How the World Champions' Insoles are Made: A Look Inside the Winsole Workshop

Exclusive insight into the production of carbon insoles for MTB World Champions Alan Hatherly, Mona Mitterwallner, and Simon Andreassen – handcrafted in Germany.

When the world's best mountain bikers compete in their World Championship races, they don't rely on standard equipment. Their insoles are as custom-made as their training plans – and are created in a small workshop in Germany.

The Champions and their Insoles

Winsole carbon insoles of the three MTB World Champions Alan Hatherly, Mona Mitterwallner and Simon Andreassen — The personalized carbon insoles of the three current MTB World Champions

Alan Hatherly (South Africa), Mona Mitterwallner (Austria), and Simon Andreassen (Denmark) – three names that dominate the sport of mountain biking. What connects them beyond their talent: All three ride on handcrafted Winsole carbon insoles with the legendary UCI rainbow stripes.

Alan Hatherly – 2-time MTB World Champion from South Africa — Alan Hatherly

Mona Mitterwallner – MTB World Champion from Austria — Mona Mitterwallner

Simon Andreassen – MTB World Champion from Denmark with gold medal — Simon Andreassen

"The insoles are more than just equipment. They are part of my success. Perfect power transfer determines victory or defeat on technical uphills."

– Alan Hatherly, 2-time MTB World Champion

From Measurement to Finished Insole

The process begins with a precise biomechanical analysis. Each athlete is individually measured – arch, pressure points, movement patterns. This data flows into the construction of the carbon shell.

Carbon blanks for Simon Andreassen's World Champion insoles in the Winsole workshop — Carbon blanks before final processing – personalized for Simon Andreassen

The actual manufacturing takes place in several steps:

Prepreg lamination: Several layers of high-strength carbon fiber are bonded under pressure and temperature
CNC milling: The hardened blanks are milled to the millimeter
Personalization: For World Champions, the UCI rainbow stripes and name are applied
Quality control: Each insole undergoes strict testing

CNC milling machine precision machining a Winsole carbon insole — Millimeter precision: CNC milling of the carbon blanks

Why Carbon?

Carbon offers a unique combination of properties: extremely light (only 35-45g per insole), extremely stiff, and extremely durable. Unlike EVA foam or plastic, carbon absorbs virtually no energy – every watt flows directly into the pedal.

+44 Watts Power Increase

Scientific tests have proven a power increase of up to 44 watts. In a World Championship race, this can mean the difference between gold and silver.

Detailed view of Mona Mitterwallner's carbon insole with UCI rainbow stripes — Detail work: The UCI rainbow stripes on Mona Mitterwallner's insoles

The Same Technology for Every Athlete

The special thing: The technology used by World Champions is not exclusive. Every cyclist can order Winsole Customized insoles – made with the same care and the same materials.

Only the rainbow stripes – they remain reserved for the champions.

Order your own carbon insoles now

Made in the same workshop as the World Champions' insoles.

Discover Winsole Customized