Inside the Factory: Boots

Inside the Factory: Boots
Jon Fewster, category manager for boots and poles, explains the technology in the Super Nano Skate boot.

What goes into a high-end ski boot, and how do you make it?

Since the first Madshus boots hit the market in 2006, our engineers and product developers have worked hard to build the most efficient, lightest and comfortable performance boots.

Category manager for boots and poles, Jon Fewster explains that efficient power transfer is the number-one concern in engineering boots.

“We work closely with the best World Cup skiers in the world, listening to their needs and taking their feedback. Ski boots are the crucial link between your body and the ski, your tool to transfer the power generated into forward propulsion. The stiffer they are, the less energy is lost,” says Fewster.

“We asked the athletes what they needed in a boot. They told us that to go fast, they need a boot that is stiff and responsive, so when they push, the ski moves,” Fewster says.

Additionally, the boot needs to fit very snugly, so that there is no slop between the foot and the boot where power is lost.

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The integrated carbon base of the Super Nano Skate boot delivers 47 percent more torsional rigidity and 10 percent less forefoot flex, providing maximum efficiency.

Maximum efficiency
In order to deliver on those key properties, Fewster and his engineers started from the bottom. They developed a one-piece carbon base, and attached the pin that connects the boot to the binding directly onto the carbon base.

“The metal pin is attached to the base with two bolts that the pin wraps around. By creating a metal to carbon connection, there is no flexibility in the connection,” he says.

The one-piece carbon base matches the contours of the foot, wrapping around the heel, under the arch, and all the way through the forefoot, minimizing the amount of material between your foot and the ski for more direct drive.

The new integrated carbon base gave the new Super Nano Skate boot 47 percent more torsional rigidity and 10 percent less forefoot flex, allowing for maximum power transfer.

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The Super Nano Skate boot

Then Fewster and his crew went to work on the classic boot, creating the new Super Nano Classic. With this boot, they also started from the bottom, with a one-piece carbon base.

“The one-piece base holds the heel and wraps through the arch to the toes, providing stability and edge control. But unlike the skate boot, the classic boot needs to flex perfectly. The forefoot layup is tuned to flex easily, with a spring-like kick,” Fewster says.

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The Super Nano Classic boot

Range of movement
While stiffness is key for efficient power transfer, there is more to the perfect boot. They also need to allow optimal range of movement and comfort.

“On the new Super Nano boots, we created a new flex notch at the back of the boot, which allows you to drive your knee forward with full range of motion,” Fewster says.

Snug fit
The new RevoWrap™ technology that wraps around the foot with a one-piece upper and minimal number of seams make it easy to lace your boots perfectly with an even pressure distribution. Paired with materials that conform to your foot, you get an extremely snug and efficient fit. The boot is also heat moldable, to further personalize the fit if needed, Fewster adds.

Finally, the MemBrain® softshell lace cover is a breathable, yet waterproof material that helps keep the foot dry, warm and comfortable.

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RevoWrap™ technology: wraps around the foot with a one-piece upper.

Performance for everyone
Once proven on the World Cup, these high-level technologies and construction concepts are applied to Madshus boots throughout the various boot series. This way, all skiers can benefit from top-level performance, Fewster explains.

At Madshus we love winter. In keeping with Madshus’ commitment to protecting our climate, Madshus RED, Champion, Race Performance, and selected Backcountry and Junior boots are designed for the best in fit and breathable performance, in a totally PVC-Free construction.

John Fewster explains boot technology.