Snow Goggles Manufacturing Process: How Are They Made

Besides the biting cold, living in snowy climates comes with its own benefits and the one that stands out the most is skiing. It is considered to be one of the most exciting hobbies and sports on earth and there are even special Winter Olympics that are held every four years just so people can go showcase their skiing skills. But for a beginner skier, you don’t wake up one day and decide to take up skiing out of the blue, you have to train hard for a while to get the basics right because it is a dangerous sport.

Most importantly, you need special gear to get that done. From skiing shoes and blades, to warm clothing, snow helmets, and most importantly, snow goggles. We will be exploring snow goggles, the different parts that make them work, the assembly techniques that snow goggle manufacturers use, and the things you have to factor in when shopping for them. So if taking up skiing has been on your bucket list, this is the article for you.

Ski and Snowboard Goggles Parts

Ski goggles are not your average eye protectors. There’s a lot of engineering that goes into their design and construction that has to counter the cold conditions of the snowy Alps. The following are the different components of ski and snowboard goggles.

Lenses

It can be argued that the lens is the most important part of any eyewear and the same is true for snow goggles. This is the part through which the user is able to make out the path ahead of them, which is the biggest impediment when it comes to skiing because there’s the cold and the snow in the air. A snow goggle is made up of 2 lenses that are put together with a foam divider in between them that has air trapped in that space.

The function of this air pocket is to create the insulation between the two lenses to stop the inner one that’s in contact with your face from freezing and fogging up. If these goggles were made of only one lens or if the insulation between two lenses wasn’t there, you wouldn’t last a minute in the snow before a layer of ice blocks the view.

Snow Goggles are usually made using a special type of material called Trivetic plastic or polycarbonate material that are not only resistant to the cold but they don’t shatter easily when compared to glasses and normal plastics. Lenses come in many types that include the following

Spherical Lenses: These are the types that curve smoothly in all directions of the face, covering the eyes from the front all the way to the edge of the ears. They are the best when it comes to keeping out the cold and for this reason, they cost a lot more.

Flat Lenses: These are vertically flat lenses with slight curves on the sides, but they don’t go all the way as spherical lenses do. They are cheaper and ideal for people on a budget.

Photochromic Lenses: These are snow goggle lenses that change depending on the conditions of the weather. Snowy areas can be a little too bright for the eyes, especially when there’s some sunlight coming through. Photochromic lenses get lighter when there’s little sunlight and get darker when the light becomes too much.

Polarised Lenses: These are lenses that have been designed to deal with the reflective glare that is reduced when sunlight is bounced off the pure white snow. This gare can be blinding and without a proper polarised lens, you could get into a nasty accident on the skiing trail.

Prescription Lenses: These are specially designed prescription lenses that are built for people who need glasses to see. They have customized in-built optical clips that allow people with eye problems to simply use the goggles as they are without having to wear their normal glasses inside, but they are very expensive since they have to be tailor-made to a user’s specifics.

The Frame

The frame is the next most important thing of the snow goggles as it is the part that holds the lenses into place. It is also the part of the goggle that gives the entire item its signature look that has come to be associated with people who ski for fun and for sport. The design of the frame is usually centered around the lenses. A frame that holds a spherical lens cannot be the same that holds a flat lens, each has been designed in a different way to increase efficiency.

The frame also comes with other vital parts that make the entire item easy to use. They include the following:

Ventilation Holes: Ventilation holes are strategically placed around them that allow for the free flow of air into and out of the snow goggles to stop fog from collecting on the inner parts of the goggles. Without any ventilation, the face would only sweat up and once all that moisture comes into contact with the cold air, things may get a little steamy in such a closed space. One thing you should note however is that frame ventilation only works when you are in motion, once you stop getting the goggles off your face.

Frame Clip: A frame clip is a part that makes it possible for a ski helmet to be fit over the goggles. They are the points where the helmet straps fit into to allow the helmet to fit onto the head without pushing out the goggles. However, the frame clip is only available in certain types of frames that are considered to be compatible. There’s a number of frames that cannot be used with helmets at the same time.

Padding: For the snow goggles to be comfortable it requires padding on the inside part of the frame. This padding usually has layers of foam in them with varying densities which help the frame to mold onto your face in a perfect fit. The softness, width, and thickness of the padding vary from one snow goggle to another so you may have to fit them on before buying to see if they are ideal for your face.

