Historical Background

• First ice skates invented in Northern Europe ~1000 years ago
  • Made by lacing animal bones to boot soles for crossing frozen water
• 1592: Scotsman invented iron skate blade
• Evolution led to modern speed skating sport

Manufacturing Company Overview

• Elite racing skates produced by small company
• Co-founded by Canadian speed skater (3-time Olympic medalist in short track)
• Every pair custom made per individual skater measurements

Foot Casting Process

• Technician measures skater's feet
• Applies layers of wet plaster bandages (same technique as medical casts)
• Each foot cast comprised of two parts
• Plaster bandages harden/dry in 5-10 minutes
• Technician removes mold one part at a time, reassembles with elastic bands

Mold Creation Process

• Surrounds negative mold with sand
• Pours liquid plaster into negative to create positive mold
• Sand provides counter pressure preventing wall distortion
• Plaster fully cures in 1-2 hours
• Negative mold removed after curing

Mold Refinement

• Technician mixes thicker plaster (pigmented for visibility against white plaster)
• Applies to select areas for imperfection touch-ups and shape tweaking
• Files toes and contour smooth for final shape
• Labels finished mold with skater's name
• Stores until boot construction begins

Boot Construction - Interior Components

• Begins with boot lining using genuine leather
• Staples leather to mold, pulling taut to prevent wrinkles (would irritate foot)
• Glues structural pieces including ankle padding
• Ankle padding made of memory foam (gradually forms to skater's ankle, holds shape)

Blade Holder Installation

• Most technically critical step (determines skate blade angle)
• Applies epoxy resin putty to front/back of sole
• Adheres aluminum blade holders
• Props up boot during 4+ hour drying period
• Sands off excess putty to lighten skate and round remainder

Exterior Boot Construction

• Layers carbon fiber pieces (strong fabric for high-performance sports)
• Ties bottom piece around blade holders with strong thread
• Binds layers with spray adhesive
• Slips plastic bag over boot, vacuums out air
• Vacuum compression tightly compresses carbon fiber layers

Resin Application Process

• Injects liquid plastic resin, distributes evenly throughout bag
• Resin impregnates carbon fiber
• 2+ hours drying/hardening time
• Results in stiff, durable carbon fiber boot

Final Assembly

• Glues vinyl exterior to boot
• Removes plaster mold after glue dries
• Stitches vinyl in place
• Attaches vinyl lace cover:
  • Sews one side to boot
  • Attaches other side with hook/loop fastener
  • Hinges open/closed for access
• Final step: attaches inline wheels or steel blades to blade holders