Project Name: Buff Trax

Team Roles: Nathan Ales- Lead Designer: Responsible for physical design, functionality, usability, and manufacturing considerations.

Aidan McLaughlin- Lead Operations Manager: Handles user outreach, on-site testing, and integrates user feedback into designs.

                                                            “The Universal, Uphill Ski Device”

Project Description:

We’ve created a hybrid ski skin system, designed to work across all ski bindings, boots, and ski profiles. Unlike current touring systems that trap users in brand-specific niches, Buffs Trax introduces a universal traction system; one device, any setup. It mounts quickly, adjusts to skier preference, and transfers seamlessly between skis, eliminating the need for multiple dedicated systems. This project was for my Capstone course and was designed throughout my Spring 2026 semester.

The Problem:

Current ski touring gear is expensive and restrictive in its design, with the prime example being Ski Skins. These products are available in different sizes, which also means different widths. Which do you need? Well, that depends on your ski. This is why we created a universal design that can fit multiple sizes with Buff Trax.

                                                                         “Sizing Ski Skins”

The Process:

The start of the semester focused on weekly iterations of our design. Using OnShape, I created around 8 iterations of the trax in total. With each iteration, changes in curvature, dimensions, and functionality were made to improve the design. These fixes were influenced by user testing conducted by Aidan at various ski resorts. He interviewed people and conducted user testing, receiving advice from skiers of all levels. Our initial designs were much more rigid, and as design choices were made, we began to refine the look and functionality of our design. After many iterations, we settled on two designs that we wanted to pursue making higher fidelity versions of.

The first chosen design utilized a rubber strap to secure skis to the trax. We CNC cut this iteration using the ITLL lab space at CU Boulder. With the help of Craig Pearson, the lead manufacturer at the ITLL, we were able to take our sketches and model files to cut out the design on HDPE plastic. This material is similar to glass-filled nylon (a common material used in ski products) and has snow-wicking properties. This would help keep our tracks from getting snow stuck in between the ridges, a slight problem that we had encountered with the 3d printed versions.

The second version was a split model that could be spun to the correct ski size. This design was cut out using the same process as the strap version, but this time out of aluminum. We wanted to see if there were any benefits to a metal version, aside from an increase in durability. This version required more time, with the main addition to our process involving having to tap screw holes into the model. This was especially difficult given that the holes needed to line up with one another.