Case Study: Jack Wolfskin achieves superior ventilation, comfort and load distribution with Carbon's 3D-printed Aerorise lattice

Jack Wolfskin Combines Exceptional Padding and Ventilation in Aerorise Backpack

Jack Wolfskin, the outdoor apparel and equipment brand, faced the challenge of designing a backpack that combined optimal load distribution and cushioning with superior back ventilation to reduce sweat and pressure points. To achieve this, Jack Wolfskin partnered with Carbon and used Carbon’s Digital Light Synthesis™ 3D printing process and dual-cure elastomer EPU 41 green to explore lattice-based padding that could vary firmness and allow airflow.

Carbon worked with Jack Wolfskin and production partner OECHSLER to design and produce four 3D-printed lattice panels using Carbon Design Engine™ software, creating zonal cushioning that improves support, breathability, and comfort in a lightweight part. The Aerorise solution delivered strong internal test results—improved ventilation and lumbar support—while OECHSLER optimized printing for scale (cutting print time by 40%); Carbon’s materials and platform made the innovation commercially viable.

Jack Wolfskin

Daniele Grasso

Vice President of Apparel & Product