Design and development of sustainable sports shoes using recycled materials in compliance with testing standards

The growing environmental impact of conventional athletic footwear manufacturing necessitates sustainable design approaches that reduce carbon emissions while maintaining functional performance. This study presents the design, development and evaluation of a sustainable sports shoe prototype using recycled and bio-based materials. A total of n = 20 male athletes (18–21 years) were included for biomechanical assessment. Digital foot scanning and CAD-based design (Shoemaster®, Version 21.04) were employed to ensure anatomical compatibility. Mechanical and functional performance was evaluated using standardized testing protocols. Results demonstrated adequate abrasion resistance, tear strength, and color fastness. Whole-shoe flexing showed durability up to 100,000 cycles with minor bond opening. Plantar pressure reduction of 20 ± 2% and impact attenuation of 31 ± 3% were observed. The prototype achieved 62–68% recycled material content and reduced carbon footprint (7.8–8.6 kg CO₂-eq/pair) compared to conventional footwear. These findings indicate that sustainability-driven material integration can achieve biomechanical and functional performance suitable for athletic applications.