The science behind Cavan Sullivan’s custom Adidas cleats: Foot scans, algorithms and 3D printing

Adidas has created bespoke soccer cleats for Philadelphia Union winger Cavan Sullivan utilizing 3D printing, algorithms, and foot-scanning data under its "Project RAP" platform. The personalized footwear process eliminates standard manufacturing molds, allowing designers like computational designer Nolan Kim to rapidly iterate and customize footwear to match Sullivan's wider foot shape and ongoing physical growth without a break-in period.

Sullivan, who recently turned 17, debuted the custom technology internationally during the USMNT's 4-1 friendly victory against Peru. His on-field performance in MLS has surged, tallying seven goals and five assists in 13 matches since the league resumed in July.