How Are Merry People's Gumboots Made?

Did you know that Merry People rubber boots are hand-crafted?

Yep, each pair is made with care by our expert rubber boot makers in world-class factories. This means that what you wear on your feet meets - and often exceeds - industry standards.

Curious about how rubber boots are designed and made? You’re in the right place! We sat down with Cass, our Head of Product, to chat through Merry People’s process - from responsibly sourced rubber to rigorous testing and beyond.

How are Merry People's rubber boots made?

First up, all Merry People boots are designed at our head office in Melbourne, Australia, before colors are chosen and the collaborative process with our international manufacturers begins.

Cass explains, “Our Product Team shares the final designs with our two world-class manufacturers in China, who help bring these designs to life. With their expertise, each boot is carefully hand-crafted from the inside out.”

What type of rubber is used in Merry People boots?

Creating the unique rubber needed for each Merry People boot is a bespoke process, Cass explains. “This includes mixing natural rubber, stabilising agents for durability and pigment for color which leaves us with the durable, colorful rubber that goes on to become your Merry People boots!”

Where does the rubber in Merry People rubber boots come from?

“Our boots are made using a blend of natural rubber, with FSC-certified rubber as the primary material,” explains Cass. “It’s responsibly sourced from forests where farmers and workers are treated and paid fairly.”

How are the boots insulated?

This is all down to the unique interior of Merry People boots, explains Cass. “We cut the rubber into shape and stitch together with the neoprene lining into a sock shape.”

“The neoprene lining makes the boot 100% waterproof, keeps your feet toasty warm and gives you comfort beyond the normal gumboot experience,” Cass continues. “These extra features - comfort and warmth - make our Merry People Boots unique from other gumboots.”

The 4mm neoprene lining in each Merry People boot is actually favored in another Aussie pastime, Cass shares. “It's made from the same material used for wetsuits!” she says. The result? “Dry socks all day long.”

How do you make Merry People rubber boots so comfortable?

The Merry People ‘sock’ is the secret ingredient here, says Cass. “The sock is wrapped around a metal foot, called a ‘last’, which creates the shape. The sock then travels to an enclosed spray booth, where they are sprayed with water-based vegan glue in preparation for ‘lasting’.”

What does the lasting process involve?

Lasting is when the rubber upper is wrapped around the neoprene sock and given a trim, Cass explains. “For additional protection, double layers of rubber are then applied on the toe and heel.”

Once the interior is perfected, the structure is in focus. “The next step is the back join which is secured with a strip of rubber, then glued and hammered,” Cass continues. “To attach the outsole of the boot, glue is applied to the bottom, and then activated through a heat tunnel. The outsole is then applied by hand, rolled and hammered with great strength to help secure the bond.”

Vulcanising is the final step. But what is it?

“This is where the boots are cured in hot ovens so that the upper and the outsole bond together,” Cass explains. “This is the best process to ensure the strongest bond in rubber boot production.”

What testing do Merry People boots undergo?

At every step of this process, each boot is checked on the production line for quality control, assures Cass. “Every production run, our boots undergo multiple tests before heading out into the world!”

Rigorous testing of every Merry People boot design takes place in the factories' in-house labs with third-party laboratories to ensure optimal quality and performance. “In these tests, we simulate the boots being worn for extended periods of time, in different conditions,” Cass explains. “We test to make sure they’re waterproof and we test to make sure that the boot has bonded together properly, for the strength of the rubber, and outsole traction.”

What’s the final step in the making of Merry People Rubber boots?

“So that your boots are ready to go out of the box, we coat them with a protective silicone spray,” Cass explains. Natural rubber boots really benefit from this care, she adds, “so it’s important to regularly reapply a silicone spray to avoid the rubber drying out and cracking.”

Now, having passed their tests with flying colors - pun intended! - "It's time for our Merry People boots to get ready for their journey to you!” says Cass.

This is the point where the boots are carefully packed in tissue paper and placed in their recycled cardboard box. “And just like that, your boots are ready to take on their next big adventure!”

Have any questions about our production process? Get in touch with us at support@merrypeople.com - we'd love to hear from you.