolan Kim, computational designer at Adidas, said the project is not just a proof-of-concept prototype.
"This is a fully functional product that's performing at the highest level," Kim said.
Kim explained that 3D printing removes the need for molds or factories to make completely new construction.
The design team adjusted the boot dimensions to fit Sullivan's specific foot shape and physical profile.
Kim said he was with Sullivan at the training ground in Philadelphia to understand where the player needed more volume and where he wanted less.
Designers initially gave Sullivan a standard pair before refining the fit at the Athlete Product Excellence Centre in Herzogenaurach, Germany.
"We needed one or two rounds to really lock in the exact fit," Kim said.
The development protocol relies on immediate feedback from the athlete during active field sessions.
Kim said Sullivan would train for an hour or two in a pair of boots, then give direct feedback afterward.
Adjustments were made and new boots provided, with the fit usually locked in after one or two trials.
The custom software setup allows designers to make quick parameter changes without manual reconstruction.
"All of the inputs are there to change instantly," Kim added.
Adidas tailored the shape to address Sullivan's wider foot dimensions and prevent midfoot numbness he experienced in standard footwear.
Kim said traditional shoes were a bit narrow for Sullivan, causing his toes to feel cramped.
The algorithmic design approach also permits digital adjustments if the teenage player undergoes physical growth spurts.
Kim said the digital printing files enable immediate structural adjustments whenever required.
"Every time we print the skin, it's one to one," Kim added.
He said Sullivan has worn the boots for two or three months without an issue or a request for changes.
Kim noted that if Sullivan needs more length or width, it can be fixed on the computer in seconds and then printed.
Sullivan recently wore the custom boots during international matches.
Kim said he hopes other players will ask Sullivan about the boots at the training ground.
Sullivan holds the most valuable homegrown player contract in MLS history.
Since Major League Soccer resumed in July following the World Cup break, the 17-year-old has recorded seven goals and five assists in 13 games.
That form has driven Philadelphia Union from the bottom of the Eastern Conference into a playoff spot.
