I love this boot but this is the biggest problem, imho they got something badly wrong here with the join between the toe cap and the boot. Oh for something like impact gel across the seam. I tape my feet up with cotton wool and or a strip of impact gel. You can also get bunion or corn gel protectors that slide on over the toe and cover the area of the foot that contacts the seam. Other than this there is no answer as the problem does not go away.