Jack Wolfskin

The challenge

Material and Part Requirements

• Superior ventilation and lower back temperature for the user
• Zonal cushioning to minimize pressure points
• Lightweight
• Durable

The longevity of mechanical qualities such as elasticity and structural support was the priority in selecting the technology. The samples Carbon sent to the Jack Wolfskin design team convinced them EPU 41 was the right material. The final product is abrasion-resistant, highly breathable through its lattice structure, and the surface finish allows for the right degree of grip while remaining easy to clean.

The second part of the challenge was ensuring the production of the design met the quality and cost requirements. OECHSLER knew it would have to optimize the part, print script, and platform position to meet these criteria.

Local for local

From design to series production

Because Jack Wolfskin’s design ethos is “Engineered in Germany / Proven in the wild,” it was important for them to find a production partner in Germany. Carbon introduced them to OECHSLER, one of the largest parts manufacturers in the additive industry. OECHSLER was able to print several prototypes to test the lattice structures. Once Jack Wolfskin was happy with the design, there were two main considerations to be made. On the one hand, they wanted to keep the industrialization process as lean as possible, but on the other hand, they did not want to compromise on the print result. In critical areas, additional struts were added for reinforcement and to avoid print defects. Additionally, they reduced the part height to shorten the print time. Exposure time reduction in certain layers sped up the print while increasing exposure time on top layers improved the part surface. OECHSLER was able to reduce the print time from prototype to serial production by 40%.

Pushing technological boundaries

Results

The early response on the Aerorise pack is positive. The pack has been tested internally with stellar results. Gerold Ringsdorf, Head of Development of Backpacks for Jack Wolfskin for two decades, claims that Aerorise plays out its main strengths of ventilation, cushioning, and support, especially in the lumbar area, and that no other packs compare. It offers a great balance between soft, hard, snug, and supportive.

“Comfort, load control, and ventilation are age-old challenges in pack design,” said Magdalen Hamel, Category Manager of Equipment, for Jack Wolfskin. “The technology presented in Aerorise is only newly available. It directly benefits hikers on the trail and takes the industry in a new direction. The design is really impressive from an engineering perspective and further supports our belief that together, in cooperation with partners, we can make a notable difference and take the industry a step forward.” Partnering with Carbon and OECHSLER made innovation possible that none of the parties could have created individually.