Enabling ski recycling by reversible bonding with Pontacol®
The goal: replace irreversible adhesives in ski manufacturing with a de-bondable thermoplastic solution and establish a new standard for circular production in the winter sports industry. The key was to find a reversible bonding technology that could withstand the extreme mechanical and climatic stresses of alpine use, while enabling clean material disassembly again on demand under defined conditions.
The central development question was: how do you create a bond strong enough to withstand mechanical stress, temperature fluctuations, and moisture in alpine environments, yet fully reversible under controlled conditions? Overcoming this recycling barrier in multi-layer composite stacks was the key design problem to solve.
Simon Jacomet, owner of JACOMET Ski, refers to this approach as “Full TP Technology.” Behind this lies the concept he developed for an integrated ski construction, in which thermoplastic technology is consistently applied throughout the entire ski structure and is not limited to individual joints. His approach goes beyond simply joining materials: it makes the composite material itself a design parameter, thereby enabling the interaction between force transmission, elasticity and vibration damping to be deliberately engineered.
With Pontacol® thermoplastic adhesive films, we have created a ski that can be repaired, reused, and fully recycled. High performance and circular economy are not a contradiction — they are a design choice. This is a blueprint for the entire winter sports industry.
As a solid hot-melt adhesive film, Pontacol® eliminates solvents, reduces cycle times, and supports circular composite manufacturing at industrial scale – proving that high performance and end-of-life responsibility are a design choice, not a trade-off.
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FAQ
How does reversible bonding work in ski construction?
Pontacol® thermoplastic adhesive films are applied between each layer of the ski stack. At 120°C, the film bonds all substrates — including Titanium-aluminum alloys, carbon fibre, TPU, and wood — into a durable, high-performance composite. Because the adhesive is thermoplastic rather than thermoset, the bond remains permanent during normal alpine use but releases cleanly at 140°C for disassembly or repair.
How are ski materials recovered for recycling at end of life?
At end of their service life, controlled heating to approximately 140°C softens the thermoplastic adhesive layers, allowing the ski’s components to be separated from one another for material recovery and subsequent recycling. This approach facilitates the separation of different material streams and contributes to a more circular ski construction.
How does the Pontacol® adhesive film enable ski repair?
The modular construction allows individual components to be replaced throughout the ski’s entire service life. The top layer, the base, and the steel edges can be renewed if damaged or worn.The Pontacol® adhesive film is softened locally through targeted hot-air treatment, allowing the relevant component to be cleanly removed. This extends the ski’s service life, reduces material consumption, and minimizes the need to replace the entire product. This approach makes reparability an integral part of ski design rather than something considered only after the fact.
What makes Pontacol® films suitable for alpine conditions?
Pontacol® thermoplastic adhesive films maintain full bond integrity across the demanding conditions of alpine use, including repeated mechanical stress, sub-zero temperatures, moisture, UV exposure and changing environmental conditions. The ski never reaches the de-bonding threshold of 140°C during normal use, ensuring the bond remains stable throughout its service life. Performance is equivalent to or exceeds conventional thermoset resin replacement systems, with no delamination under normal operating conditions.
Can de-bonding on demand be applied beyond ski manufacturing?
The principles behind debonding on demand – thermoplastic film bonding, modular layer construction, and thermal de-bonding process – could be transferred to other multi-material composite applications. Protective equipment, lightweight structural panels or automotive trim and décor parts are all viable candidates. The Pontacol® adhesive film portfolio provides the material foundation for this transition, making reversible bonding a scalable design principle for more circular composites.
Key benefits
- Supports circularity: Enabling full material recovery/separate recycling of all layers at end of life.
- Allows for repair: Hot air application enables individual component replacement, extending service life.
- Efficient: Precise film application reduces material waste and improves ski manufacturing processes.
- Durable: Reliable bond strength between a wide variety of composite materials.
- Zero VOC: Solvent-free solid film eliminates VOC emissions throughout the bonding process.
