Talk Commerce continues to showcase innovative entrepreneurs who’re reshaping traditional industries through technology. In this compelling episode, host Brent Peterson sits down with Elias Stahl, founder and CEO of HILOS, to explore how 3D printing technology is revolutionizing footwear production. The conversation unveils a fascinating glimpse into sustainable manufacturing practices, local production methods, and the integration of creativity within supply chain operations. What emerges is a vision that challenges conventional shoe manufacturing while addressing environmental concerns and empowering designers worldwide.
Key Takeaways
• 3D printing technology reduces waste significantly in shoe manufacturing processes
• Local production models can bring manufacturing closer to consumers, reducing transportation costs
• Design creativity becomes an integral part of the supply chain rather than a separate function
• AI-powered generative design tools democratize access to production-grade footwear design
• HILOS’s Interplay™ software bridges concept to production without traditional CAD requirements
• The “Made in Old Town” initiative aims to revolutionize domestic manufacturing in Portland
• Sustainable manufacturing practices don’t compromise product quality or innovation
• Technology empowers individual designers to compete with large-scale manufacturers
• Customization capabilities through 3D printing create new market opportunities
About Elias Stahl
Elias represents a new generation of entrepreneurs who combine technological innovation with environmental consciousness. As the founder and CEO of HILOS, he’s pioneering revolutionary approaches to footwear manufacturing that challenge industry norms. His background spans technology development, sustainable business practices, and manufacturing optimization. Elias brings unique insights into how emerging technologies can transform traditional industries while creating positive environmental impact. His work focuses on integrating advanced manufacturing techniques with creative design processes, establishing new paradigms for local production models. Through HILOS and the ambitious “Made in Old Town” project, Elias Stahl demonstrates how innovation can address both market needs and sustainability concerns simultaneously.
Episode Summary
The conversation begins with Brent establishing the exciting nature of this particular episode, noting his shared interest with co-host Isaac Morey in running, making the footwear innovation topic particularly relevant. This personal connection sets the stage for an engaging discussion about technological advancement in an industry that directly impacts active lifestyles.
Elias introduces HILOS as more than just another footwear company, positioning it as a transformative force in manufacturing methodology. “We’re not just making shoes differently; we’re reimagining how creativity fits into the entire production process,” he explains. This statement encapsulates the broader vision driving the company’s mission and reflects the fundamental shift happening across ecommerce.
The discussion explores how traditional ecommerce models are being disrupted. “All ecommerce is built on the old industrial world of making something in advance and then getting people to buy it,” Elias observes. “The internet is changing the way we buy things and make things. Barriers to entry drastically lower as this evolves.” This transformation creates massive opportunities for aggregators and cultural tastemakers, particularly when combined with AI capabilities, while traditional players risk losing market position by ignoring these industry shifts.
AI emerges as a central theme throughout the conversation, particularly its impact on ecommerce and manufacturing. When discussing AI’s transformation of online retail, Elias emphasizes practical applications that businesses should consider adopting. “AI is making it much easier for footwear designers to access production-grade design tools without investing millions in R&D,” he explains. Generative tools enable designers to experiment with structure, fit, and materials before committing to physical production, dramatically reducing development costs and time-to-market.
The conversation moves into HILOS’s upcoming product launch. This fall, the company plans to introduce Interplay™ software to enterprise teams. This cloud-based generative design and production platform specifically targets footwear development, enabling brands and designers to transition from concept to production-ready 3D-printable files without traditional CAD software requirements. The platform bridges sketches, moodboards, or text inputs directly into manufacturing workflows, streamlining the entire design process.
Interplay™ represents a significant advancement in design democratization. Teams can leverage custom data training to tailor AI models to their brand specifications, optimizing design consistency and performance across product lines. This capability addresses one of the industry’s biggest challenges: maintaining brand identity while scaling production and design capabilities.
