Zellerfeld Expands with Advanced 3D Printed Footwear Facility

Zellerfeld has opened a new production facility in Austin, Texas, marking the 3D printed footwear company’s first site outside of Germany. The print farm is now operational, extending the company’s distributed manufacturing network and supporting localized production for the U.S. market.

With the Austin facility online, Zellerfeld is eliminating transatlantic shipping and tariffs for American orders. The company reports the site was activated within a week of acquisition, thanks to an on-site task force from Hamburg and support from investor Valor Equity Partners. The expansion is part of Zellerfeld’s broader plan to scale from 200 printers in Hamburg to thousands across multiple locations.

GEN3 system aims to unlock mass-scale 3D printed footwear

The Austin launch coincides with the deployment of Zellerfeld’s new GEN3 system, described as its fastest and most advanced footwear 3D printer to date. GEN3 is three times faster than the previous generation, offers multi-color capabilities, and operates fully autonomously—features designed to support large-scale, on-demand manufacturing without human intervention.

Zellerfeld claims the system is scalable by design and will allow the company to transition from producing thousands of shoes annually to millions. The printer was developed in partnership with the Fraunhofer Institute and reflects a culmination of years of beta testing, production feedback, and material R&D. According to the company, the shoes are now more durable, comfortable, and better fitting than in previous iterations, aided by the introduction of a proprietary printed textile aimed at improving wearability.

“From MONO1 to GEN3, we’ve evolved from a prototype to a platform that can deliver mass-customized footwear globally,” said Cornelius Schmitt, Chief Executive Officer at Zellerfeld. “GEN3 takes us closer to our goal of printed shoes on every foot.”

The company’s earlier systems—MONO1 and GEN2—laid the foundation for this model. While the original prototype required roughly 150 hours to print a single shoe, GEN2 expanded capacity to tens of thousands of pairs and supported partnerships with brands including Louis Vuitton and Moncler. GEN3 now represents the company’s shift from experimentation to industrial deployment.

Platform opens to designers as production scales

Zellerfeld has ended its beta program and opened its platform to designers worldwide. Anyone can now upload footwear designs to be manufactured and sold through Zellerfeld’s system. The company expects over 1,000 new designs and silhouettes to become available for on-demand purchase by the end of the year.

The expansion to Austin, coupled with the GEN3 system rollout, supports Zellerfeld’s broader mission of reshaping the footwear supply chain through localized, on-demand production. By reducing shipping needs and centralizing output near major customer bases, the company aims to cut costs, shrink delivery windows, and offer greater customization at scale.

Zellerfeld continues to hire for both its Austin and Hamburg operations as it ramps up production and broadens its catalog of designer footwear.