Ski Boot Thermoforming

One of the most interesting and challenging projects we have experienced was brought to us by the skiing equipment industry, with particular regard to the improvement of ski boot design in several key areas :

• Alleviating the discomfort and reduced performance associated with the wearing of ill-fitting ski boots.
• Obviating the dampness and chill of morning starts due to ski boots not having dried out from the previous day’s exertions.

It was simply accepted that ski boots were uncomfortable ; an irrefutable fact of life like Tax or The Great Wall of China. Lateral thinking was therefore necessary, along with a willingness to put aside accepted practice.

The germ of an idea for applying heat to a malleable foam which could have a ‘memory’ was proposed by the ski boot manufacturer ; EXO² then designed a shaped FabRoc® pad around this concept, enabling the application of heat to mould or ‘Thermoform’ the foam into a snug fit around the users heel and ankle area, setting as it then cooled. This would provide the highest level of comfort which could possibly be achieved in being specific to each user, closing gaps around the heel to ensure maximum manoeuvrability, whilst still allowing for natural expansion of the foot during periods of high activity.

Well & good ; but this still left the user with boots he or she was less than enthusiastic to pull on if they had been ploughing through snow a few hours previously..The application of a 12v transformer (or optional cigar lighter adaptor for those on the move), provided for Chalet/Hotel use and left to thoroughly dry out the boots overnight, also rendered them with a warming glow for the next early start.

The same FabRoc® pad was therefore able to address each of the project objectives and in doing so, changed orthodox thinking in this area forever. Sales have reflected this transformation and have exceeded all realistic expectations.

Skiers seem to like our other products too, including the HeatWave Heated Back Support and StormWalker Heated Vest, which both deliver warmth directly to the kidney region, from where the suffusion of warmed blood is circulated to create a soothing upper body warmth which helps to keep skiers alert and enjoying the adventures en piste !