Quick Disconnect Ski Baskets for Cross Country Skiing
Class: ME74 - Senior Capstone Project
Skills: CAD, Teamwork, FEA, Iterative Prototyping, Injection Molding, Material Science
Prototype 1
For the first prototype, we envisioned a system similar to the mechanisms found in impact drivers and other tools for removing bits. In our design, a collar would be pulled back to release the bit, or, in our case, the basket. We purchased an off-the-shelf chuck and attached it to some 3D-printed components. While the design functioned fairly well, it was extremely heavy, approximately 1000% heavier than a traditional basket. We attempted to create a similar chuck using plastic materials to reduce the weight, but it ultimately lacked the necessary strength and kept breaking. As a result, we decided to pivot to a different mechanism.
Picture of Prototype 2
Picture of all Prototypes and Iterations
Project Description
The goal of this project was to design and manufacture a user-friendly, quick-disconnect basket for cross-country skiing to address the issue of occasional basket breakage. Traditional replacement methods require tools and significant time, causing disruptions to training sessions, lost seconds in competitive races, and added weight to a skier's gear. This project aimed to provide a lightweight, efficient solution that eliminates these challenges and enhances the overall skiing experience.
Picture of Prototype 1
Prototype 2
For the second prototype, we adopted a new mechanism: a pin system that clips securely onto the ski pole. This approach showed significant promise, leading us to iterate on the design multiple times to refine its performance. One key challenge was ensuring compliance with FIS regulations, which require ski baskets to have a ring around them for safety. We successfully integrated the pin mechanism into the ring design, making it flush with the basket for a seamless appearance and functionality. Importantly, all components of this prototype were made exclusively from plastic to maintain a lightweight and cost-effective construction.
​
The pin mechanism includes a small notch designed for easy operation, allowing users to release it using the other end of a ski pole or their fingers. We utilized GD&T (Geometric Dimensioning and Tolerancing) and FEA (Finite Element Analysis) to ensure that the pin would not bear any load during use. Instead, the load is efficiently transferred from the basket directly to the pole, enhancing durability and reliability.
This design underwent extensive testing to validate its lightweight and robust construction. Weighing approximately the same as traditional ski baskets, it offered a significant improvement in usability without compromising on weight or durability. By exclusively using plastic, we ensured the design was easy to manufacture while meeting the strength and performance requirements. Through careful material selection and iterative refinement, this prototype demonstrated a balance of innovation, compliance with regulations, and user-centric design.