The Green Step Upper: A Novel Sustainable Bonding Method Replacing Solvent-Based Adhesives in Footwear Upper Assembly

The Green Step Upper project introduces an innovative, solvent-free adhesive application technology designed to transform stitching preparation processes in footwear manufacturing. Traditional methods rely on double-sided application of solvent-based adhesives, resulting in high VOC emissions, increased labor dependency, inconsistent quality, and environmental burdens. This project eliminates these limitations through a specially engineered single-surface adhesive tape system that provides stable fixation, homogeneous bonding distribution, and improved process efficiency. The research covers material selection, ergonomic apparatus design, prototype development, and performance testing across different upper materials. Results demonstrate a complete removal of solvent use, a significant reduction in operational time and labor costs, improved product consistency, and zero VOC emissions, enabling fully sustainable production. The proposed system offers a scalable and commercially viable model that can be adopted by both domestic and international manufacturers, contributing to national competitiveness while supporting global sustainability targets.