Optimizing Work Shoe Performance with Dr. Geoffrey Gray Part 3: Cushioning

Would you believe that consumers rate high heels as more comfortable than many occupational shoes that workers wear all day? According to Heeluxe™ founder Dr. Geoffrey Gray, that’s exactly the uncomfortable truth, and it’s costing employers and employees alike. The good news is that work shoes have improved by leaps and bounds over recent years. But, Dr. Gray says, we’ve still got a long way to go. In part 3 of this series, Dr. Gray walks us through the ins and outs of occupational shoe comfort, where we are and where we’re headed.

In the Heeluxe™ labs, Dr. Gray has discovered and ranked comfort levels based on shoe type. And it probably comes at no surprise that the top performers are running shoes. Here’s the breakdown from most comfortable to least.

1. Running Shoes
2. Hiking Boots
3. Casual and Walking Shoes
4. High Heels
5. Occupational Shoes

What makes that a really hard pill to swallow is the fact that employees wear occupational shoes for longer than any other type. And not only are they less comfortable than the other categories, they get even less comfortable over time, especially after long work shifts.

This sounds like it’s all doom and gloom, but there is a huge caveat here. Dr. Gray’s results speak to a broad spectrum of products and brands. That is to say, not all work shoes are created equal. To put it plainly and to offer some peace of mind: during the design phase, we fit test all of our SR Max^® footwear with Dr. Gray’s team at Heeluxe™ to ensure your employees can achieve optimal comfort. This is part of a larger effort to improve work shoe comfort industry wide. 

The Relationship Between Comfort and Performance

While feeling good in your shoes is a top priority for workers, employers usually want to see how it impacts their bottom line. Fortunately, we’re talking about a win-win scenario that’s easiest to illustrate when considering runners. Why runners? Because running shoes have received more research than any other category by a long shot. Dr. Gray notes that this research shows that “for runners of all ability levels, if the shoes are more comfortable, individuals are able to run faster, farther, more efficiently and with fewer injuries.” These key findings demonstrate a clear correlation between comfort and performance. 

Dr. Gray drives this point home as he observes that fatigue and overuse injuries have become the second leading cause of missed shifts in the US. But the good news is that work shoe performance research is currently on the rise and is corroborating the data we’re seeing in the running world. In fact, one study showed that providing better cushioning caused a whopping 55% reduction in foot injuries and a ⅔ reduction in hip and lower back injuries. The end game of comfort is happier employees, fewer workplace injuries and fewer avoidable days missed. With comfort so tightly linked to both safety and performance, understanding the mechanics of cushioning is critical.

Cushioning: The Key to Comfort

We all know that better cushioning just feels plain good. But since it also helps reduce fatigue-related injuries, it’s so much more than initially meets the eye.  

Two features contribute most to the quality of a shoe’s cushioning: the insole and midsole. Flat insoles are a huge red flag, but lots of brands use them because they’re inexpensive. On top of that, it’s virtually impossible for manufacturers to provide insoles that match every individual’s foot shape. That’s why it’s sometimes necessary for an upgrade. Dr. Gray recommends molded insoles because they provide better cushioning, support and durability than most insoles. If you can’t find the shoes you want with molded insoles, your best bet is to replace the existing factory insole with one of better quality. Research has shown that simply replacing insoles like this reduces hip, back and knee pain in a single work shift by up to 38%. 

Sometimes workers wonder if aftermarket insoles are really worth it, especially if they’re replacing the ones found in a new pair of shoes. Dr. Gray tells us that they often are “worth their weight in gold” because they improve comfort and performance over the long haul. For a 170-pound person, an average insole is only going to last for about 175 miles of walking. Premium insoles, on the other hand, are going to last more than three times longer. And aftermarket orthotics can last four times longer (~704 miles of walking). 

Beneath the insole lies the midsole, the key shoe feature that contributes to supported muscles, tendons, bones and ligaments. The two main things to keep in mind are the material and shape of the midsole. The two most common materials are EVA (Ethylene-Vinyl Acetate) and PU (Polyurethane). EVA is lightweight and flexible, but it can compress and lose cushioning faster during long shifts. PU is denser and more durable, offering firmer support that holds up over time, an advantage in demanding work environments. Some brands also use hybrid or advanced foams that combine softness with durability.

Just as important as the material is the midsole’s shape. Added thickness or sculpting in high-impact zones can improve comfort, while stability features help control fatigue. The takeaway: not all foam is equal, and matching the right midsole design to the demands of the job and the physical needs of the individual wearer is key to keeping workers supported throughout their shift.

Dispelling the Cushioning Myths

Now that we have a clear picture that cushioning has a huge impact on employee performance and that insoles and midsoles are the key players in this category, Dr. Gray says it’s time to set the record straight about three myths that compete with these insights. 

Myth: If premium insoles and anti-fatigue mats have the same capabilities, installing mats would keep employees from having to upfit their occupational shoes. 

Fact: It’s true that based solely on injury rates, both anti-fatigue mats and insoles provide the same reduction in injuries. However, mats might not be everywhere that your workers are going. They’re not going to be in halls or on stairs. In real life situations, better insoles provide more versatility and have improved outcomes overall, making them the better investment. There’s one caveat though: combining premium insoles and mats gets the best outcome hands down. Together, they give workers the support and protection in areas where they spend the bulk of their time. 

Myth: A great way to determine if a shoe has decent cushioning and support is to use the thumb test.

Fact: Sometimes people press their thumbs into the insole or midsole to feel the level of give a particular shoe might have. But when we walk, we put up to four times our body weight on the balls and heels of our feet, making the thumb test a useless tool. The best option is rigorous professional testing. Dr. Gray notes that the Heeluxe™ testing machine, which they affectionately call “The Hulk,” offers precise impact data and clearly identifies cushioning quality. The good news here is that SR Max’s new PU insoles perform better than most competitor insoles.

Myth: The more energy return the better.

Fact: For many sports like running, high energy return is a huge bonus. It adds bounce, which is especially beneficial. So, now we’re seeing many shoe categories taking notice and modeling their shoe choices after that with one harmful assumption: if energy return benefits runners, it’ll benefit me and make me feel more comfortable. But workers don’t need copycat options; they need shoes that are finely tuned to their needs.

When workers are in their shoes for 10-12 hours at a time, that high level of bounce that comes from high-energy-return shoes starts to feel more like getting punched in the bottom of the foot. It will wear out their muscles and won’t feel as good at the end of the day. Additionally, the high energy return foam tends to be unstable. It’s a lot like jumping on a trampoline; you’re going to go really high. But if you try to run on a trampoline, it’s really hard and you’re probably going to fall because it’s unstable. High energy return shoes aren’t the best choice for occupational settings for those reasons.

While cushioning plays a critical role in injury prevention and comfort, it's only part of the equation. As Dr. Gray points out, even the most cushioned shoes can fall short if they don’t fit properly. And that’s where many work shoe programs miss the mark. Proper fit isn’t just a nice-to-have—it’s essential for comfort, performance, and long-term health.

In the next part of our series, Dr. Gray will walk us through how to get fit right—and how the right fit can turn good shoes into great ones for your team. Stay tuned.