SNOWBOARD BUILD

PROJECT OBJECTIVE

My goal was to design and build a 100% functional snowboard—following traditional layout methods, including a wood core and composite fiber layup

PHASE 1: CNC WOOD CORE

With no experience in snowboard construction, I researched and learned about the process for snowboard construction. The most critical element was the core. Using a special Ski/Snowboard modelling software I learned about, my first step was to model and CNC the wooden core of my board.

Model Core in snoCAD Software

Laminate Wood Planks

CNC Wood Core

PHASE 2: BUILD SNOWBOARD MOLD

Snowboards are composed of several different materials layered together through an epoxy layup process. Without access to the sophisticated presses of industrial snowboard manufacturers, I chose to design my own mold out of specially-cut planks of wood to achieve the desired contour of my snowboard.

Cut and Secure Mold Supports

Adhere Surface Layer

Finished Mold

PHASE 3: COMPOSITE LAYUP

After mounting the steel edging to the base, I could move to the most critical step: the composite layup. Working quickly, I prepared the resin and layered the base, fiberglass, wood core, more fiberglass, decal, and topsheet together. I chose to seal these layers using a vacuum bag method and applied additional weight to shape my board to the contour of my mold.

Mount Steel Edging

Vacuum-sealed Fiberglass & Epoxy Composite Layup

Cured Composite Layup

PHASE 4: POST-PROCESSING

After a cure time of 1 week, the excess material wash machined and sanded off. The final post-processing steps were to waterproof the edges of the board with additional resin and mount the binding inserts into the board.

Edge Cleanup and Waterproofing

Mount Binding Inserts

FINISHED SNOWBOARD

The final result was a 100% fully-functional snowboard, when I finished with just enough time in the spring season to get a couple good days of riding in! I continue to use the board to this day.

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