Originally Posted by XJguy
I dont think that this will be the case at all. The reason you break in anything worn is so that it can conform to your body. In the case of custom made boots that are made from a computer scan they will fit you like another layer of skin, you can then decide how much room you want between the shell and your foot and size the data ratios accordingly. Pain in a boot is due to bad fitment, period.
I agree with XJ here, but offer a slightly different suggestion. Have a system with maybe 3-4 varieties of liners available, so that lower-end recreational skiers who want more comfort get thicker liners (more padding, more warmth), and racers have very thin liners. When you plug the info into the computer for grinding, it takes into account which liner you want, and grinds more for thicker liners and less for thinner liners. This may also make the plastic thiner for recreational skiers, and therefore the boots softer, whereas cutting less material away for a thinner liner for a racer would result in a stiffer shell.
I love this idea. With the cost of technology today and in the future, it may even be able to be done at a reasonable cost, although you may need to send the boots off to the milling factory to be able to do the volume necessary to make it feasable, but I think that most people would be okay with waiting a week or two for boots that fit that well.