How Are VKTRY Insoles Made?

THEY ARE CRAFTED
WITH OUR USERS IN MIND

HANDCRAFTED, JUST FOR YOU

Most insoles available on the market are constructed from basic foam and plastic, being rapidly manufactured. In contrast, VKTRY Carbon Fiber Insoles are a product of intricate engineering, requiring over two hours to meticulously craft a single pair. VKTRY's patented shape and design consists of multiple layers of carbon fiber, bonded together to produce a customized spring strength to optimize your performance, protection, and comfort.

STEP-BY-STEP
MANUFACTURING PROCESS:

STEP 1:

CARBON FIBER

The baseplates for VKTRY Insoles use multiple layers of aerospace-grade carbon fiber in different weaves (twill and unidirectional), weights (measured in grams per square meter), and lengths. Specifically, they have more layers and shorter lengths in the midfoot area to provide increased support and stability.

STEP 2:

CUTTING THE CARBON FIBER

A roll of refrigerated carbon fiber is laid out on a Gerber Table where a powerful vacuum system holds it firmly in place. The precision CNC-guided blade cuts at about 45 inches per second. The process utilizes ply nesting software to minimize waste (i.e. - cutting scraps).

STEP 3:

STAGING THE CARBON FIBER LAYER

VKTRY Gold Insoles are available with up to five different Pro Levels, which are determined by the strength of the spring. For instance, the VKTRY Gold Pro 6 is made up of six layers of carbon fiber with varying lengths and fiber orientation. This is the stage when the carbon fiber components are laid out.

STEP 4:

LAMINATING THE CARBON FIBER LAYERS

We use “pre-preg” carbon fiber, which means that the material is pre-impregnated with an epoxy-based bonding resin. Each carbon fiber layer is hand-laid into a mold, one on top of the other.

STEP 5:

VACCUM SEALING

Then the molds are “bagged” and vacuum-sealed to remove any possible entrapped air between the layers of carbon fiber, improving the bonding process and strengthening the product.

STEP 6:

AUTOCLAVE BAKING

The bagged molds are carefully positioned inside an autoclave and exposed to high heat and pressure for over 2 hours. This meticulous process guarantees that the carbon fiber layers are expertly bonded without any air pockets, resulting in unparalleled product strength and durability.

STEP 7:

UNMOLDING

Once the autoclave baking process is completed, the molds are unbagged and the insole baseplates are carefully removed from the molds.

STEP 8:

TRIM & POLISH

At this stage, the insole baseplates have been precisely bonded to ensure high quality. We use a soft grinding wheel to eliminate any carbon fiber flashings and perfectly polish the nearly completed product.

STEP 9:

GRIP TAPE APPLICATION

VKTRY Insoles are more effective in certain sports shoes with a “grip tape” covering the front part of the baseplate. This not only provides traction in the shoe but also an extra layer of protection for the carbon fiber.

STEP 10:

QUALITY CONTROL INSPECTION

The carbon fiber baseplates undergo multiple levels of inspection: visual check, weight check, flex test, contour check, etc. This ensures that you receive the premium quality you expect from VKTRY.

STEP 11:

BONDING THE TOP COVER TO THE BASEPLATE

We use multiple top cushions to customize the fit for various athletic shoes. We employ state-of-the-art adhesive to bond the tops to the bottoms.

STEP 12:

LABELING & BOXING

VKs are customized for you and your sport. For example, a size 9 VKTRY Gold Insole comes in 15 unique variations (due to different top covers and Pro Levels). So, we label the insole to identify it properly.

HOW THE WORLD'S BEST
PERFORMANCE INSOLES ARE MADE