How hiking boots are made

Hiking boots owe their grip to a tread called tank track that was designed after six climbers died in a storm.

stations: 6
things upstream: 58
raw sources: 16
steps from the ground: 8

The short version

A hiking boot takes more than 100 production steps and up to 200 parts. Leather upper pieces are punched out, skived, stitched and reinforced, then stretched over a last. A molded rubber sole with deep lugs is cemented on in a press. The cemented construction makes the boot sturdy and lets it be resoled later.

Punch out the upper parts

A unique punch knife for each part and size is pressed into the leather, and its spikes mark where the lace holes go. Leather with minor visual defects goes to parts hidden inside the boot.

Goes in
Leather Nylon
Stitch and reinforce the upper

Reinforcing pieces with a layer of glue are sealed onto the upper sections in an ironing press. Panels are sewn together, a heel cap and padding are glued in, and lace hooks are riveted on.

Goes in
Sewing thread Adhesive
Stretch it over the last

The upper is pulled tight over a foot-shaped last and its bottom edge is lasted down onto an insole. Heat helps the leather set into the shape of the last.

Goes in
Adhesive
Mold the outsole

Rubber is pressed in a hot steel mold to form the lugged sole. Heat and pressure cure it so it stays tough and springy, and the deep lugs bite into mud and loose rock.

Goes in
Vulcanized rubber Carbon black
Cement on the sole

Glue is applied to the upper and to the sole unit, and a press bonds the two. Hanwag runs about 40 processes in its sole assembly hall.

Goes in
Adhesive
Lace and inspect

Insoles are dropped in, laces threaded, and each boot is checked for stitching flaws and gaps between the sole and the upper.

Goes in
Nylon

End of the lineHiking boots

Worth repeating

The first major improvement in mountaineering boots followed a deadly climbing accident in 1935, when six of Vitale Bramani's companions died in a snowstorm.
Bramani's 1937 vulcanized rubber sole, called Carrarmato, Italian for tank tread, replaced hobnails.