Composite Structures Build - Snowboard

2016-11-01

This follows the process to build a snowboard using methods for composite structures. It was my first experience with composite techniques which is significantly different from general fabrication methods.

I was fortunate enough to have the opportunity to participate in a snowboard building class. We learned about CNC, composite layup of different materials (including wood, plastic, fiberglass, carbon fiber stringers) and a lot about "figuring out what works". I was surprised by how open ended the class was, in terms of allowing us to experiment with configurations if we wanted to. That freedom was appreciated and I think is essential in allowing creativity and innovation in a fabrication environment.

Process:

1. We recieved the wood core and base plastic (ABS?) layers and the profile was trimmed or CNC machined out to fit our snowboard size.
2. For the edge rails, metal rails were bent and shaped and adhered to the curvature of the base plastic board edges.
3. Plastic (?) siding was adhered to the walls of the wood core.
4. The holes for the boot strap bindings in the wood core had metal fittings inserted. These metal fittings have threads for the binding screws.
5. A graphic top layer was printed.
6. Fiberglass sheets were cut into the profile of the board.
7. LAYUP: Using resin as the binding liquid matrix, layers of the base plastic, fiberglass sheets, wood core, carbon fiber stringers, plastic sheet cover, excess resin absorbing filler were layed up and put into a vacuum bag. This process is quick.
8. The vacuum attachment was secured and the board was clamped into tooling which provides the camber characteristics.
9. After curing, the board was removed from the vacuum bag and the consumable materials removed.
10. The excess material in the board profile was cut out giving its final shape.
11. To access the mounting inserts, holes were drilled through the top layer.
12. Final cleaning and touch up.
13. Shred the Gnar!

Outcome:

The board rides amazing, even 5 years later. It has incredible strength to weight ratio characteristics and is one of the most flexible boards I have tried. It rides smooth and I always have a good time riding it. By seeing and doing the work first hand, I have an appreciation for what it takes to make a good board. I also know now what processes and components make can a board great.

In the future I would try experimenting with different board profiles and degrees of camber.