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Precision Manufacturing With Less Waste

Sustainability – WearSun

THE WEARSUN EFFECT

FOR THE PLANET

WearSun measures the environmental impact of every step in our process, from materials and 3D printing to delivery. Most emissions come from insole production itself, making manufacturing the main focus for reduction as we scale. Across our current model, one pair of WearSun insoles averages around 2.5 kg CO2e, and lowering that figure is built into how we design, print, and ship every order.

Sustainability – WearSun
HOW WE REDUCE WASTE

Precision Manufacturing. Less Waste by Default.

Traditional orthotics manufacturing is inefficient. Up to 97 percent of material is discarded during production, creating unnecessary waste and energy use.
Our HP Multi Jet 3D printing process uses PA11, a renewable material derived from castor oil. Each insole is produced additively, using only what is needed, with minimal material loss.
MATERIAL WASTE PER PAIR
CNC Milling
Chips waste: 1,222g per pair
Borders waste: 923g per pair
Total waste: 2,145g per pair
HP Multi Jet
Powder degradation waste: 212g per pair
90 percent waste reduction
Waste from CNC vs. HP Multi Jet printer in orthotics production. Source: HP
Less material. Less energy. Less waste.
Sustainability Impact

Product Lifecycle Breakdown

A comprehensive analysis of our product's environmental impact across its complete lifecycle, from raw material sourcing to end-of-life processing.

47%
18%
17%
10%
8%
47%

Raw Materials

Sourcing and extraction of sustainable materials with minimal environmental impact.
18%

Manufacturing

Energy-efficient production processes using renewable energy sources.
17%

Distribution

Optimized logistics and carbon-neutral shipping methods.
10%

Use Phase

Long-lasting product design with minimal maintenance requirements.
8%

End of Life

Recyclable materials and responsible disposal programs.

Lifecycle Phases

Each phase represents a critical stage in our product's environmental journey.
Raw Materials
Manufacturing
Distribution
Use Phase
End of Life
HOW IT CONTINUES

Precision Doesn't Just Fit Better. It Wastes Less.

By designing each pair individually, we avoid the waste built into standard footwear manufacturing.
01

Made only after your data is complete

Your quiz and scan create one digital foot profile. Nothing is produced before this step. No surplus.
02

Digital fitting replaces physical inventory

One digital profile per customer removes the need for excess sizes and SKUs.
03

Built to last, not to be replaced

Targeted support and durable materials reduce repeat purchases and material waste.
One quiz. One foot profile. One pair made specifically for you.
Sustainability – WearSun

We’re implementing initiatives in every aspect of our business to reduce emissions and minimize waste. Simple yet impactful changes can make a lasting difference.

LED Lighting Powered by REC Electricity

Our entire headquarters in Ferndale, Washington is powered by Renewable Energy Certified (REC) electricity, including energy efficient LED lighting.

Recycled Materials

Using innovative recycled materials in our products keeps millions of plastic bottles and other pollutants out of landfills. Recycled content in our top covers, foam, and arch support caps are introduced on a rolling basis to reduce waste.

Eliminating Polybags

We have eliminated 90% of the polybags used to deliver raw materials from overseas.

Sustainability commitment

We believe in creating products that respect both people and planet. Our commitment to sustainability guides every decision we make, from sourcing materials to packaging design. This isn't a marketing campaign—it's how we operate, every single day.

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