Skis are a composite sandwich, constructed by bonding multiple layers together. A list of the layers in order from bottom to top is below:
Base: DuraSurf sintered base material provides good glide performance, wax absorption, and impact resistance.
Edges: Steel edge material hardened to Rockwell 48
VDS rubber: Thin rubber specially treated for bonding is used over the edges to enhance bonding and reduce the chance for delamination.
Fiberglass: 19oz triaxial fiberglass with fibers oriented the length of the ski and ±45° for torsional strength.
Core & Sidewalls: We use a combination of birch and maple to create the core. Maple strips are placed on the sides of the core so that they run directly over the ski edges for stiffness where it matter most. The sidewalls are also maple which makes them durable, impact resistant, and gives them a great natural look.
Tip/tail fill: UHMW plastic filler. Similar material to what is used on the bases and stands up well to abuse.
Carbon fiber: Carbon stringers running the length of the ski for responsiveness and “pop”.
Fiberglass: Another layer of 19oz. triaxial fiberglass as well as a section of additional fiberglass over the binding area to reduce screw pullout.
Topsheet: Sublimated with your custom graphics, these nylon topsheets look great and resist chipping.
Epoxy: The glue that holds it all together. We use a bio based resin specifically designed for ski construction.
Once all the materials are shaped to the required specs, we assemble your skis with the resin and put the whole assembly into the press. In the press, the skis are heated and squeezed together to properly cure. After cutting away the excess and cleaning them up your skis are ready to go.
I was looking to make myself a pair of tele skis and thought this would be the perfect opportunity to try out a new lightweight core and fiber combination I’ve been scheming about. Using a hybrid foam and wood core and increasing the ratio of carbon fiber to fiberglass reinforcement resulted in around a 20% weight reduction compared our traditional construction. These skis weigh in at only 6lbs for the pair! With a great touring shape and lightweight construction these will be great for exploring the backcountry.
To save weight foam is used to replace sections of what would normally be the birch core. We kept the maple core section and sidewalls to transfer power along the length of the skis edges. A section of birch core under the binding area maintain strength underfoot as well as providing a secure area to mount bindings. Biaxial ±45° fiberglass combined with 0° oriented (length of ski) carbon fiber fabric reduces overall weight and maintains strength while avoiding the snap and chatter of a full carbon layup by using enough fiberglass to keep the ski somewhat damp.