Nike has launched the Air Max 1000, a new version of its 1987 Air Max 1. The model is made in collaboration with Zellerfeld, a company known for fully 3D-printed shoes. This updated design keeps the original silhouette but uses a single-material construction made from a special TPU material.

3D Printed Construction and Fit

The Air Max 1000 retains the wavy mudguard pattern of the original design. However, instead of multiple components, the shoe is printed as a single piece, removing the need for adhesives and reducing production steps. The laceless slip-on design increases ease of use, while Nike’s Air cushioning is integrated for impact absorption.

Zellerfeld’s approach allows for precision fitting through a digital foot scan. Customers can complete the scan with only a sheet of paper and a mobile phone camera, using a browser-based process. This scan creates a model of the wearer’s feet, enabling a more accurate fit than standard sizing. The fit can improve over time as the material adapts to the wearer’s foot shape.

Material Properties and Sustainability Potential

The shoe is made from zellerFOAM, a specially developed thermoplastic polyurethane (TPU). This material is said to be 100% recyclable, breathable, washable, and odour resistant. Its resilience and flexibility make it suitable for repeated wear, while its cushioning properties come from custom-engineered printed midsoles.

Additive manufacturing reduces excess material waste and allows on-demand production, which can help prevent overproduction. Using a single material may also simplify recycling, as there is no need to separate different components. Zellerfeld has previously tested closed-loop systems in which worn shoes are returned, shredded, and reprinted into new products, demonstrating potential for circular production if adopted more widely.

While positioned as a performance and lifestyle product, the Air Max 1000 also demonstrates how additive manufacturing, recyclable materials, and digital customisation can intersect. This approach has potential applications in other sectors, including sports equipment, automotive interiors, and consumer goods.

Source & photos: Nike / Zellerfeld