Polymaker: 3D-Printed Mattresses and AI-Customized Shoes — POLLYFAB Platform Redefines Consumer Goods

The 2025 Formnext Shenzhen exhibition attracted more than 20,000 professional attendees, while Panda3dp.com’s livestream drew over 34,000 online viewers.

At the event, Panda3dp.com visited Polymaker, a company dedicated to scaling production of consumer end-products. Manager Xiao introduced the POLLYFAB platform, highlighting three revolutionary showcases: the world’s first fully usable 3D-printed mattress, AI-powered gait-analysis custom shoes, and a lights-out “black factory” with stunning efficiency. Together, these marked a bold step in bringing 3D printing directly into consumer markets.

1. World’s First 3D-Printed Modular Mattress

Polymaker and renowned sleep brand Blue Box jointly unveiled the world’s first 3D-printed mattress designed for real use.

· Modular Design: Composed of multiple segments joined via interlocking structures, enabling unprecedented freedom in configuration and personalization.

· Unique Comfort: Soft touch combined with high elasticity delivers a fresh sleeping experience.

· Breakthrough Significance: Marks a leap from small parts to large, durable consumer goods—demonstrating 3D printing’s ability to redefine furniture manufacturing.

2. POLLYFAB Concept: Empowering Designers, Accelerating Production

At its core, POLLYFAB aims to return creative control to designers, allowing individuals to express themselves while protecting their IP.

· Ultra-Fast Production: A pair of shoes can be printed in about 2 hours.

· Black-Light Factory: With thousands of printers operating autonomously, the facility requires only a handful of engineers. Robots handle workflows, enabling truly scalable, intelligent manufacturing.

3. AI + 3D Printing: Scientific Shoe Customization

Polymaker demonstrated how AI and additive manufacturing converge to deliver genuine personalization.

· Real-Time Gait Analysis: Visitors on treadmills had their running posture captured, including foot pressure distribution, pace, pronation/supination, stride, and swing angles.

· True Custom Fit: Using these unique data profiles, Polymaker prints shoes tailored to each individual’s biomechanics and habits—bringing “custom fit” to a new scientific level.

4. Ecosystem Partnerships: From Sports to Global Fashion

The booth resembled a brand collective, displaying collaborations across categories:

· Sports Brands: Partnerships with Li-Ning and Peak yielded 3D-printed footwear.

· Global Icons: Collaborations with COLE HAAN and Skechers resulted in several new product launches.

· Export Market: Integrated-color 3D-printed shoes designed for overseas consumers.

· Co-Exhibitors at Formnext: Xing Shixian, Jifeng, Baliston, Hashi, and Muxiaoli presented products ranging from running shoes and casual wear to AI-customized sandals, outdoor gear, and stress-relief toys.

Applications are also extending to golf putters, automotive cushions, cycling helmets (including the “Xiangyun Helmet” for the national team), backpacks, and cultural-creative toys.

5. Material and Design Innovations

Polymaker showcased material versatility and structural creativity:

· Gradient Properties: Achieving “soft-on-top, firm-underneath” profiles with tunable hardness.

· Rich Colors: Over 20 hues demonstrated onsite, with countless combinations available.

· Advanced Lattice Structures: Lightweight, breathable, and comfortable—ideal for performance and lifestyle products.

Polymaker’s booth was less about machines and more about a consumer-facing ecosystem of end products. From a fully functional 3D-printed mattress to AI-driven customized footwear produced in just 2 hours, Polymaker demonstrated how additive manufacturing can empower designers, delight consumers, and reshape industries. With its POLLYFAB platform and black-factory production model, the company is proving that the future of 3D printing lies not only in technical possibility, but in personalized, distributed, and scalable consumer manufacturing already becoming reality.