3D Printing Paves the Way for Both Comfort and Performance With the Aerorise Backpack

Increasingly, it seems as if the sky’s the limit for applications in 3D printing. We have already seen parts made for everything from rocket engines to sneakers. Though when it comes to consumer goods, particularly for sports, 3D printing has truly found its footing. 3D printing’s vast customization capabilities, among other benefits, can greatly improve performance and comfort for athletes. Even major organizations like the NHL, NFL, and the Olympics have started to adopt the technologies. A recent example of this is how Jack Wolfskin looked to 3D printing, and more specifically, the respective technologies and expertise of Carbon and OECHSLER, to create a better backpack called Aerorise.

Jack Wolfskin is a German-based outdoor wear and equipment producer. Though they have been active for almost 40 years, they have only recently moved into the North American market. The company is passionate about creating products that are proven effective in the wild using innovative, eco-conscious technologies. They turned to 3D printing for this latest product as a way to overcome ventilation issues in backpack padding. In traditional pack design, padding is added to make the wearer comfortable at pressure points while carrying heavy loads, but it can also cause a lot of back sweat, as any experienced hiker will tell you.

Jack Wolfskin turned to 3D printing to create better padding for their Aerorise backpack (photo credits: Jack Wolfskin)

Now thanks to the use of additive manufacturing, Jack Wolfskin, Carbon, and OECHSLER have created a backpack that offers both optimal load distribution and excellent ventilation. Namely, the newly designed cushioning system can provide an optimal distribution of weight and pressure thanks to its ergonomic shape while still providing excellent ventilation. The dual-cure elastomer EPU 41 material from Carbon was especially key in the process. Richard Collier, CEO of Jack Wolfskin, commented, “It’s not every day that material advancements come along that make such a difference. Aerorise addresses all of the primary challenges of backpacks – ventilation, support, and comfort – through a single technology advancement. Our customers are going to love this product.”