Batch Production with Additive Manufacture

Batch Additive Manufacture

Phoenix Consultants X Greeper Laces

In 2026 Phoenix Consultants partnered with Greeper Laces to deliver their next batch of products that could be made locally and in short runs.

Black Greeper Prime - Source: Greeper.com

Commercially launched in 2008 by Peter Greedy, Greeper Laces are a patented, no-tie shoelace that make use of a clever toggle system that once fitted to a shoe can be easily tightened and loosened, and most importantly never come undone. Greeper Laces can be used with a single hand, and are far quicker and easier to use than conventional shoelaces. These have become a popular product for use in sports, running, and by outdoor enthusiasts, as well as become a valuable accessibility product widely adopted by people with limited dexterity; typically these people are limited to slip-on or Velcro shoes however Greeper makes lace-up shoes accessible.

Greeper Laces originally manufactured their products overseas but looked at ways to produce the parts more locally, this also needed to not incur further costly tooling setup and be agile in volume of production. Additive manufacture uses 3d printing technology and requires no tooling set up to begin batch production of parts.

Production of Greeper Lace toggle - Source: Phoenix Consultants

A few benefits of additive manufacture are the volume of production can vary from batch to batch and can be agile to demand, modifications and improvements can easily be made to the design and implemented into the next batch run without issue, and colours/materials can be changed during production to suit what is needed.

Greeper Laces provided Phoenix Consultants with a 3d CAD file for the components they were looking to manufacture, this included the Toggle and Plunger parts. These files were ran through a simulation to optimise quantity of parts produced at a time while maximising part quality and consistency. It was decided to manufacture the parts from recycled PETg for its mechanical properties, durability, and sustainability, this material was also sourced from a local UK supplier. Production could begin immediately as there is no tooling/set-up lead time for this method of manufacture and in quick succession the first run of 500 units were complete, handed over to Greeper, and signed off ready for online retail.

See more about this project on our portfolio here.

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