The New DH - Ski Boot Design Proposal & Prototype

Ski slopestyle, park, & pipeBoot

© 2009 Jake Szymanski

ChallengeDesign a new downhill ski boot concept that is lighter and more comfortable than existing solutions.

Target AudienceSlopestyle, park, and pipe skiers

ResearchMy research process started with in store observation. I work at a ski and snowboard shop in Baraboo, WI called Wildside Adventure Sports. While photoshopping my first sketch of my ski boot idea, I also

started thinking about how the sole is often the heaviest part of a downhill ski boot. My solution is to use carbon fiber not only in the frame or structure of the boot, but also as the basis for the sole of the boot, much like a cycling shoe. This would eliminate even more weight.

I started thinking about how the light weight lateral stiffness of the carbon fiber supports on the Fischer RCS skate boot might be incorperated into downhill ski boots to reduce weight. After trying on a few pair of XC boots and actually going out skiing myself, I realized how much more comfortable XC boots are than downhill boots. After this, I started quesitoning even futher - how could the light weight comfort of XC ski boots be incorperated into downhill boots?

Initial Photoshop Sketch

Research

After my initial sketches, I wanted to find out more about current ski boot designs and how real people are using them. My first step was to explore a sports store for current products. I went to Hoigaards in St. Louis Park, MN and talked with a few salesmen about current technologies, took pictures of boots and notes on immediately apparent usability issues.

Next, I went to a ski hill - Afton Alps in Afton, MN. There, I spent a few hours observing skiers in the chalet and skiing on the hill.

Below is the board where I recorded the findings from my Usability Exploration. I found that some ski boots have slippery areas on the upper cuff to make entry easier, and that some boots were becoming a little more freestyle oriented, but are still quite heavy. While at Afton Alps, I whitnessed numerous people slipping and generally struggling to walk in their boots, especially up and down stairs.

Ski Boots Are:

*Heavy and not good for jumps and rails*Hard to get into and out of*Difficult to walk in.

Usability Exploration

Key Findings

Development

Following the initial research and observation, I was ready create a new design revision. From my research and observation I had noticed differences between freestyle skiers and snowboarders. Snowboarders have all kinds of freedom in their boots to jump, get set up for, and slide rails. However, since skiers have such stiff boots, it is more difficult for them to perform these maneuvers.

With this in mind, my second design concept incorporated a stiff snowboard-boot-like inner that would provide a level of support reinforced by a revised carbon fiber structure for lateral and forward stiffness while remaining lightweight. All this would be bonded to a traditional plastic ski boot sole, but with a carbon fiber bridge for weight savings and super direct binding engagement.

Design Version 2

Development

After research, observation, and a new design iteration, I was ready to step back from my ideas to make sure that my mind was open to as many options as possible. Using a technique from my Creative & Critical Thinking class, I came up with 12 Creative & Critical Options for my ski boot design.

12 Creative & Critical Options

ResearchMidwest MountaineeringExpert Interview on telemark boots and fit.

I came out of my 12 Options exercise with an important insight. I started thinking about what other types of footwear technologies might further inspire the development of my ski boot designs other than just XC ski boots and cycling shoes. What about Telemark boots? I proceeded to visit Midwest Mountaineering where I talked to a number of salesmen who were expert telemark skiers. I gained a variety of knowledge on the subject, but a few important things stuck out to me.

*Telemark boot design focuses more on being light weight because telemark skiers need to hike or ski up the mountain, not just down.

*When I asked about the use of carbon fiber in telemark boots, one of the salesman hinted about a new boot that is due to come out soon that will utilize carbon fiber.

Key Findings

ResearchResearch So FarThe current standard for downhill ski boot design utilizes a hard plastic shell and sole.

This design is good because plastic is inexpensive and makes for a stiff and responsive boot.

However, using such a large amount of plastic makes the boot extremely heavy; weighing in at as much as 19lbs for a pair.

All the stiff plastic makes this design very difficult to get in and out of. Many skiers also have consistent problems with blisters. Even after proper fitting.

Many new boots make entry and exit easier by adding anti-friction areas on the inside of the boot.

Learning from Telemark Boots

In addition, telemark boots also have soles made for walking with tread on the bottom, while they are still able to engage with a full toe and heel binding system similar to a full downhill boot.

Manufacturers of telemark boots have released designs in the last two years that make use of carbon fiber construction to reduce weight and improve stiffness. Weight is very important to telemark skiers since they are hiking or skiing up the mountain as well as down. The Stratos by La Sportiva pictured here weighs a mere 2.81lbs.

