Our Technology

Prevolve’s AthLast™ tech stands on four pillars: a 3D scan of your exact foot, your athlete profile (weight, position, sport, foot strength level and stud type), a design built around your five foot functions, and a 3D Fit Sock that confirms the fit before your cleats are built.

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

Cleats 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 cleats, but no one ever got back to me."

Prevolve 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 cleat 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 optimized daily cycles. The process is highly automated, yet only two skilled hands finish each pair, which is how a made-to-order cleat still comes out consistent.

Your foot is one of a kind. Your cleats 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 optimizes for What the process optimizes for

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

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

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

Making each cleat 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 $100 off any pair of custom cleats or shoes.

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 we built the code that designs every cleat, one prototype at a time.

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