The custom sole manufacturing process combines artisanal expertise, cutting-edge technology, and in-depth knowledge of the footwear sector. At PBS Soles, each project begins by listening to the client’s needs and develops through a structured yet flexible production path, adaptable to both small and large quantities.
Phase 1: Listening and Personalized Design
Everything starts from a technical brief or a sketch. Our team works alongside the client to fully understand the sole’s final use, the type of footwear, the target market, and the required performance.
Based on this input, we develop a custom design using CAD software for modeling and defining the sole’s lines. In this phase, we also select the technical specifications: thicknesses, grip, flexibility, lightness, and the most suitable materials.
Phase 2: Material Selection
PBS Soles works with a wide range of high-performance materials, selected according to the characteristics required by the final shoe:
- EVA: lightweight, shock-absorbing, ideal for sneakers and comfort.
- Microporous: perfect for orthopedic use due to its adaptability.
- Rubber: durable, non-slip, ideal for outdoor and technical footwear.
- Agglomerated cork: sustainable, breathable, natural.
Each material can be combined with specific processes, such as milling, manual finishing, or bonding with fabrics or inserts.
Phase 3: Sampling and Prototyping
Once the project is approved, we move on to prototype creation. This phase is crucial to verify the alignment between the design and the final result. Thanks to our in-house flexible production, PBS Soles can quickly create samples even in small batches.
The prototype is tested by the client or directly on sample shoes to assess its ergonomics, fitting, and aesthetic performance.
Phase 4: Industrial Production and Quality Control
When the prototype is validated, full-scale production begins. Our systems are designed to ensure:
- Precision and consistency
- Fast turnaround
- Flexibility for customization
Each batch undergoes quality checks on thickness, density, material bonding, and surface finish. Our goal is to maintain artisanal standards even in industrial-scale production.
Custom Soles: A Competitive Advantage for Shoemakers
Working with a custom sole manufacturer like PBS Soles means relying on a technical partner capable of turning ideas, sketches, or functional needs into high-quality footwear components.
Our clients include shoemakers, designers, fashion brands, and orthopedic professionals who seek to differentiate their collections with unique, reliable soles aligned with market trends.