Strap

This is the band that goes around the back of the head to hold the snow goggles in place. The straps have to be wide to avoid digging into your head and at the same time, they have to be elastic and adjustable to accommodate people who may have extra hair on their head or those that want to wear helmets at the same time. Some goggles come with removable straps which makes it possible to clean them but others have fixed straps. When choosing a snow goggle, try wearing it to see how comfortable it is beforehand.

How are Snow Goggles Made?

The process of manufacturing snow goggles is not an easy one. It goes through stages that focus on each part of the goggles to ensure that each component of the item works as intended without interfering with how the other parts function. The following are phases of assembling snow goggles.

Injection Mold

The first step in making snow goggles begins with the cleaning of the molding machine. The operator sprays a non-stick spray on the sections of the injection mold that will hold the skeleton of the entire snow goggle frame. The machine then sucks in plastic pellets and melts them into the shape of a snow goggle frame based on the installed mold shape and size. This process takes mere seconds. This is followed by the cupping phase. In this stage, a worker clips off the parts that are not needed from the plastic model to allow it to get to the shape that’s needed. This process is handled manually by hand and involves small clipping tools like pliers and is done on a small desk.

Cellophane Cuts

A cellophane sheet is then cut to a specific size and immersed print side down into a solution of water and a solvent. A chemical reaction takes place that detaches the printed graphic design off the cellophane film, suspending it in the liquid. This is then followed by the spraying of a solvent on the side facing up to activate a bonding agent and to dissolve the cellophane film completely.

Immersion of Goggles

Once the cellophane film has been dissolved, a rack of snow goggle frames that had been prepared in the injection mold is lined on an overhanging rack of metal and slowly immersed into the resulting solution below that contains the perfect floating graphic design. The surface tension of the water in the solution forces the graphic print to quickly wrap itself around the surface of the goggle frames with the bonding agent making the print stick.

Washing

The goggle frames are then removed from the solution after a minute and placed on another metal rack where they are cleaned to get rid of any chemical residue left on the goggles. This is followed by the application of clear lacquer by spraying as a finishing touch to lock in the graphic paint and give it a refined look.

Foam Application

Using special glue, a worker applies the sticky substance in the grooves around the frame and places the snow goggle foam on it to create the ventilation system. This will keep snow from going into the goggles but will allow air to seep through the tiny perforations on the foam itself to prevent fogging. A thicker foam layer is then applied on the entire inner perimeter of the frame to provide a tight fit on the skier’s face, stopping cold air from getting in and freezing their faces.

Strapping

This is then followed by the addition of straps which are designed wide to hold the back of the head without cutting into the flesh and at the same time they are made elastic to allow for adjustments. This is the point where micro-electronic fans are also installed in the most recent models to further prevent fogging when the goggles are in use.

Polycarbonate Films

A machine then begins cutting polycarbonate films into the shape of the snow goggles. These films will form the outer covering of the lens. They are placed in a curved trough and heat is applied to them until they attain the smooth curve that is associated with skiing goggles.The polycarbonate lenses are then pressed to a piece of cardboard that’s shaped exactly like the shape of the goggle frame.

AirTight Foam Ribbon

Once the piece of cardboard is pulled off, it leaves a narrow piece of foam that will now combine with a similar foam that will be part of the inner lens to create a thin barrier of air between the two lenses to prevent the build of condensation and fogging. The two are then combined and taken through a series of tests where pellets are shot at their surfaces at random using a special gun. If it doesn’t shatter then it is ready for application.

Lens Insertion

The lens is now deemed ready for use and it is installed into the ready goggle frames and can now be released for use. This princess is handled manually by gloved hands and takes less than a minute per goggle. The goggles are then packaged. Ready for shipping.

Taking Care of Your Snow Goggles

Looking at the process involved in making snow goggles, it is evident that they are not ordinary eyewear and for this reason, there’s a need to take care of them to get the most out of them. The following are some of the ways through which you can maintain your snow goggles to ensure they last you for as long as they can.

The Lens

The lens is the most delicate part of snow goggles and should be handled with care. First of all, you should never at any time touch the inner lens with your bare hands or scratch it with something rough. The inner layer has a special coating that helps keep fogging at bay and once this coating is touched, its ability to repel moisture is compromised. When cleaning the lens, use the special microfiber cloth that comes provided on purchase.

Another important point to keep in mind is that the lens has to be dry before any form of cleaning is done. Wiping any surface of the lens when still wet will create friction which will destroy that special coating. If possible, use a blowdryer to get rid of dirt from the inner parts to avoid coming into physical contact with that surface.

