Talon Ski Bindings

A ten-month capstone program that turned an ACL-injury problem into a four-direction ski-binding prototype, then tested where the concept worked and where it still needed development.

Period: 2023–2024
Role: Project manager, with CAD, FEA, and visualization contributions
Methods: Project Management · SOLIDWORKS · FEA · Testing

Talon toe and heel binding concepts rendered on a pair of yellow skis on a snowy slope

01 / Challenge

Engineering Challenge

Conventional alpine bindings primarily release laterally at the toe and vertically at the heel. The team set out to address straight-back and backward-twisting fall modes by adding adjustable vertical and horizontal release at both ends of the boot, while staying compatible with standard alpine boots and skis.

02 / Approach

Approach

I led the five-person engineering team through the work breakdown structure, Gantt schedule, design reviews, manufacturing plan, test campaign, business pitch, and expo handoff. I also contributed concept generation, heel-piece CAD, FEA, drawing reviews, and final renders. The team progressed from FDM pretotypes to a PA12 SLS test article, then used measured failures to drive three major redesign cycles.

03 / Result

Results

The final 3.11 lb prototype demonstrated independently adjustable horizontal and vertical release at both the toe and heel. It reached equivalent DIN ranges of 3.25–8.75 horizontally and 1.5–7.5 vertically, averaged 1.6% release-torque deviation across temperature testing, and completed the team's 300-cycle manual fatigue protocol in every tested direction without observed component failure. No human testing was performed, and full ASTM and ISO validation remained future work.

04 / Architecture

Four Release Directions, Set Independently

Both the toe and heel use separate horizontal and vertical release mechanisms. Spring-loaded grips pivot around pins, while screw-driven spring compression controls each setting independently. Repeated components across the toe and heel simplified the architecture. The prototype used PA12 SLS parts and formed steel hardware as a practical stand-in for a production concept based on glass-filled PA6 and stainless steel.

05 / Test and Redesign

Failures Became Design Inputs

Early test articles exposed poor boot fit, inconsistent release, thin walls around pivot features, and stress concentrations that fractured at higher settings. Three redesign cycles improved contact geometry, increased critical wall thickness, replaced abrupt corners with chamfers, and strengthened the release grips. Final horizontal releases averaged 3% variation across repeated torque tests, while the vertical release averaged 4%.

06 / My Role

Technical Leadership Across the Whole Program

As project manager, I owned the integrated schedule, progress reviews, deliverable coordination, and alignment between design, manufacturing, testing, finance, and the business workstream. My technical contributions included early concept generation, heel-piece CAD, FEA, drawing reviews, prototype reviews, and the final visual package used for pitches and the engineering expo.

07 / Validation Boundary

A Credible Prototype, Not a Certified Product

The team validated basic release behavior, temperature response, and a limited fatigue protocol using available equipment. It did not conduct human testing or complete the full ASTM F504, ISO 9465, or ISO 11087 procedures. A production path would also need a forward-pressure adjustment, a heel cam lock, a completed brake system, and a much broader verification program.

Key Outcomes

4independently adjustable release directions

Led a five-person engineering team through a ten-month program and all major deadlines
Connected torque data and SLS part failures to three iterative redesign cycles
Contributed concept work, heel-piece CAD, FEA, drawing reviews, and technical renders
Delivered the prototype and test program for under $1,300 of a $2,000 materials budget

Cutaway CAD render of the Talon spring, guides, housing, and release grips — Cutaway view showing how the spring package, guides, adjustment screw, and release grips share a compact housing.

Rendered Talon toe and heel binding prototype mounted on a yellow ski — Toe and heel assemblies were independently mounted to remain compatible with different alpine boot lengths.

Three physical iterations of a Talon vertical release grip arranged side by side — Three physical release-grip iterations document changes to leverage, boot contact, wall strength, and manufacturability.

Isolated CAD render of the Talon adjustable spring and clamp mechanism — The adjustment screw changes spring compression, giving each release direction its own setting.

SOLIDWORKS draft analysis on a Talon horizontal release component — Draft analysis supported the team's production-intent injection-molding study before the SLS prototype build.

SOLIDWORKS factor-of-safety result on a Talon horizontal release component — FEA and physical failures were used together to identify weak regions and prioritize redesign work.