February 20, 2026
Recycled rubber from tyres is one of the most resistant, durable and sustainable materials for manufacturing soles. More and more artisans, shoemakers and footwear brands are choosing it for its grip, long life and reduced environmental impact. However, working with this material is not exactly the same as working with EVA, leather or new rubber. It has its own rules.
When you are not familiar with it, problems such as delamination, uneven cuts or unprofessional finishes can arise. In this article, we compile the most common mistakes made when manufacturing recycled rubber soles and how to avoid them in order to achieve clean, durable and professional-quality results.
1. Using the wrong adhesive
The problem
One of the most common mistakes is using adhesives designed for foam, leather or porous materials.
Recycled rubber is denser and less absorbent, so the adhesive does not penetrate well and the sole ends up coming off with use.
How to avoid it
- Use contact adhesives or specific glues for rubber.
- Apply adhesive to both surfaces.
- Allow sufficient drying time before joining.
- Press firmly or use a press during curing.
👉 Good adhesion accounts for 50% of the sole's durability.
2. Not preparing the surface before gluing
The problem
Sticking directly onto smooth rubber greatly reduces adhesion. Even if it looks clean, the material may have:
- Dust
- Manufacturing residues
- Oils
- Surface too smooth
All of these weaken the bond.
How to avoid it
- Lightly sand the contact area (medium grain).
- Clean with alcohol or a suitable solvent.
- Remove all dust before applying adhesive.
This small step makes a huge difference.
3. Choosing an unsuitable thickness
The problem
Sometimes the sole is chosen solely for aesthetic reasons, without considering the end use of the footwear.
Result:
- Soles that are too rigid
- Excess weight
- Poor flexibility
- Premature wear
How to avoid it
First, define the type of shoe:
- Casual or urban → medium thicknesses
- Outdoor or work → greater thickness
- Lightweight footwear → thinner options
👉 Working with calibrated, uniform bands, such as those from Tiresoul, makes it easier to choose the right thickness and achieve consistent results.
4. Imprecise cuts or inadequate tools
The problem
Recycled rubber is more resistant than other materials.
Attempting to cut it with weak blades or blunt tools results in:
- Jagged edges
- Crooked cuts
- Excessive effort
- Wasted time
How to avoid it
- Professional cutter or industrial blades
- Bandsaws or die cutters for production
- Always keep blades sharp
- Mark the piece before cutting
A clean cut saves a lot of finishing work later on.
5. Not considering design flexibility
The problem
Designing soles that are too thick or rigid without flex zones can make the shoe uncomfortable or cause the material to crack over time.
How to avoid it
- Incorporate grooves or flex zones.
- Reduce thickness in the forefoot if necessary.
- Test prototypes before production.
Comfort is just as important as durability.
6. Do not test before mass production
The problem
Moving directly to manufacturing large quantities without testing the actual performance of the material can lead to returns or unexpected failures.
How to avoid it
Before production:
- Make a prototype
- Test adhesion
- Test flexion
- Check grip on different surfaces
A small test can save a lot of costs later on.
Working with the right material makes all the difference.
Recycled rubber offers incredible advantages: durability, grip, resistance and sustainability.
But like any technical material, it needs the right process.
Having strips specifically prepared for footwear — clean, calibrated and easy to handle — greatly simplifies the work and reduces errors from the outset.
At Tiresoul, we develop recycled tyre strips designed for artisans and footwear professionals, ready to be cut, glued and transformed into resistant and durable soles.
Conclusion
Most problems when working with recycled rubber do not come from the material, but from the process. With:
- Buena preparación
- Herramientas adecuadas
- Adhesivos correctos
- Y algo de práctica
- Good preparation
- The right tools
- The right adhesives
- And some practice,
you can achieve extremely durable soles with a much lower environmental impact than traditional alternatives.
And today, more than a technical detail, that is a competitive advantage.
