Designing a New Standardfor Equine Protection
SmartPak ImpactFlex Technology
ImpactFlex was a ground-up product development project focused on creating a new line of equine protective equipment using advanced impact-absorbing foam. The goal was to bring together proven material technology, equine anatomy, functional design, and rigorous testing to create protection that was both effective and practical for everyday and competitive riders.
ImpactFlex technology features a flexible layer of high-performance, closed cell foam that reacts to the force of an impact by absorbing and diffusing the energy slower and over wider area. The products are designed to protect the horse from concussive or striking forces.
The first step in bringing ImpactFlex to life was identifying the right material technology. Rather than attempting to develop a new foam from the ground up, I researched proven, impact-absorbing foam technologies that could be adapted to the demands of equine products.
I connected with a specialized U.S. manufacturer whose closed-cell foam technology was already thoroughly tested and proven in other industries. The foam offered a strong combination of impact absorption, durability, flexibility, and low weight, making it an exciting foundation for exploring a new category of equine protection.
Working directly with the manufacturer allowed us to understand the foam beyond its technical specifications. We had access to explore and test different densities, thicknesses, fabrication methods, and performance characteristics to determine how it could best function for our products.
The products needed to protect the horse without compromising movement, comfort, fit, or usability. The biggest downside to using a closed cell foam is that it is not inherently breathable and when placed against the horse, will trap sweat.
I approached the designs with the horse’s anatomy and natural movement at the center of the development process. Every component had to serve a purpose, from foam placement and coverage to shape, construction, closures, and overall fit.
To solve the lack of breathability, we were able to perforate the foam without compromising on the impact absorption. This data was already proven from the manufacturer. Creating holes in the foam would allow for airflow and evaporation of heat and sweat from the horses body.
This was not a one-prototype project.
ImpactFlex went through numerous rounds of prototypes, testing, evaluation, and redesign. Each round provided new information about the product, like how the foam performed, how the construction held up, how the product fit, and where improvements were needed.
Testing wasn’t simply a final approval step. It became part of the design process.
Prototype → Test → Evaluate → Adjust → Prototype Again.
The foam placement and shaping needed to be perfect to contour the horses body and not cause any rubs. The materials we paired with the foam needed to absorb and/or wick any sweat that could get trapped against the horse. Development required patience and a willingness to continually challenge the original design to reach our final approval.
XC Boots
The initial goal of ImpactFlex was to develop a lightweight boot that could help protect the horse’s legs while allowing airflow and supporting comfort. The result was the SmartPak ImpactFlex XC Boots, featuring lightweight, flexible impact-absorbing foam, 360° coverage, and a perforated outer shell designed to support airflow and water drainage.
Saddle Pads
The initial product launch included 4 different saddle pad designs, all created for a different purpose.
- Half Pad Liner – The thinnest, most lightweight option to provide impact protection without altering saddle fit
- Half Pad – A contoured spine half pad with faux suede outer and CoolMax lining.
- Dressage Saddle Pad – A full dressage saddle pad with breathable mesh spine and CoolMax lining.
- Jump Saddle Pad – A full contoured jump saddle pad with breathable mesh spine and CoolMax lining.
