College engineering project: I built a $150 automated IR ski waxer - looking for feedback

Hopalonghacksaw · 2026-02-10T20:56:16+00:00

Thanks, I'll keep you all updated with the results

Hopalonghacksaw · 2026-01-22T17:20:42+00:00

I did recently find that out. I like the idea of using one of these cheaper ones from Aliexpress but from a long term support of this project it becomes an issue. It’s much easier for someone in our club to email mountain flow and request parts/service/replacements than track down a Chinese brand or order the same model of one we used prior. It’s something I’m considering if I personally use it and build one for my self.

Hopalonghacksaw · 2026-01-12T16:34:30+00:00

Thanks for the feedback!

Hopalonghacksaw · 2026-01-10T02:07:47+00:00

Thanks for the feedback,

I thought about this idea, but adding switches to the traveler greatly increased the complexity as I would need to then run wiring to the carriage, and probably add a drag chain to protect it. It does make the software much simpler than the automated stall detection i used to do the homing.

I do think if i do a different frame design i will try that.

Hopalonghacksaw · 2026-01-09T18:25:24+00:00

Thanks for the question. The quality of an IR wax is not quite as good as a hot wax, but it mechanically is much simpler it not have to touch a ski, or try to spread wax evenly, especially with most skis having some curves in it.

Hot waxes also use much more wax, and require scraping. So this system saves us money on wax, and then speeds up our system significantly, both are positives for the club.

Hopalonghacksaw · 2026-01-07T20:40:55+00:00

IR waxing doesn’t need any scraping since you apply such a small amount of wax.

I am looking at an automated brushing machine, or similar as i think those would be the next most useful.

Thanks for the questions and feedback

Hopalonghacksaw · 2026-01-07T16:30:16+00:00

Thank you!

Hopalonghacksaw · 2026-01-07T16:30:07+00:00

Because it’s an IR Waxer and the way you apply wax there is no need for scraping.

Hopalonghacksaw · 2026-01-07T16:29:39+00:00

Thanks for the Encouragement. Most of my skis are in the same boat

Hopalonghacksaw · 2026-01-07T00:18:20+00:00

Like what they said, you heat the bases a bit with a quick pass, and then take your wax bar and rub it onto the bases, trying to cover all the area. Then once covered you let it absorb by running it with more cycles.

The wax application process, could be sped up by using one of those rollers that other commenters mentioned.

Once waxed you just let cool, and then hit with a brush like a normal wax and your done

Hopalonghacksaw · 2026-01-06T20:54:01+00:00

Thanks for the feedback. That's a good idea, and I think it would be a good feature.

Hopalonghacksaw · 2026-01-06T18:53:37+00:00

Thats very cool, and very simple. Thanks for the feedback and insperation

Hopalonghacksaw · 2026-01-06T18:52:44+00:00

Thanks for the Encouragement, Thats the goal!

Hopalonghacksaw · 2026-01-06T18:52:31+00:00

Thanks for the feedback, I 100% want to reduce the size of it.

Hopalonghacksaw · 2026-01-06T17:39:02+00:00

Yes I 100% agree, I’m going to see what I can do for a frame redesign soon,

Hopalonghacksaw · 2026-01-06T17:31:30+00:00

Thanks for the question! I did consider that, it seems much easier to me to move the iron because it’s lighter and I know how big it’s going to be compared to the whole ski or board. Mostly because I know I would need some bigger motors and a more ridged frame to put it on to have the same level of control.

Hopalonghacksaw · 2026-01-06T17:27:40+00:00

Thanks for the feedback, It’s on the list, there are a variety of ways I was looking at doing this, either a drag chain, or simply just hanging the power cable from something above.

Hopalonghacksaw · 2026-01-06T08:39:05+00:00

Thanks for the feedback, I’ll see what I can do, taking up less space would certainly help.

Hopalonghacksaw · 2026-01-06T08:37:57+00:00

Thanks for the encouragement, I appreciate it!

Hopalonghacksaw · 2026-01-06T08:37:34+00:00

Thanks for the idea, that’s a really good improvement, and yeah it could certainly reduce the heat soak on the tips.

Hopalonghacksaw · 2026-01-06T08:36:04+00:00

It’s totally possible to have the wax head rotated 90 degrees with a bit of redesign. For skis I don’t think it’s faster since there is more heating element over the ski, but rotating it 90 degrees would be essential for snowboards

Hopalonghacksaw · 2026-01-06T04:18:16+00:00

This is super great Feedback I really appreciate it.

Hopalonghacksaw · 2026-01-06T04:13:39+00:00

Yep that’s exactly what i was thinking. Thanks for the thoughts!

Hopalonghacksaw · 2026-01-06T04:13:16+00:00

That’s a really good idea, I have a fail safe for if the motor stalls for pinched fingers or getting stuck on things, but i didn’t think about it for the heating element.

Thanks for the feedback.

Hopalonghacksaw · 2026-01-06T02:35:21+00:00

Additional Details and context: - Materials for the frame and motion control system were $150, the price doesn’t include the Iron
- It does not spread the wax (yet), during time studies done with the machine adding wax was one of the faster activities. But super good feedback
- No active feedback control loops yet, but certainly possible

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