Optimization of a Blade Holder for Bauer Hockey Skates

Bauer Hockey aimed to enhance the performance of their blade holder (Edge Holder model) by optimizing its rigidity and to improve player performance, particularly skating agility and power. Bauer Hockey developed an initial prototype that met the desired performance characteristics, but its geometry did not meet the requirements for product design and production. Furthermore, the materials used in the prototype were different from those preferred for the final version.

Challenges

Optimize the blade holder's geometry according to specific requirements, including material properties and design volume constraints.
Meet rigidity objectives in bending, torsion, and compression in various areas of the blade holder.
Maintain product functionalities, particularly the blade attachment system.

Solutions

Step 1 - Correlation of the FEA Model with Physical Tests

Correlation of Results : Compare FEA model results with physical tests conducted by Bauer Hockey on a reference blade holder (Edge Holdermodel).

Physical Tests : Perform bending, compression, and torsion tests performed on 12 points of the blade holder, both with and without the blade.

Modeling Constraints for Optimization :

Linear static model
Simplified contacts
Modeling of secondary components (blade attachment system)
Mesh size

Correlation Results : Normalize targets to reflect model characteristics and validate initial design adjustments.

Step 2 - Optimization of Design Volume to Achieve Objectives

Optimization Parameters :

Define design volume for FEA model
Normalize target values of force versus displacement for 12 physical tests on the blade holder, both with and without the blade

Optimization Results :

Optimization guided the design towards denser areas, indicated by red colors, representing main reinforcement zones.
Less dense areas were lightened to maximize performance while maintaining necessary mechanical properties.

Step 3 – Validation of the Final Design

Validation Parameters :

Maintain previous FEA modeling parameters, such as linear static model, simplified contacts, discretizing of secondary components (like the blade attachment system), and mesh size.
Incorporate design iterations provided by Bauer Hockey into the FEA model.

Validation Results :

The final design met rigidity and minimum thickness requirements.

Results

Lx Sim and Bauer Hockey worked closely together to develop an optimized blade holder that combines performance, rigidity, and functionality. The project met the rigidity objectives in bending, torsion, and compression while adhering to the client's specified minimum material thicknesses, without compromising performance or strength. The final blade holder design was successfully put into production and marketed in the Hyperlite 2.0 skate.