Skia Sweet Spot Ski Trainer
Easyline Edge Line Marker
Photo Realistic Rendering of our production level 3D CAD models.
Our Initial Concept Designs explored different options for how to achieve the variable difficulty balance challenge and how to attach the Trainer to the Ski Boot.
We created a series Functional Test Prototypes to develop the fit with the large range of Ski Boot sizes and to gauge the level of difficulty of the balance challenge.
Having proven the functional principles we developed the design detail in 3D CAD. One challenge was to provide sufficient adjustability to cater for the large range of Ski Boot sizes. The flexible side sections of our Foot Plate design allow the Trainer to fit to any boot.
A small batch of SLS prototypes were built for extensive performance testing in a live Ski School training environment. Feedback from these sessions led to further design enhancements.
Design 4 Plastics managed the entire process of realizing the product into production. We sourced suitable manufacturers and assessed all pre-production moulded and riveted samples, printed labels, user manuals and packaging for final quality approval prior to supplying complete finished product.
Photo Realistic Rendering of our production level 3D CAD assembly.
We created alternative concepts for producing sharp edged sprayed lines and experimented with these in our workshop to find the best way of controlling paint over spray on the move. This led us to the novel idea of introducing airflow that blows stray drips into the wet line to eliminate fuzzy edges. This proved to be a patentable feature.
Once the basic function was proven we produced the first 3D CAD assembly including all the features agreed from the Concept stage. Appropriate manufacturing processes were considered to ensure the parts could be made economically.
We employed SLS Nylon to build the first fully working prototype. This was used to test and develop the function of the Line Marker and underwent many changes to refine the performance.
Evaluating the geometry of the spray nozzle posed one of the biggest challenges of the project. The accuracy demands of the orifice, material and surface finish were impossible to achieve by conventional prototyping techniques. We used a prototype injection mould tool to fine tune and prove the design.
We sourced and managed production of all tooling for the project and were responsible for checking the first off samples. This included approving mould drawings and final tooling adjustments. We rigorously inspected the initial batches of finished products to ensure a smooth introduction to market.