Jack Wolfskin’s Outlet Online Sale Store 3D-Printed Aerorise Carry System Improves Hiking Pack Design

Jack Wolfskin, the manufacturer of outdoor gear in Europe, improves hiking pack design, eliminating common pain points around weight, durability and ventilation with its 3D-printed Aerorise Carry System.

The 3D Aerorise Carry System uses four independent 3D-printed panels on the shoulders and lower back for a lightweight, multi-zone body fit. The panels are made of an open-cell structure with thousands of struts to enhance ventilation while combining lattice patterns to provide vertical and horizontal firmness for comfort and load distribution. 

The design is breathable, reducing back temperatures by up to 41°F. 

Jack Wolfskin collaborated with Oechsler, an additive manufacturer from Germany, and Carbon 3D printing, to transition technology often used in performance running shoes to the performance hiking pack category.

“Comfort, load control and ventilation are age-old challenges in pack design,” said Magdalen Hamel, category manager, equipment, Jack Wolfskin. “The technology presented in Aerorise benefits hikers on the trail and takes the industry in a new direction. The design is impressive from an engineering perspective and further supports our belief that together, in cooperation with partners, we can make a notable difference in sustainability commitments and performance equipment.”

The 3D Aerorise pack is the latest in the brand’s series of collaborative and sustainable innovations, including tapeless seam construction, mono materials and Wax Weave, a synthetic wax treatment. Its latest creation, the 3D printing production process, decreases waste with a customizable production process reducing material used and gluing processes involved in post-production carry system assembly.

“Additive manufacturing is changing the outdoor equipment and sporting goods world,” said Matthias Weisskopf, general manager, Oechsler. “Working with Jack Wolfskin allowed us to further develop the Aerorise hiking backpack and solve problems that weren’t achievable until recent years. Aerorise is the start of a new movement in improved product development through 3D design.” 

The 3D Aeororise carry system will debut in Spring 2023 and will be available in three models—3D Aerorise 40L pack and 20L and 30L roll-top options. The body of the pack is constructed with 100 percent recycled 70D polyamide. The 40 liters of carrying capacity includes a waterproof main compartment, a top lid compartment, customizable compression options, and webbing on the exterior for attaching equipment.