HALS Lattice Cushioning: The New Era of 3D-Printed Comfort

Why Everyday Movement Needs a New Kind of Cushioning

We walk thousands of steps a day, through commutes, errands, and everything in between. The right shoes make each movement feel effortless. Yet real-world motion is far from simple or predictable; our steps twist, pivot, and adapt to whatever the day requires. Traditional cushioning systems, designed for straightforward downward impact, were never intended to support this complexity. Modern footwear needs an approach that accommodates the full spectrum of everyday movement.

How Lattice Engineering Changes the Way Shoes Respond

Across the footwear industry, researchers and designers are increasingly turning toward lattice engineering, a structural approach enabled by 3D design and additive manufacturing. Unlike uniform foam, lattice systems allow internal geometries to handle pressure, redirect energy, and maintain stability with far greater accuracy. The result behaves less like soft padding and more like a controlled mechanical system.

A notable example of this shift is Zyphor’s HALS (Hanging-Air Lattice Structure) v2.0, a multi-directional 3D-printed cushioning platform designed to respond to the way people truly move.

Inside the HALS Lattice System

Engineered with digitally sculpted networks, rebound tunnels, and hollow ventilation channels, HALS introduces a form of motion support built around geometry rather than material density. According to Zyphor’s internal technical documentation, the system incorporates:

• Adaptive compression zones that absorb heel impact and return energy forward.
• Triple-zone pressure mapping, tuning each region of the sole for its distinct role: stability at the heel, fluid transition through the mid-foot, and propulsion at the forefoot.
• Hollow airflow channels embedded into the lattice, promoting ventilation during extended wear.
• High-precision manufacturing, ensuring consistent performance across every pair, a level of uniformity difficult to achieve in multi-material, glue-based assembly.

From Cushioning to Smart Comfort

Industry analysts note that lattice systems mark a broader trend toward “smart comfort”, cushioning that responds to the user rather than resisting them. Instead of treating shock absorption as a one-directional task, these systems distribute force along engineered paths, mapping foot mechanics the way suspension systems map road conditions.

Zyphor’s approach aligns with a larger movement within sustainable footwear: replacing traditional foams with recyclable, digitally produced structures that minimise material waste. Because HALS is printed rather than cut, it forms part of the brand’s circular design model, which allows worn pairs to be reprocessed and reprinted.

What Lattice Comfort Feels Like in Daily Life

In daily use, wearers don’t experience lattice comfort as softness alone, but as a tuned fluidity with an adaptive response that moves with them throughout the day. It lightens morning commutes, eases the steps between meetings, and keeps long evenings on foot from becoming tiring. 

For decades, footwear comfort has been defined mostly by materials, but lattice engineering introduces something more human. The lattice structure adapts to every step. It provides comfort that listens to movement rather than resisting it, offering steady and supportive alignment beneath the foot.