Case Study: TAILORED FITS achieves comfortable, high-performance 3D-printed ski boots with Materialise

TAILORED FITS Goes Off Piste in Ski Boot Design

Tailored Fits, founded by Reto Rindlisbacher, set out to solve a long-standing trade-off in ski boots: comfort versus competitive performance. To create bespoke boots that deliver both, Tailored Fits partnered with Materialise and adopted a digital, scan-to-print approach using 3D printing (FDM) and custom software to enable mass customization.

Materialise co-created the full solution—R&D, design & engineering, and certified manufacturing—developing a tablet-based scanning workflow, automated design tools, and FDM printing in flexible, UV-resistant materials with lattice structures for localized stiffness. The outcome is 3D-printed liners and boots that “fit like a sock,” eliminate pressure points, keep feet warmer, and, according to Tailored Fits, provide “100% comfort” while maintaining full performance and power transmission from scan to finished product.

Tailored Fits

Reto Rindlisbacher

Founder