How does On's robot factory work?
LightSpray and the robot factory changing shoe making
On’s latest manufacturing step centers on LightSpray, the technology the company introduced in 2024 to apply ultralight filament uppers by spraying material directly onto foot‑shaped forms. The new facility outside Busan, South Korea, that produces the Cloudmonster 3 Hyper uses robotics to automate that process at scale. At a glance, the operation looks less like a traditional textile mill and more like a precision‑driven, robot‑led production cell.
Why it matters: the shift from stitched and cut uppers to sprayed, one‑piece constructions changes both how shoes are made and what they can do. By depositing filament layer by layer, LightSpray can create a contoured, socklike upper without the seams and waste of conventional cut‑and‑sew workflows. The Cloudmonster 3 is the first major mainstream rollout using this upper tech, and the shoe is now widely available after the facility began output.
Key promised benefits:
- Reduced material waste, because filament is applied only where needed.
- Consistent fit and geometry across pairs through precise robotic control.
- Faster prototyping and potential for custom geometry in future runs.
Outstanding questions and trade‑offs:
- Durability and repairability of sprayed uppers versus traditional fabrics remain under observation.
- How well the process scales globally and whether it will lower costs for consumers over time.
- The environmental footprint depends on materials used and end‑of‑life recyclability; automation reduces some waste but introduces energy and material sourcing questions.
For runners and shoppers, the immediate takeaway is practical: On has moved LightSpray from concept to production, and the Cloudmonster 3 gives a first look at what robot‑made uppers feel like on foot. The broader industry will monitor whether other brands embrace similar automated techniques or continue to refine traditional manufacturing.