On Running's New Cloudmonster Shoes Use Spray-On Technology to Change How Running Sneakers Are Made

Swiss running brand On Running has released the third generation of its Cloudmonster collection, with three new versions: the Cloudmonster 3, Cloudmonster 3 Hyper, and LightSpray Cloudmonster 3 Hyper. The line has become one of the company's flagship products since the original model arrived several years ago.

A Different Way to Build the Upper Part of the Shoe

The LightSpray variant stands out as the most technically advanced of the three. It uses On Running's proprietary spray-on technology to create the upper part of the shoe — the part that wraps around your foot. Instead of cutting fabric and stitching pieces together like traditional sneakers, this process sprays polymer material directly onto a 3D mold, creating a seamless upper in one piece. The result is less material waste during manufacturing and finer control over how thick the fabric is in different areas of the shoe.

For the sneaker industry, spray-on manufacturing tackles some longstanding problems. Traditional uppers are made from multiple fabric layers glued and stitched together, and all those seams and glue joints can fail under the stress of repeated running. A spray-on upper creates one unified structure instead, spreading stress more evenly and using fewer separate parts overall.

The manufacturing shift carries significant practical challenges. Spray-on production needs different equipment and tighter process controls than a traditional assembly line. Factors like temperature, how fast the material flows, and how it cures all become critical — they have to be monitored constantly to make sure every shoe turns out the same.

Who Else Is Doing This, and Why It Matters

On Running's focus on manufacturing innovation reflects a broader shift in premium running shoes. Brands increasingly try to stand out through proprietary production methods rather than buying the same parts from shared suppliers. Nike has Flyknit, Adidas has Primeknit, and New Balance has FuelCell technology — all attempts to build a technical advantage that competitors can't easily copy.

The Cloudmonster collection sits in the "maximal cushioning" category, where shoes have thicker midsoles designed to absorb impact and return energy. It competes with shoes like the Hoka Clifton and Nike's Invincible. This segment has grown significantly over the past five years as casual runners have embraced thicker soles that promise better shock absorption and a more comfortable ride.

We have seen cycles like this before. In the early 2000s, the industry shifted from basic foam to advanced polymers. In the mid-2010s, carbon plates became common in running shoes. Each time, the pattern is the same: a smaller brand innovates first, big manufacturers copy the idea, and eventually the technology becomes standard across the industry because material suppliers develop cheaper, standardized versions.

The Midsole: Balancing Comfort and Durability

The Cloudmonster 3 keeps On Running's signature CloudTec midsole design — which features hollow pods that compress when you land and expand as you push off, meant to provide both cushioning and a push forward. The new version uses updated foam compounds designed to last longer under heavy use.

From an engineering standpoint, there is a constant trade-off: softer foam feels better on impact but wears out faster, while firmer foam lasts longer but feels less comfortable. The third generation tweaks this balance, though the exact recipe stays proprietary to the company.

The Hyper variants adjust the midsole's shape and how the foam density is distributed to improve energy return. The specific changes are kept secret, but industry experience suggests they likely use two different foam densities — firmer under the heel, softer under the ball of the foot.

What Spray-On Manufacturing Actually Requires

Spray-on production needs specialized equipment that looks nothing like a traditional shoe factory. This creates both advantages and constraints. On one hand, the process allows On Running to prototype and customize shoes much faster than traditional cut-and-sew methods would allow. On the other hand, the equipment is expensive and hard to move around — you can't easily spread this manufacturing across multiple factories the way you can with traditional assembly.

For the broader industry, spray-on technology fits into a larger trend toward automated manufacturing. As wages rise in the countries where most shoes are currently made, manufacturers are looking for ways to bring production closer to where shoes are actually sold. Spray-on technology could help with that shift because it requires fewer workers and can operate in different locations.

The Reality Beyond the Marketing Claims

The marketing around maximal-cushioning shoes often suggests they prevent injuries and improve performance for everyone. The actual evidence is messier. Research shows that thicker soles do reduce the force your body absorbs on impact, which sounds good. But whether that actually prevents injuries varies from person to person — the research community hasn't settled the question.

Studies also show that runners adapt differently to thick-soled shoes. Some runners become more efficient with the extra cushioning, while others actually run less efficiently because the shoes change how their feet naturally move. There is no one-size-fits-all answer.

The broader context here is worth flagging: whether the Cloudmonster 3 succeeds in the market will probably depend less on the technical innovations and more on whether the shoes are well-made, durable, distributed in stores where people can buy them, and backed by clear messaging about what they actually do. The sneaker market has shown repeatedly that clever technology alone does not sell shoes — execution and brand trust matter just as much.