New Balance Senior Product Developer Kenneth Straka checks in from Bali
Update: Since this post was published, the official name of the product line referred to here has been defined as 'Sonic welded 574' rather than 'Sonic 574'. In order to avoid confusion, the content of this post has been updated to reflect that name change.
The Sonic welded 574 attracted a fair bit of attention when it was announced in January - a new series of colors and textures and the first New Balance shoes made with a sonic welding process. Sonic welding utilizes tremendous heat and pressure to create an airtight (and watertight) seal using significantly less labor than is required for traditional stitching. To commemorate their launch this week, we threw a few questions about the shoes at New Balance Senior Product Developer Kenneth Straka. And in celebration of that saved labor, Ken spoke to us from a beach in Bali.

The Sonic welded 574 in black, gray, and brown
NB: Just as the Sonic welded 574 launches in the US, one of the key people behind the shoe is halfway around the world. What gives?
KS: Other than surfing?
NB: Other than that, yes.
KS: I had two primary goals for the this trip: Finalize materials for products in development for the beginning of 2011, and to start revised prototypes for the shoes coming out next summer. There were secondary goals, as well, like helping out with design explorations for fall of 2011 – (New Balance designers) Jodi Klann and Kai Marcucelli have been sending me ideas during the trip.
NB: How does being on-site in a place like Southern China further the design process?
KS: When you have strange/different ideas, it’s much easier to explain them to the factory in person. The Sonic [welded] 574 never would have worked had Taylor Canby (Sr. Designer, Lifestyle/NB Asia) not been in China to initially help explain the concept.
NB: How so? To what extent does manufacturing enable the design process for you?
KS: Our factories basically had to develop this process from scratch. Jenny Chen and Mad Johnson of New Balance China actually brought irons and hairdryers into the office to melt materials together, in order to help prove that the process worked. After the proof of concept, the factory started to invest in proper equipment and machines. A year and a half ago, none of our factories knew how to do any of this, so it was pretty awesome to be involved in the initial exploration.

The watchful eye of Jenny Chen reviews Sonic welded 574 materials
NB: Now that you’ve applied this to the 574, do you foresee this same process informing future designs of other New Balance shoes?
KS: My favorite thing about the process is its simplicity – now that we know how to do it. It took a lot of trial and error to figure out the correct temperature and the correct materials to use. Once we figured that out, though, it opened up the doors to so many different opportunities, which we’re continuing to explore for upcoming seasons.

Mfg. Eng. Mad Johnson shows off his Sonic welded shoes
NB: Beyond the technology that shapes the way the Sonic welded collection is manufactured, how do you feel about the shoes themselves?
KS: In looking at the Sonic [welded] 574, I see it as a work of art…or rather a work of art that’s meant to be worn. We didn’t sacrifice anything in terms of durability, fit, or function – even though it feels so soft and lightweight. If anything, the bonding actually makes the shoe more durable.
NB: How so?
KS: On a conventional shoe, if a stitch detail comes undone, the shoe starts to fall apart. The Sonic [welded] 574 doesn’t have this problem, because there’s no stitching. It’s also probably one of the most comfortable and breathable shoes I’ve ever worn because there’s no glue used in the shoe’s upper. It’s cool to walk around the factories and see all the NB China associates rocking Sonic [welded] 574s.
NB: With that accomplished – and once you’re done surfing – what are you looking to explore next?
KS: One thing that’s really interested me as of late is high-end leathers. I’ve been trying to find ways to work them into shoes without increasing cost – which often means taking out other unnecessary things. We have some 574s coming out mid-2011 that are using high-end fashion leathers made from Goat.
NB: Goat?
KS: The leathers are much thinner and softer than our factories are accustomed to using, so I had to spend a lot of time working with them to figure out how to properly stitch and back the leather without ruining the feel or appearance.
NB: And the side trip to Bali is a convenient side-benefit?
KS: That it is.
The Sonic welded 574 is available in select retailers as of 4/1/2010, and will be available online at shopnewbalance.com within the next several weeks. To get a closer look at the shoes, check out this Flickr gallery where we'll also be uploading some behind-the-scenes shots showing how the sonic welding process works. For more information in the meantime on the materials and process, check out this presentation. Update: The collection will hit select retailers on Thursday, April 15th, rather than April 1 as initially anticipated.

