So I have been making many of these replacement parts for the last 1.5 years. And while I have been able to answer the most important request which is: “Filling the void between the binding and the snowboard with a new toe ramp in order for the user to regain feedback with the snow", I knew there was, room for improvement.

So what’s up with a 3d printed part and how are the new ones better than the first ones. FYI the parts are now in iteration 4!

A “normal” FDM 3d printer will build the part layer by layer, but because of this, the parts will not be isotropic. Meaning that the part can break between the layers.

In order to help this problem, I used to print them with 100% infill, out of industrial PETG, then sand them until they were smooth and coat them with rubber paint in order to protect them from water condensating and freezing between the layers.

Product demands

I’d like people to understand that the conditions under which these parts have to perform are very extreme. We’re talking about high exposure to UV light, which causes ultraviolet light decay to plastics, while being in fluctuating temperatures. From -20°C to right above 0°C. There aren’t many plastics and rubbers that can perform well under these circumstances while being pushed to their limits. Think about people who do high jumps and shred very fast through snow. Polyurethane, the material that Burton uses for the toe ramps (you can see it cast in the part) varies in UV stability depending on the formulated compound. The design is very clever and this proves its popularity, but the demands are also very high. Materials that could withstand these circumstances are a lot more expensive and difficult to handle/produce.

So back to my replacement parts. With all this in mind, I kept on experimenting with different low series manufacturing techniques. So far, 3d printing is the only one that makes it possible for me to manufacture these parts for this price. All other manufacturing processes are way more expensive.

CNC: the part needs to be split in two, meaning more parts, different materials, and therefore different temperature coefficients. But also I need to be present during the whole process.

Casting: I have not been able to find the right material for non-massproduction use and I have not been able to reach the needed pressure. This is still work in progress.

The two 3d printed options are Rigid and Performance.

Rigid: These are now SLA printed parts. Meaning that they are isotropic and will be able to handle the forces much better. While SLA materials are known for being more brittle than for example PETG, I have been experimenting in order to get a good balance between flexible and tough resins.

Performance: The more expensive of the two, but in my perspective the right choice for everybody. The material used for this version is very durable and rubberlike. Of the two versions, it is the one that looks and behaves more like the original PU toe ramp. So far everybody that bought this version have been very happy. People that live in the Netherlands and that come to see the parts before buying are also instantly sold. It is the better one of the two. Is it indestructible? Of course not, I tested them so many times and tried so many different load cases, even those that aren’t likely to happen, that I found their weaknesses. But used as should be, these parts are just awesome.

So there you have it. An update on the development of these parts. I am currently working on more products for snowboarding as well. If you have any ideas of products that could be interesting, please let me know. If it is interesting, you will get yours for free, including shipping. There's so much more to tell about these amazing products, but I will probably bore you with all the technicalities.

 Cheers,

Juan David