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Making mountain skis
· Although Estonia is geographically not best suited for mountain skiing, · The most common materials for the outer part of the skis are
it is still quite popular. The largest market is perhaps in the United
States, but also in mountainous parts of Europe. fiberglass, carbon fibers, or a type of epoxy. Polyethylene is the most
· Throughout history, alpine skis have been made out of light wood, popular material used in the bottom part of modern skis. One of the
usually hickory or ash, steel edges were introduced on the bottom for drawbacks of the polyethylene base is its softness, and with time the ski can
smoother glide, but the depletion of inexpensive wood meant a need for become scratched by small stones and ice. A polyethylene candle is used by
product development and usage of modern materials. Metal skis became skiers and ski repair technicians to patch such scratches on the base. Also
common in the mid-1950s. The light metal was sandwiched around a
wooden core and fused by glue and heat, but this aluminum bottom froze because of its chemical nature, polyethylene is easily broken down by
easily and was not the best solution. ultraviolet rays. This is remedied by applying a coat of wax to the skis after
each use. The edges of skis are made of steel, which may be regular strength
or hard tempered.
· The Manufacturing
Process
·Modern skis can be classified into three different types: laminated, torsion-box, and single- · Milling the core: for skis with wood cores, the pre-
laminated wood is put through a mill for precise cutting
shell(as shown in the picture). The laminated method is the one most commonly used in ski manufacturing, since and finishing. This process is also used for aluminum
the combination of various materials allows for greater array of models. Laminated usually contain the following cores. The machine cuts and mills the material, including
materials: plastic, fiberglass, carbon, wood, steel, aluminum, neoprene, or ceramics. These elements are the core's thickness and side-cut, and also collects the
sandwiched or layered on the top and bottom of the core. In a torsion-box ski, the core material is surrounded by excess material. In skis with polyurethane cores, the top
fiberglass or carbon fibers. Instead of being sandwiched around the core, the layers wrap around it in what is and base layers are put into a mold, then a press, and the
known as "wet wrap construction." The core is then sealed with resin and heat. This more complex manufacturing foam is injected with a hose. As it expands and hardens,
the foam fuses the layers and becomes the core.
process means that torsion-box skis are more expensive than laminated ones, but they provide better handling and
thus are more appealing to serious skiers. Single-shell skis are made from a strong inner material such as wood, but · Assembling the layers: the core and the rest of the layers,
enclosed by a flexible fiberglass or plastic shell and sides. The lighter weight of single-shell skis means that more including the top and base, are placed into a mold and
control is located at the tip of the skis, giving the user better steering control and turning ability. then into a press. Heat and pressure result in a
·http://www.madehow.com/Volume-2/Ski.html rudimentary ski, then epoxy resin is used to completely
seal the layers together. Single-shell, or "cap" skis, require
a more complicated assembly process and more precise
molding chambers. Wood or foam cores are still used, but
the top and sides are united in one sheet and this makes
the core less integral to the ski's overall performance.
· Bonding the base and edges: the polyethylene base, the
running surface of the ski, is bonded onto the ski. Steel
edges are also bonded onto the ski surface.
· Applying graphics: with traditional laminated and
torsion-box skis, the graphics are applied in one of the
final steps of the manufacturing process. The actual ski
goes through a silkscreen process, where the design is
first put on a piece of silk or other thin fabric.
· Different core/chassis solutions: · Finishing: the bases must be put through a machine that
grinds and polishes them, and this is done with a
combination of belt sanding and stone grinding. Ofcourse,
a complete quality check follows. In the final stages, the
steel edges are oiled, the skis waxed, wrapped in
· I-Beam polyethylene, and boxed for shipping to retail outlets.
· The new I-Beam technology fulfils the two most important The laid up ski, inside
requirements that a special freeride ski has to face ­ low weight its mold, is placed in a
and high stability. This is made possible by cutting grooves into ski press where both
the wood core for considerable weight reduction, whereas the heat and pressure are
applied. This step
special-purpose carbon I-profiles which are placed into the wood takes around 30
core ensure extremely high stability. The result is a ski that, thanks minutes.
to its stable construction, makes light work of all off-piste
challenges. Moreover the low weight guarantees optimum
handling and perfect performance at all times, in all situations and
conditions. After the ski comes out
of the mold it is taken
to an area where the
excess material is
trimmed off.
· Air channel
· Air channels integrated into the glass fibre wood core save
considerable weight. Extreme strength and optimum surface
pressure distribution.
This stone grinder is
used to prepare the
base(bottom part of
· Sandwich construction the ski). Other
machines are used to
· A unique concept in ski core manufacturing that gives the entire bevel the edges and
ski construction the ultimate in stability. The Sandwich Sidewall apply hot wax.
Construction is the result of an intelligent layered structure with a
wood core to give the ski edges perfect support and make them
harder and more durable. Compared with other constructions the
absorbing properties of the skis are improved considerably. This http://www.telemarktips.com/SkiFactory.html
also applies to the even power flow to the edges.
· These technologies are used by Fischer http://www.fischerskis.com/en/technology.php?
id_group=40006#