Custom Skis and Monoski
As a lifelong skier, I’ve always been interested in ski construction and technology. Despite having a relatively simple composite construction, small tweaks in material or shape can transform the feel of a ski and vastly improve the experience. In 2021 I decided to design and build a pair of my own skis.
I built a parametric CAD model that allowed me to experiment with many designs and compare them to common ski models. The website Soothski is a great resource for comparing ski dimensions and flex. Once I settled on a design suitable for my skiing style, I was able to build a mold and prep all the necessary materials.
The skis have industry-standard UHMW Polyethylene bases and steel edges. I opted for a poplar wood core and 2 layers of triaxial fiberglass to give the skis their strength. The layup process and finishing work went well for the most part but there was definitely room for improvement, which became apparent out on the mountain. The skis were passable, but my manufacturing process was not precise or refined enough to rival commercial products.
A year later I revisited the project, coming up with a new design for a custom monoski. The materials and construction were similar, but this time around I had the knowledge to drastically improve my mold and processes. The build was a lot smoother and I have used the monoski for 20+ days so far with no issues.
It was really fun digging deeper into a hobby I enjoy so much and gaining an understanding of how much the technology has improved over the years. And even though most days I’m still on a pair of Black Diamond or WNDR skis, it’s always special to bring out the monoski for a day every once and a while.
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