Our Technology

Prevolve’s AthLast™ brings together three things no traditional boot has: a 3D scan of your exact foot, the parametric algorithm Oliver spent 12,500 hours building, and a fully 3D-printed TPU plate made to order in our US workshop.

The result is a zero-drop, anatomically shaped boot with gradient stiffness tuned to your weight and foot strength, built for one player, not an average of a million feet.

Boots built around your foot, not the other way around.

"I didn't realize my feet were wider than normal and that Adidas and Nike were built for an average. I reached out to see if they made custom fitted boots, but no one ever got back to me."

Oliver Brossmann, Founder

The engineering process behind every pair

A look at the technology behind what actually happens between your scan and your first step on the pitch.

  • Two-minute scan, no app

    Capturing your foot takes a two-minute Volumental scan from your phone, with no app to download. It records biometrics precise enough that every measurement downstream is built on real data, not a size you guessed at.

  • Verified before a gram is printed

    The algorithm generates a 3D Custom Fit Sock from your scan. You receive it within 3-5 days after order and tell us how it fits. Nothing gets printed until the geometry is proven against your actual foot.

  • Printed in layers thinner than a hair

    Each boot is built from GCODE containing millions of points of data, laid down in layers around 0.2 millimetres thick, finer than a human hair. That resolution is what gives the plate its smooth, strong, highly detailed surface.

  • One workshop, two skilled hands

    Every part prints within 24 hours, so the workshop runs on optimised daily cycles. The process is highly automated, yet only two skilled hands finish each pair, which is how a made-to-order boot still comes out consistent.

Your foot is one of a kind. Your boots should be too.

Built around your exact foot shape, sport, and surface. No off-the-shelf compromises.

Prevolve Footwear

Prevolve Footwear

Traditional cleats

Traditional cleats

Time to improve a design Time to improve a design

Weeks. An improvement is coded in and the next pair prints with it already built in

Weeks. An improvement is coded in and the next pair prints with it already built in

Years. A design is fixed at the tooling stage and stays frozen until the next product cycle

Years. A design is fixed at the tooling stage and stays frozen until the next product cycle

Changing the design Changing the design

We update the algorithm and print again, with no new tooling and no added cost

We update the algorithm and print again, with no new tooling and no added cost

Every change means retooling a factory and waiting on a fresh overseas production run

Every change means retooling a factory and waiting on a fresh overseas production run

How it's produced How it's produced

Printed to order from your scan, so nothing is built until it's yours

Printed to order from your scan, so nothing is built until it's yours

Mass-produced in bulk long before anyone has ordered a single pair

Mass-produced in bulk long before anyone has ordered a single pair

What the process optimises for What the process optimises for

Making each boot better, because there is no factory line to slow a change down

Making each boot better, because there is no factory line to slow a change down

Making each boot cheaper to produce at scale, because that is what mass production rewards

Making each boot cheaper to produce at scale, because that is what mass production rewards

Still curious?

Then dig in. See the process in action, get the full story behind the algorithm, or take the first step on a pair of your own.

Find out what your feet need

Take the free assessment and get $75 off any Prevolve purchase.

See a pair come together?

Go inside the workshop and watch the scanning, printing and finishing for yourself.

The 12,500-hour algorithm

The full story of how Oliver built the code that designs every cleat, one prototype at a time.

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