The process begins by designing a shoe. The design may be based on a theme, a picture, a memory or a creation out of scribbles. The design of a shoe is the first step in visualizing the actual shoe. In this step our designers decide on the shoe shape, strap widths, heel heights, materials and accessories.
02 The Pattern
Almost every pair designed in our PAIO studio is unique and requires a unique pattern to be cut. This pattern is cut based on the design. Each measurement for the upper (the main shoe design that sits on your foot) is taken into account when cutting up the pattern. Like the upper, patterns are cut for the sole (the bottom of the shoe), insole (the internal part of the shoe that your foot rests on) and the outsole (the part of the shoe that touches the ground).
A last is a foot shaped mold. Lasts come in various sizes, shapes and heights. Depending on the design and heel height, a particular last gets selected. Almost every design requires a unique last. The cut pattern is then placed over the last and nailed in. The remaining patterns such as the insole, sole and outsole are attached.
Based on the heel type and height selected, the appropriate heel is chosen and attached to the shoes.
Once the shoe patterns have been attached over the last, the entire shoe is glued together. Any excess material is trimmed off.
The PAIO logo is stamped inside the shoe on the insole.
In this step a thorough quality check is conducted on the shoe for any defects, changes or trimmings required. The shoes are then left on the last to dry for over a day.