cork footbed manufacturing
These images from our factory in Paços de Brandão, Portugal, show some of the steps involved in turning components into footbeds.
From Component Definition to Moulding
Development begins with the footwear and the customer’s requirements. A technical drawing, a sample or an outsole can provide the starting point for defining the footbed’s geometry, profile and construction.
The cork formulation and mould are developed alongside these requirements. Samples allow the fit to be assessed and any necessary adjustments to be identified before production begins.
On the moulding line, the cork mixture is placed into moulds that shape the component. This stage creates the base onto which the other materials specified for the model will be assembled.
Combining Materials Around the Project
A footbed can combine cork with foam, leather, textiles or other functional layers.
Each combination addresses specific requirements for thickness, flexibility, contact and finish. Material selection therefore needs to consider both the footbed itself and its integration into the footwear.
The assembly photographs show a foam layer being applied to a cork base. Its positioning follows the component’s outline, preparing it for the next operations.
Assembly and Finishing
Industrial production and manual work complement each other. Assembly requires attention to component orientation, layer alignment and bonding areas.
Depending on the approved construction, coverings are applied and the specified finishing operations are carried out. Options can include different colours, textures and markings, allowing the footbed to reflect the identity of the customer’s product.
Serial Production and Preparation for Dispatch
Once samples are approved, the project moves into serial production using the specifications defined for the model.
The batch of footbeds pictured in a production container offers a glimpse of this everyday work. Order preparation and packing complete the journey towards dispatch.
A Component Developed for Your Footwear
At 3DCORK, our aim is to translate the customer’s requirements into a footbed that can be integrated into their product and manufactured consistently.
From initial development through to production, we approach geometry, materials and finishes as parts of one solution.
Do you have an outsole, a sample or a drawing to develop? Contact our team to discuss your cork footbed project.
Summary
A footbed brings together several decisions: the shape that allows it to fit the footwear, the materials used in its construction and the finish of the surface in contact with the foot. At 3DCORK, we develop and manufacture cork footbeds around each project’s requirements, combining industrial processes with assembly and finishing operations.