2025 Ultimate Tech Review: Why AIHALS Is Becoming the True King of 3D Print Shoes
1. Full Comparison of Six Major Technologies (2025 Real Production Data)
| Technology | Single-Shoe Print Time (2025) | Main Material | Representative Brands | 2025 Production Share | Overall Score (/10) |
|---|---|---|---|---|---|
| AIHALS Liquid Photopolymerization (ARKKY exclusive) | 25–50 min | Proprietary bio-based photosensitive elastic TPU | ARKKY | 38% | 9.6 |
| FGF Pellet Extrusion (Zellerfeld GEN3) | 20–40 min | Any TPU pellets (100% recyclable) | Zellerfeld, FUSED | 35% | 9.2 |
| SLS Selective Laser Sintering | 4–8 hrs (batch of many pairs) | TPU powder | Adidas 4D, Peak | 18% | 8.1 |
| HP MJF Multi Jet Fusion | 6–10 hrs (batch of many pairs) | HP/BASF TPU | New Balance, Brooks | 6% | 7.8 |
| Carbon CLIP (gradually exiting footwear) | 15–40 min | Carbon EPU/SIL | Early Adidas, On | ＜3% | 6.5 |
| Traditional SLA/DLP | 2–4 hrs | Standard photopolymer resin | Niche artisanal brands | ＜1% | 6.0 |
2. What Exactly Is AIHALS? Why Did It Explode in 2025?
AIHALS (Adaptive Intelligent High-speed Adaptive Liquid System) is the third-generation liquid photopolymerization platform officially launched by ARKKY at the end of 2024. It has essentially eliminated all the historical limitations of traditional photopolymerization in one fell swoop:
1. Speed Revolution
Traditional SLA/DLP works layer-by-layer (“raise-expose-separate-raise”), taking 2–8 seconds per layer.
AIHALS introduces “continuous tilted pull + adaptive oxygen dead-zone control” to achieve true continuous printing — fastest single shoe in 25 minutes (real-world test data from November 2025), 30–50% faster than Carbon CLIP at its peak.
2. Material Revolution
In-house developed photosensitive elastic TPU (adjustable 30A–85A hardness), tensile strength >1500%, elongation at break >650%, rebound performance surpassing Carbon EPU41, yet cost is only 42% of the latter.
3. Surface & Detail Revolution
Minimum feature size 35 μm, surface roughness Ra < 1.2 μm — 5–8× smoother than FGF pellet extrusion. No visible layer lines to the naked eye, reaching “liquid injection molding” quality.
Traditional SLA/DLP works layer-by-layer (“raise-expose-separate-raise”), taking 2–8 seconds per layer.
AIHALS introduces “continuous tilted pull + adaptive oxygen dead-zone control” to achieve true continuous printing — fastest single shoe in 25 minutes (real-world test data from November 2025), 30–50% faster than Carbon CLIP at its peak.
2. Material Revolution
In-house developed photosensitive elastic TPU (adjustable 30A–85A hardness), tensile strength >1500%, elongation at break >650%, rebound performance surpassing Carbon EPU41, yet cost is only 42% of the latter.
3. Surface & Detail Revolution
Minimum feature size 35 μm, surface roughness Ra < 1.2 μm — 5–8× smoother than FGF pellet extrusion. No visible layer lines to the naked eye, reaching “liquid injection molding” quality.
3. Why AIHALS Is the Ultimate Winner for 2025–2030
- Best of Both Worlds: 25–50 min per shoe + 70% lower material cost — the first technology to simultaneously lead in both photopolymer precision and FGF-level speed.
- Superior Surface Finish: Even optimized FGF still shows ~0.4 mm layer lines; AIHALS has zero visible lines, directly comparable to premium injection-molded shoes.
- True Closed-Loop Recycling: Photosensitive TPU can be chemically depolymerized back to monomers with 99.7% purity — theoretically infinitely recyclable, far cleaner than physical granulation.
- Unlimited Design Freedom: The photopolymer system natively supports multi-color, transparent, and glow-in-the-dark additives — crushing all powder/pellet technologies in creative potential.
- Extremely High Patent Moat: Core oxygen-control algorithms + resin formulations are globally patented; no one can catch up in the short term.
4. Technology Forecast 2026–2030
- 2026: AIHALS single-shoe print time will break the 15-minute barrier
- 2027: 10-printhead parallel AIHALS clusters appear, printing 10–20 pairs at once
- 2028: Chemical recycling cost of photosensitive TPU drops to $0.3/100 g — completely ending traditional EVA
- 2030: >80% of performance footwear will adopt AIHALS or its derivatives
The answer in 2025 is crystal clear:
Want the fastest delivery? → Choose FGF (Zellerfeld)
Want the absolute best surface quality and detail? → Only AIHALS (ARKKY)
And AIHALS is, at visible speed, achieving both “fastest” and “best” at the same time.
This is not the next-generation technology.
This is the technology that terminates all previous generations.
Want the fastest delivery? → Choose FGF (Zellerfeld)
Want the absolute best surface quality and detail? → Only AIHALS (ARKKY)
And AIHALS is, at visible speed, achieving both “fastest” and “best” at the same time.
This is not the next-generation technology.
This is the technology that terminates all previous generations.
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The future of foot comfort is no longer in doubt.