The Straps

The straps are the most flexible parts of snow goggles and this means that taking care of them is much easier. Since they go around the head, it is very likely that they pick up a lot of dirt and absorb sweat since they come into contact with the skin. You can detach them from the goggles and wash them once in a while. Most of them are strong enough to handle a couple of washing over time. It wouldn’t be comfortable if you keep using a dirty strap, the accumulated sweat can end up emitting some odor that could distract you from seeing the skiing trail well.

The Frames

The frames are also quite notorious for accumulating dirt since they have a lot of hidden spaces and corners. Although dust is not common in snow areas, the possibility of other solid debris finding its way into exposed parts of the frame is not far-fetched. If these solid objects, small as they may be, are allowed to accumulate with time, they may end up destroying the inner lens due to friction. Since taking your snow goggles apart is not something you should do on your own, you can buy a good blow dryer that you can use to blow all the solid debris out without physically touching anything inside the goggles.

Have Spares

Having extra pairs of lens and straps is a good move as that will give what you bought a chance to breathe and dry. Having spare lenses actually comes in handy in skiing competitions. You could find yourself being forced to ski every day and that may not leave you with enough time to clean and maintain your gear. But if you have an extra pair of snow goggles, you can switch them every day, allowing each pair to dry and be cleaned for another day. This ensures your vision stays sharp reducing chances of running into an accident.

Use a Goggle Bag

When you buy snow goggles, they come in their own special bags that are designed to accommodate them in a certain way. These bags are padded on the inside to create the best conditions for snow goggle storage. Every time the goggles are not in use, ensure that they are stored safely away in their respective bags to avoid physical damage. However, make sure the goggles are cleaned and dry before storing them in their bags. Always store them at room temperature away from moisture, cold or direct sunlight. This reduces the chance of the googles experiencing fog the next time you need to take them out for use.

Air Them Out

Sometimes, when the conditions are right, take the snow goggles out and air them for a bit to allow them to dry naturally rather than speeding up the process with an air dryer which may miss some parts. When airing them, avoid exposing them to direct sunlight, do it under a shade, and let the air do the rest of the work. If the weather conditions are too extreme for airing, once you are done with the goggles, have them hang on top of your car’s radiator to let that warmth get rid of any moisture that may have built up on the inside.

Factors to Consider when Choosing Snow Goggles

Snow goggles come in many brands, sizes, and shapes, and finding the right one is like finding a needle in a haystack. Each brand will present their products as the best in the market but until you use them, there’s no way of telling whether what they are pitching is true or not. That’s why we have compiled a detailed list of the factors to keep in mind when shopping for a snow goggle.

Anti-Fogging Features

This is a very important factor, a deal-breaker. Using goggles that fog every time you hit the snow trail is not only dangerous but it takes away all the fun that comes with skiing. Fogging clouds the inner lens and stops you from seeing what lies ahead of you completely. Check if the goggles you are looking for have that inner anti-fogging coating that stops fogging from happening. There are some recent models that come with an inbuilt mini-fan that keeps the air inside cool.

Safety

The reason why snow goggles use anti-shatter polycarbonate materials for the lens instead of glass is to protect the eyes. But there are some polycarbonate lenses of lower quality that can shatter on impact. Check every goggle carefully and ask around to ensure that it has impact-resistant properties that will ensure nothing happens to your eyes even when you are involved in an accident that throws projectiles towards your face.

Appearance

There’s nothing wrong with looking good and fashionable on the skiing trail. Snow goggles come in varying designs and colors, and some that use photochromic lenses look very good when they are hit by the sunlight. If style is important to you then go to the most colorful snow goggles that you can find and rock it with all the pride you can muster. You’ll be surprised at how big a motivation it can be to wear a good-looking snow goggle.

The Budget

The average price of a normal snow goggle starts at about $15 and goes all the way up to $100, these are considered to be budget-friendly snow goggles and they pack all the features that you need in one. Some high-end snow goggles can cost from $180 to as high as $300. They are usually made by well-known brands and pack extra features and look much better. However, there’s absolutely no reason why you should spend that much when a budget-friendly product can work all the same.

Conclusion

Snow goggles are a necessity if you ever want to get into skiing. They are designed for protection and without them, you cannot be allowed to ski. Experienced skiers better understand the value of having a good pair of snow goggles, but if you are new, don’t fret too much. We have all the solutions for your needs.

At Fetoptics, we pride ourselves as the best manufactures of snow goggles that will fit all your needs perfectly. If you have any questions, concerns, or an urgent need for a good pair of customized snow goggles, feel free to get in touch with us at any time of the day and we will get back to you with all the information you need to get started.

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Snow Goggles Manufacturing Process

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