Case Study: BOA achieves same‑day design validation and durable, sewable fit‑system parts with 3D Systems' Figure 4

BOA Dials In to Better Performance Fit Systems with Figure 4 Parts

BOA, maker of the patented BOA® Fit System used across cycling, snowboarding, workwear and medical products, faced a materials challenge: their small, mechanically demanding dial components couldn’t be reliably prototyped with existing 3D printing resins, which were brittle and didn’t match injection-molded performance. This slowed validation and made it hard to test parts on-shoe early in development.

By adopting 3D Systems’ Figure 4 Standalone and production-grade Figure 4 PRO-BLK 10 (plus other Figure 4 materials), BOA now produces high-resolution, thermoplastic-like parts the same day instead of waiting three weeks. The printed parts withstand sewing onto shoes for real-world testing, often match injection-molded performance in correlation tests, and have accelerated design cycles while reducing late-stage redesigns.

Boa

Daniel Hipwood

Senior Design Engineer