Is The Future Of The American City In Making Shoes? Portland’s Answer Is ‘Yes’

by admin on August 27, 2024

In a time when global supply chains are under unprecedented strain, the “Made in Old Town” project in Portland, Oregon, represents a bold new vision for American manufacturing—one that combines cutting-edge digital production technologies, like 3D printing, with the growing trend of reshoring. The result may redefine U.S. cities altogether.

A New Urban Model

Old Town in Portland, once the city’s manufacturing hub, has faced economic decline and underutilization of its historic buildings, becoming a “net drain on civic resources.” Despite these challenges, its rich industrial heritage and strategic location near Portland’s thriving footwear and apparel industry make it the ideal site for the Made in Old Town project.

An illustration of the Made in Old Town location.Image courtesy of Travis Dang, Sera Architects.

At the heart of this initiative is the idea of transforming urban centers into vibrant ecosystems where production, retail, and living spaces coexist in harmony. Matthew Claudel, founder of civic design firm Field States and a key architect of the Made in Old Town project, highlights how this approach not only addresses the post-COVID urban economy but also reimagines how cities function.

“Cities were initially a place where you have manufacturing, retail, and housing all in one unit,” Claudel explains. “We’re exploring what the next generation of cities will look like, creating something that is truly an integrated ecosystem.”

This vision draws from historical urban models but is powered by the latest in digital manufacturing technology. The integration of 3D printing, for instance, allows for manufacturing to occur in a way that is “lightweight, environmentally clean, and has a very small footprint,” enabling production facilities to be embedded directly within city neighborhoods. The result is a dense, vibrant downtown where products are conceived, designed, and manufactured in close proximity to local consumers.

Reshoring Through Innovation

Elias Stahl, CEO and Co-Founder of HILOS, sees this project as a blueprint for reshoring manufacturing in the U.S., particularly in industries that have become highly globalized, such as footwear and apparel.

“We’re living at a real inflection point for supply chains,” Stahl notes. “There’s a massive opportunity for the industry to work closely again with brands and their suppliers to build the next supply chain for the 21st century—one that is sustainable, on-demand, and close to the market.”

An illustration of HILOS’s future location at Made in Old Town.Image courtesy of Travis Dang, Sera Architects.

HILOS, a company that started as a 3D-printed footwear brand, now sits at the center of this transformation. The company uses HP’s Multi Jet Fusion (MJF) printers to create soles from thermoplastic polyurethane derived from 80% recycled material and which can be fully recycled after use. This technology allows HILOS to produce shoes on-demand, eliminating overproduction and reducing waste by streamlining the manufacturing process from 65 parts across 360 steps to just five parts in 12 steps. By fulfilling orders within 72 hours, HILOS not only meets consumer demand quickly but also sets a new standard for sustainable and agile manufacturing in the footwear industry.

In turn, HILOS is helping to develop what Stahl describes as “the lowest cost and most scaled form of not just 3D footwear, but even U.S.-based footwear production.” This capability is critical for reshoring efforts, as it addresses two major barriers: cost and capacity.

The XII Modular Sandal by HILOS and Unknown Union, featuring three 3D printed parts and 80 percent … [+] reclaimed material.Image courtesy of HILOS

Sustainability at Scale

Sustainability is a cornerstone of the Made in Old Town project, with 3D printing playing a key role in reducing waste and making production more responsive to market demands. Noel Kinder, former Chief Sustainability Officer for Nike and a member of the Made in Old Town stewardship committee, emphasizes the importance of this technology in achieving environmental goals.

“I’ve always been fascinated by 3D printing and where that would fit in the footwear supply chain,” Kinder says. “HILOS has done a really nice job of proving that it can fit at scale and finally reach the promise that has been out there for so long.”

This promise includes the potential to drastically reduce the environmental footprint of manufacturing by enabling localized production, reducing the need for transportation, and minimizing excess inventory through on-demand production. The project has already garnered substantial support, receiving $2 million in state funding, with plans to scale significantly in the coming years.

A Model for the Future

The Made in Old Town project is a clear vision for the future of Portland’s Old Town neighborhood. The development is designed to spark the future of clean, environmentally sustainable footwear and apparel manufacturing while transforming the neighborhood for the better. Grounded in high-quality urban design and inclusive wealth-building for Portland’s community, the project will strategically invest in vacant and under-utilized properties, transforming four Portland city blocks into a world-class sustainable industry campus.

In total, this mixed-use development will encompass 323,000 square feet across nine buildings, including 80,000 square feet of advanced manufacturing space and 110,000 square feet of workforce housing. Alongside anchor manufacturing companies, the Made in Old Town district will be home to dozens of small businesses—from creative brands to tier-two suppliers. The project’s integration of various functions—manufacturing, retail, logistics, and housing—creates a self-sustaining ecosystem that supports both the local economy and the broader goals of reshoring.

The implications of the Made in Old Town project extend far beyond Portland. As Claudel points out, this model could be replicated in other American cities, each with its unique industrial heritage.

“Regions across the country have their own unique heritage of manufacturing,” he explains. “This is a roadmap that every American city can use to embrace the future with technological possibility, job creation, and tapping into craft and that heritage culture of making.”

The timing for such initiatives is particularly opportune, given the significant federal support for infrastructure revitalization and reshoring efforts. The Biden Administration’s Infrastructure Investment and Jobs Act, now two years into implementation, has allocated over $306 billion into state and local projects, with much of this funding aimed at rebuilding and modernizing critical infrastructure.

With 80% of competitive grant funding still available, cities across the U.S. have an unprecedented opportunity to secure resources that can support projects like Made in Old Town. This influx of federal investment aligns with the goals of reshoring and sustainable urban redevelopment, providing the financial backbone needed to turn such ambitious visions into reality.

Indeed, the success of this project could signal a broader shift in how manufacturing is approached in the U.S., blending the benefits of advanced technologies with a resurgence of local production. It’s a vision that, if realized, could redefine urban economies and make reshoring not just a possibility, but a reality.

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