Sport Infinity · Project

Making Custom Sports Goods From Waste Materials Without Glue

manufacturingPilotedTRL 6

Imagine making a football or a running shoe from recycled waste fibres, snapping layers together like a sandwich — no glue needed. That's what Sport Infinity figured out: automated rotation moulding that bonds different materials by heat and pressure alone, then lets you customise the shape, colour, and performance of each product on the fly. Think of it like 3D-printing meets recycling meets mass customisation, all run from a smart design platform that knows which material combinations work best. The result is sports goods that are greener, cheaper to produce, and can be tailored to individual customers right in the store.

By the numbers

EUR 7,770,947

EU funding for technology development

consortium partners across the value chain

countries involved (AT, DE, EL, FR, UK)

73%

industry partners in the consortium

total project deliverables completed

The business problem

What needed solving

Sports goods manufacturing relies heavily on adhesives to bond different material layers — glue is expensive, introduces chemical hazards, creates production bottlenecks during curing, and makes products nearly impossible to recycle at end of life. At the same time, consumer demand for customised products is rising, but traditional mass production cannot economically deliver one-off designs. Manufacturers need a way to produce personalised, high-performance sports goods from sustainable materials without the cost and environmental burden of adhesive-based assembly.

The solution

What was built

The project developed waste-based long-fibre reinforced composite materials and an automated adhesive-free rotation moulding process for producing customisable sports goods (balls and shoes). A Design-Knowledge Platform/Expert System was built to a 2nd prototype stage with advanced functionality and user interface, guiding material selection and design optimisation. Across 11 deliverables, the consortium validated the full chain from waste-based material formulation through automated shaping to customised decoration via 3D printing.

Audience

Who needs this

Sports equipment manufacturers looking to eliminate adhesives and reduce production costsFootwear brands wanting in-store or near-customer customisation capabilitiesPlastics recyclers seeking high-value markets for waste fibre streamsConsumer goods companies facing upcoming EU recycled-content mandatesContract manufacturers exploring flexible, modular production setups

Business applications

Who can put this to work

Sporting Goods Manufacturing

enterprise

Target: Sports equipment manufacturers producing balls, footwear, or protective gear

If you are a sports goods manufacturer struggling with rising adhesive costs and glue-related production defects — this project developed an automated rotation moulding process that bonds composite layers without any adhesives. With Adidas leading an 11-partner consortium backed by EUR 7,770,947 in EU funding, the technology was validated for balls and shoes and includes a Design-Knowledge Expert System to optimise material combinations for each product.

Plastics & Composites Recycling

mid-size

Target: Recycling companies or waste processors looking for high-value output markets

If you are a recycling operator sitting on post-consumer or post-industrial fibre waste with limited high-value buyers — this project created long-fibre reinforced composites made partly from waste streams, turning low-grade material into performance sports products. The technology was tested across 5 countries with 8 industrial partners, proving that waste-based composites can meet the demands of consumer sporting goods.

Custom Consumer Products

any

Target: Retailers or brands offering personalised or made-to-order products

If you are a retailer or brand exploring in-store customisation but held back by slow production and high tooling costs — this project demonstrated modular production cells that can shape, decorate, and customise sports goods on demand using 3D printing and flexible moulding. The Design-Knowledge Platform prototype guides operators through material and design choices, reducing the expertise barrier for local manufacturing.

Frequently asked

Quick answers

What would it cost to adopt this adhesive-free moulding technology?

The project does not publish per-unit or licensing costs. However, rotation moulding equipment is generally less capital-intensive than injection moulding, and eliminating adhesives removes a significant consumable cost line. Contact the consortium for pricing of the Design-Knowledge Platform and process licensing.

Can this scale to industrial production volumes?

The project was explicitly designed for automatic production and explored configurations ranging from modular factories to in-store production cells. With Adidas — one of the world's largest sports goods companies — as coordinator, industrial-scale viability was a core design requirement. Based on available project data, the 2nd prototype of the expert system was completed, indicating the process was validated at significant scale.

Who owns the IP and how can I license it?

IP is shared among the 11 consortium partners across 5 countries, with Adidas AG (Germany) as coordinator. Licensing terms would need to be negotiated directly with the consortium. The Design-Knowledge Platform and the waste-based composite formulations are the primary licensable assets.

Does this meet EU regulations on recycled content in consumer products?

The project aligns with EU sustainable economy goals and uses waste-based materials, which positions it well for upcoming recycled-content mandates. Based on available project data, specific regulatory certifications are not detailed, but the adhesive-free process also eliminates chemical bonding agents that face increasing regulatory scrutiny.

How long would integration into an existing production line take?

The rotation moulding approach was designed for flexibility — the objective mentions modular factories and in-store production cells. This suggests the technology can be deployed as a standalone unit rather than requiring full line retrofitting. Based on available project data, the Design-Knowledge Platform guides material and process selection, which should reduce integration time.

Is this limited to sports goods or can it be applied elsewhere?

While the project focused on balls and shoes, the underlying technology — adhesive-free bonding of layered composites via rotation moulding — applies to any shaped plastic product. Automotive interior panels, protective cases, and consumer electronics housings are plausible adjacent applications using the same process.

Consortium

Who built it

This is a heavily industry-driven consortium: 8 out of 11 partners (73%) are industrial players, with only 2 universities and 1 research organisation providing scientific support. Adidas AG — a global sportswear giant — coordinates the project from Germany, which signals serious commercial intent rather than an academic exercise. The consortium spans 5 countries (Austria, Germany, Greece, France, UK) and covers the full value chain from material development through design, production, marketing, and distribution. With EUR 7,770,947 in EU funding and a 3-year development window (2015-2018), this project had substantial resources behind it. The low SME count (just 1) combined with the enterprise-led structure suggests the technology was developed at a scale and quality standard that meets major-brand requirements.

ADIDAS AGCoordinator · DE
FRIEDRICH-ALEXANDER-UNIVERSITAET ERLANGEN-NUERNBERGparticipant · DE
HYPERCLIQ IKEparticipant · EL
ASSOCIATION CETI (CENTRE EUROPEEN DES TEXTILES INNOVANTS)participant · FR
UNIVERSITY OF LEEDSparticipant · UK
BASF POLYURETHANES GMBHthirdparty · DE
FILL GESELLSCHAFT MBHparticipant · AT
BASF SEparticipant · DE
KISKA GMBHparticipant · AT

How to reach the team

Adidas AG (Germany) — contact via company R&D or innovation department. SciTransfer can facilitate an introduction to the project team.

Order a report on this consortium See ADIDAS AG profile →

Next steps

Talk to the team behind this work.

Want to explore licensing or applying this adhesive-free composite technology in your production? SciTransfer can connect you directly with the project team and provide a detailed technology brief tailored to your use case.

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