The discussion shifts to future ecommerce trends and business preparation strategies. Elias predicts that supply chain complications and tariff challenges will drive more companies to consider domestic production as a profitable alternative. This shift isn’t just about cost management; it’s about building resilient, responsive supply chains that can adapt to changing market conditions.
Here, Elias introduces the groundbreaking Made in Old Town initiative, which represents perhaps the most ambitious aspect of HILOS’s vision. This project aims to create a district-scale hub for footwear and apparel design and manufacturing in Portland, Oregon. By building a vertically integrated ecosystem of suppliers, brands, and independent talent, the initiative seeks to reshape domestic manufacturing while driving local economic development and innovation.
The Made in Old Town project benefits from industry expertise drawn from companies like NIKE, KEEN, Under Armour, and Adidas. This leadership brings credibility and practical knowledge essential for executing such an ambitious undertaking. The Portland metro area already hosts 300+ footwear and apparel brands, and Oregon accounts for 90% of domestic footwear manufacturing exports, creating a strong foundation for expansion.
Currently, only one brand in Oregon—Nike—has in-house rapid sampling capabilities. Made in Old Town aims to change this dynamic by providing shared infrastructure and resources that enable smaller brands and independent designers to access similar capabilities without massive capital investments.
Local manufacturing emerges as another central theme throughout the conversation. Rather than relying on distant factories with complex supply chains, HILOS envisions production facilities closer to end markets. This proximity reduces transportation costs, minimizes delivery times, and allows for greater responsiveness to local preferences and trends. “When production happens locally, we can respond to market changes much faster than traditional models allow,” Elias notes.
The empowerment of designers through technology becomes a fascinating aspect of the conversation. Traditional footwear design often requires significant capital investment and manufacturing partnerships that favor established players. However, 3D printing technology democratizes the design-to-production process, allowing individual creators to bring concepts to market without extensive infrastructure requirements.
Sustainability considerations weave throughout the discussion, with Elias emphasizing that environmental responsibility isn’t separate from business success. The reduced material waste, lower transportation requirements, and more efficient production processes create a business model that performs well financially while addressing environmental concerns. This alignment becomes increasingly important as consumers prioritize sustainable options and regulatory frameworks evolve.
The conversation explores challenges facing the implementation of these innovative approaches. Scaling 3D printing technology for mass production presents technical hurdles, while consumer acceptance of new manufacturing methods requires education and demonstration of quality standards. However, these challenges represent opportunities for continued innovation rather than insurmountable obstacles.
Future possibilities discussed include mass customization capabilities, where consumers can specify design preferences and receive products tailored to their individual needs. This level of personalization was previously impossible at scale but becomes feasible through advanced manufacturing technologies combined with AI-driven design tools.
When discussing long-term growth strategies for ecommerce businesses, Elias emphasizes the importance of understanding technological convergence and consumer behavior shifts. Companies that recognize these trends early can position themselves advantageously, while those that ignore changes risk obsolescence. The key lies in balancing innovation adoption with practical business considerations.
The discussion reveals how technology convergence creates opportunities for reimagining entire industries. By combining 3D printing, digital design tools, AI capabilities, and local production models, HILOS represents a case study in how multiple innovations can work together to transform traditional business approaches.
Final Thoughts
This episode illuminates how technological innovation can address multiple challenges simultaneously, creating business models that benefit consumers, designers, and the environment. Elias Stahl’s vision for HILOS and the Made in Old Town initiative demonstrates that sustainable practices and business success aren’t mutually exclusive but can reinforce each other when approached strategically. The conversation reveals how 3D printing technology extends beyond manufacturing efficiency to enable new forms of creativity and market participation.
The transformation happening in footwear manufacturing reflects broader trends affecting many industries. As technology continues advancing, traditional boundaries between design, production, and distribution continue blurring. Companies that understand these shifts and adapt accordingly will thrive, while those clinging to outdated models risk losing relevance. The question isn’t whether these changes will continue, but how quickly established players will adapt to new realities. Perhaps the most intriguing aspect is watching how innovation can quite literally reshape the very foundation we stand on.
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