Product Improvements

Every pair is better than the last

We build made to order, so an improvement reaches you the day it is finished, not at the next model year. This page is the record: how the shoe evolved era by era, the changes that matter most, and the full log if you like receipts.

1,938 recorded changes

Every completed change in our internal design log, grouped by the part it touches.

14 areas of the shoe

From the stud tips to the box it arrives in.

Most apply to every sport

The last, the upper and the insole are shared across boots, so an improvement for one sport usually improves all of them.

Product Improvements

Every pair is better than the last

We build made to order, so an improvement reaches you the day it is finished, not at the next model year. This page is the record: how the shoe evolved era by era, the changes that matter most, and the full log if you like receipts.

1,938 recorded changes

Every completed change in our internal design log, grouped by the part it touches.

14 areas of the shoe

From the stud tips to the box it arrives in.

Most apply to every sport

The last, the upper and the insole are shared across boots, so an improvement for one sport usually improves all of them.

How we got here

The story of the shoe, told in eras, newest first. Everything below happened to real prototypes, many of which did not survive.

Next

What's next

Most of what comes next stays under wraps until it ships. We will say this much: the idea Prevolve started with in 2014 is back on the bench, and this time the materials, the bonding, the pattern algorithm and a decade of logged mistakes all exist. When it is ready, you will hear about it.

The parts we can talk about: curved, non planar printing that follows the shoe's surface instead of flat layers, dissolvable lasts that end our shelf of heavy plastic feet, and a growing library of print defects we analyse automatically so the printers themselves keep getting smarter. The log below keeps filling in.

  • Non planar printing for the boot plate
  • Dissolvable lasts instead of a shelf of plastic feet
  • Print quality that learns from every defect we log
  • And a bigger one we are keeping quiet until launch
2026

The comfort year

Our most common comfort complaint had always been the heel, because seams used to sit exactly where feet are most sensitive. The foam heel cup fixed it: one sculpted piece with flex lines for the arch, and the seam moved forward to the midfoot. The tongue got rebuilt around a single lacing slot with interlocking pins at a thinned, glue soaked base, and we have not seen one detach since. The insole grip texture now prints directly into the insole, so nothing is glued and nothing curls.

The fit sock changed the business: instead of paper fit sheets, you wear a printed sock version of your shoe and tell us exactly what is off before we build. First build success jumped. And our flex tester has taken a full shoe past one million flex cycles without a crack. We are going for two million, mostly out of curiosity.

  • The foam heel cup ended our most common comfort complaint
  • The fit sock replaced guesswork before every build
  • One million flexes on the tester and still counting
  • Toe box curves tuned by sport: closer for football, roomier for baseball
  • Toe spacers lost the top strap and disappear into the toe box
Late 2025

The assembly line

We moved to printing the upper flat and separately, which made better uppers and created a brand new failure: assembly was weakening the printed eyelets, and some broke in the field. The fix became one of our favourite parts of the shoe: a laser cut ballistic nylon backing bonded behind every eyelet. Prototype eyelets now hold close to 140 pounds on the bench rig, and a finished shoe keeps gaining strength for days after assembly as the bond cures.

December brought automation to the print farm: every printer managed from one queue, every part on labeled clear trays. Mixing up a left and a right used to be easy. Now it is nearly impossible.

  • Ballistic nylon backing behind every eyelet, bench tested near 140 pounds on prototypes
  • The whole print farm went onto one automated queue
  • Vacuum forming the upper on the last: nailed, bagged, heated, cooled, then bonded
2023 to 2025

The materials wars

Out on our own, we built a stitchless shoe almost immediately: glued, clamped, not a thread anywhere. Then the materials fights started. Our outer shell material looked great and came in every color, but it cracked after enough flex cycles, so the 68A shell replaced it and we have not worn one out since. The foam got stronger. The insole plate material we loved went out of stock entirely, and three or four replacements broke in testing before we landed on a glass fiber reinforced polymer set into the foam, printed as an adaptive hex. If a plate ever does crack, the hex contains it to one small arm and the plate keeps working.

We even printed a whole upper as one sequential print for a while, three materials stacked in a single run. It made a lovely upper with roughly a fifty percent success rate and three manual filament changes per shoe. We retired the method and kept everything it taught us.

  • Stitchless construction, start to finish
  • The 68A outer shell ended cracked uppers for good
  • An insole plate that fails safe instead of failing big
  • Crossed 45 degree print orientation for tougher parts in the cold
2021 to 2023

The barefoot education

These were the years the shoe got a philosophy. We finally understood what a wide toe box actually does for a foot, and meeting Dr. Ray McClanahan, the podiatrist behind Correct Toes, changed the roadmap: his thinking directly inspired our custom toe spacers and metpads. Credit where it is due.

It is also when pattern making became an algorithm. Cut the last into sections along its flattest lines, at the vamp and at the heel, flatten each section, spring the pattern, and match it back. That code has been refined continuously ever since, and it is why toe box creasing is a battle we are still fighting: every foot stretches the pattern differently.

  • Wide toe boxes went from a feature to the foundation
  • Custom toe spacers and metpads were born, inspired by Correct Toes
  • The pattern making algorithm got its first lines of code
2020 to 2021

Split it up

The breakthrough was giving up on the single print. We split the shoe into separate parts, printed each one in its ideal orientation and material, and assembled them. Suddenly every part could be the best version of itself.

Two more unlocks landed in the same stretch: we learned to print 68A TPU, the nearly indestructible flexible that still forms the structure of our uppers, and we developed a bonding process that permanently fuses printed parts into one piece. No stitches, no seams that peel. The exact recipe is one of the few things on this page we keep to ourselves.

  • The shoe became printable parts plus assembly instead of one impossible print
  • 68A TPU unlocked: flexible, and it basically refuses to wear out
  • A permanent bonding method replaced stitching entirely
2014 to 2017

The one piece dream

Prevolve started with a stubborn idea: print an entire boot as one piece, standing upright on the print bed. Dual material printing with flexible filament was a nightmare then (honestly, it still is), and that whole era produced maybe two prints worth keeping.

The real lesson was humbling: we did not know filament absorbs moisture from the air. Prints came out beautiful for half a spool, then quality fell off a cliff, and we blamed everything except the open workshop windows. The upper printed in a TPU that was durable but too stiff to feel like a shoe. Funny thing: a decade later the whole industry is chasing one piece printed shoes. We took our lumps early.

  • Learned to print flexible TPU vertically, a skill we still use on every pair
  • Discovered the hard way that filament needs drying before printing
  • Got our first working dual material prints (barely)

The changes that matter most

Grouped by the part of the shoe they touch. Open one to see what changed and why.

The full log

Found something that should be on this list?

A good share of these started as a customer email. If something on your pair is not working the way it should, tell us and it goes into the log.

Found something that should be on this list?

A good share of these started as a customer email. If something on your pair is not working the way it should, tell us and it goes into the log.