ResearchCrowd Sourcing

ResearchSkier Interviews

ResearchCrowd Sourcing and Skier InterviewKey Findings:*Freestyle skiers want a light-weight boot*They are jealous of snowboard boots*Warmth is a large component of comfort*Weight is not as big of a factor for racers*Four buckles equal stiffness in race boots*Women want soft and fuzzy boots*Proper fit is extremely important

Development

Low Price Point $*Comfort focused for reacreational skiers*Pastic Frame*Carbon Fiber Split Sole*Two large - simple buckles*Folding vamp*Soft inner boot

Mid Price Point $$*Lightweight for dedicated freestyle skiers*Carbon Upper Frame*Plastic Lower Frame*Carbon Fiber Split Sole*Snowboard-style ratchets*Soft inner boot

High Price Point $$$*Race Specific Skeleton*Full Carbon Frame*Four buckle rigidity*Carbon Fiber Split Sole

3 designs informed by research that meet three price points and levels of technology for the recreational skier, freestyle/park rider, and racer.

Define

Design Benefits*Light weight*Comfortable*Freestyle flexibility

Phase in*Start with plastic*Add budget option*Small cut-outs appear*Carbon in small amounts*Full carbon

*Innovative carbon chassis*Visually appealing*Increased walkability

Challenges*How much $$ is carbon?*Total cost?*R&D / Engineering Cost*Adoption

Let’s bring all this ideation, research, and development back to our original challenge. The final design must be a new downhill ski boot concept that is lighter and more comfortable than existing solutions. It will be a light weight boot for park, slopetyle, and pipe skiers who demand freestyle perfomance coupled with comfort and sharp visual appeal.

Narrow Scope & Focus

Research

I developed a SurveyMonkey survey and let it loose to my freestyle skier friends and an online community of downhill skiers. A total of 33 skiers were surveyed.

The majority of people surveyed classified themselves as advanced skiers between 20 and 30 years of age.

The survey showed that most park/pipe/slopestyle skiers tend to be jealous of snowboard boots.

In addition, almost half of those interviewed said they would be willing to spend more than $500 on a pair of boots.

This testing confirms that a high end park/pipe/slopestyle boot that incorporates a snowboard-like soft inner boot is on track for the target audience’s boot criteria.

Concept Testing

SolutionHybrid Carbon Chassis Park Boot

The final design solution is a new downhill ski boot concept that utilizes a super light weight carbon fiber chassis to achieve maximum lateral stiffness while allowing adequate forward flex for popping off kickers and onto rails or jibs. Forward support is achieved in a way similar to a snowboard binding. The rigid outer chassis encases a snowboard-like soft inner boot that brings a new level of comfort and ease of entry to downhill ski boots while contributing a portion of the boot’s forward stiffness. The chassis reinforces forward support with a large vamp dual buckle strap similar to a snowboard binding. The large strap distributes pressure throughout the front of the boot for comfort, and folds away when unbuckled to make it easy to take the boot off after a day of hard riding.

Carbon fiber chassis is laterally rigid and provides freestyle performance oriented forward support.

Snowboard-like inner boot provides support while improving comfort.

Large vamp strap provides support and control through the carbon chassis .

Carbon chassis, plastic binding interface, and inner boot are bonded together for control.

Super light weight carbon chassis and bridge bonded to traditional plastic binding interface.

PrototypeFinally, I decided to construct a prototype to illustrate my concept in 3D.

Since I have been using Flow snowboard binding straps in my Photoshop renderings, I decided to contact Flow to see if I could purchase some straps. Christian at Flow was gracious enough to send me a set of straps !

After scouring Craigslist for a few weeks, I came upon this pair of Lange CRL 70 ski boots. After a quick trip across town to meet at a local ski shop, the boots were mine for just $10.

PrototypeProcess photos from construction of the prototype

PrototypeFinished Prototype

Process BlogThroughout the development of this project, I have been keeping a process blog online. The blog can be viewed at the following URL:

http://thenewdh.tumblr.com/

ConnectionsThroughout the project, talking and blogging about my process and ideas has lead me to a number of conncetions in different areas of expertise who have helped me further develop this project.

As the owner of an outdoor sports store, Pete has a wealth of knowledge and industry connections. As my boss and mentor at Wildside, he is always encouraging me.

Christian is the extrordinarily kind customer service representative at Flow Snowboarding that graciously sent me binding straps for my prototype at no charge.

Kim is a Lab Manager at 3M whom I met at Wired for 2020. She was kind enough to show me around 3M and introduce me to their Product Design department.

Chas is a designer that I met through Tim Brunelle after a MIMA event. Chas used to race downhill slalom and provided great feedback on my project as well as a potential contact at Nordica.

Pete SchmidtzWildside

Christian AbelFlow Snowboarding

Kim Tsujimoto3M

Chas PorterThe Attractive

© 2009 Jake Szymanski