After skis are designed and created in a CAD program, cores are offset from finished dimensions by 8mm, planed and cut using 48 x 96 gantry CNC machine.
PTEX bases are offset 2mm from finished ski dimensions (to account for metal edging and cut out using CNC machine.
Ptex bases prepped.
Some base material is left on tip and tail to negate the need to wrap edges around entire ski, simplifying fabrication.
Layers of each mold are layed-up, glued and bolted together.
Custom molds awaiting lay-up in the press.
Fiberglass and carbon fiber ready for lay-up
Trough method set-up
Pour epoxy into troughs
Putting epoxy into trough
clamped during curing of epoxy
Dyed epoxy sidewalls adhere well to the core.
Attach metal edges
Skis are pressed
1 hour at 170 dgerees F, 50psi.