Ski boots from the 3D printer: visit to Tailored Fits

As a skier with a high throughput of equipment, I think that my interest in the development and innovation of hardware means that I am aware of many items of equipment on the mountain. Photo collections from ISPO and co. provide an overview of what's coming onto the market soon. However, it feels like there hasn't been anything really innovative for a long time.

I was recently surprised in the gondola of a family ski resort in central Switzerland. I spotted something unusual on the foot of the person next to me: a ski boot without buckles!"
Curious, I ask for information:

"I'll make it myself"
"What do you mean?"
"With my 3D printer"
"And it fits?"
"Yes, I scan the foot and then we print the inner boot into a shell."

"Where can I order?"" I ask immediately. "We're still testing" I'm initially put off.

On a descent together, I was able to see for myself that the material at least seems to be functional. While queuing for the next gondola, Reto introduces himself and talks about his development, which he also wants to launch on the market. They are currently in the test phase with regard to durability. After many years working in the ski boot sector for a major manufacturer, Reto has the experience that is probably needed for this promising product. He has been working with 3D printing technology for three years. In order to realize his idea, he has now set up his own business, patented the invention and founded a company: Tailored-Fits.

Digital competence center on Lake Lucerne

He would love to show it to me one day, he says when I ask. Two weeks later, I'm near Lake Lucerne in his test lab, where I meet Benni. Benni is an application developer and, as a passionate boot fitter, the person who covers the other interfaces of complex development. Before a personalized, printed object can be created, it needs a scan and the software that can process and translate this data. Together, Reto and Benni created a network of specialists from the USA, Canada, Belgium and Malaysia. They see themselves as a digital competence center.

Supported by well-known sporting goods manufacturers who are investing in Reto's idea, they have now been working together for a year to develop tailored fits and have already made it to the first product ready for series production. Fully personalized, 3D printed insoles for ski, bike, hike and running shoes.

A new skiing experience

Benni reports a completely new skiing experience with the ski boots from the printer. The natural fit provides much more direct control. Better blood circulation leads to less cold feet and less fatigue. Performance increases significantly. And why does the ski boot not need buckles? The ideal form-fit from the foot to the inner boot and from the inner boot to the shell transfers the power to the ski boot sole. Buckles that hold the foot in place are therefore superfluous. A strap to close the form-fit is sufficient.

Reto believes that as soon as production on the laboratory's capacity-limited printer, which is still in the test phase, can be assigned to suppliers, it will probably not be long before a series rollout? He hopes to be able to start selling the insoles in the fall. The insoles can already be purchased in two stores.

The insoles can be fitted into ski boot shells, for example as an alternative to foamed insoles. To do this, both the foot and the shell are scanned so that the inner boot fits exactly. Complete ski boots from the 3D printer, i.e. including inner boot and outer shell, are already being tested as prototypes (see photo above). Reto and Benni do not yet know exactly when these will be ready for the market. For now, the focus is on the inner shoes.

I say goodbye and once again express my admiration for their determination. They are working flat out on this difficult project. I wish them continued support and am already looking forward to the next ski season. Perhaps finally without the pressure of shoes!