How Our Reclaimed Ski Lamps Are Made

From Retired Skis to Functional Lighting

Every Upcycled Skis piece is built through a hands-on process that combines engineering, craftsmanship, and material reuse. What starts as retired ski equipment and discarded components is transformed into a durable, high-quality lighting fixture designed to last.

All fixtures are engineered in alignment with the safety principles of UL 48 and UL 1598, incorporating low-voltage Class 2 systems, UL-recognized components, thermal management considerations, and enclosed, strain-relieved wiring pathways; final assemblies are not UL listed.

1. Sourcing Reclaimed Materials

Each project begins with sourcing retired skis and snowboards from:

  • Ski shops and rental fleets
  • Resorts and local partners
  • Individual skiers

We look for skis with strong structural integrity and unique topsheet designs to ensure both durability and visual impact.

At the same time, we source recycled TV diffuser panels—materials originally used inside flat-screen televisions to evenly distribute light. These panels play a critical role in the final lighting quality.

2. Material Preparation

Before fabrication begins, all materials are cleaned and prepared:

  • Topsheets are sanded and treated to increase surface energy and mechanical adhesion
  • Edges are smoothed and surfaces are flattened as needed
  • Internal structures are inspected for strength and stability

This step ensures the skis are safe to work with and ready for precision fabrication.

3. Design & Layout

Each piece is carefully designed based on:

  • The shape and size of the skis or boards
  • The intended lighting effect
  • Mounting orientation (wall sconce, vertical lamp, sign, etc.)

For custom work, layouts are created to incorporate logos, text, or specific visual elements while maintaining structural integrity.

4. Precision Cutting & Fabrication

Using a combination of routing and laser cutting:

  • Openings are cut for lighting elements and designs
  • Veneers or overlay designs are adhered to prepped topsheets and lenses
  • Structural modifications are made while preserving the strength of the ski

This step blends engineering precision with artistic design.

5. Integrating the Lighting System

Lighting is built into each piece using:

  • High-efficiency, CRI 90+ LED systems
  • UL-certified electrical components
  • Recycled TV diffuser panels to create a soft, even glow
  • Recycled TV Fresnel lens laser cut to create the back plate

The diffuser panels are key—they transform raw LED light into a clean, professional lighting effect without hotspots.

6. Assembly & Finishing

Once components are fabricated:

  • Lighting systems are installed and mechanically secured for strain relief
  • Wiring is insulated and protected with heat shrink tubing and butt splice connections
  • Surfaces are sealed or coated for durability
  • Mounting hardware is integrated using factors of safety of >2
  • Veneer edges are sealed to prevent delamination

Every piece is assembled to ensure both aesthetics and long-term performance.

7. Testing & Quality Control

Before leaving the shop, each piece is:

  • Fully powered and tested
  • Checked for light consistency and brightness
  • Inspected for structural integrity
  • Verified for safe installation

This ensures the final product performs reliably in real-world environments.

8. Installation & Use

Finished pieces are designed for easy installation in:

  • Homes and cabins
  • Ski lodges and resorts
  • Retail spaces
  • Breweries and restaurants

Custom installations may include additional design coordination or mounting support.

Why This Process Matters

This process is about more than fabrication—it’s about redefining how materials are used.

By combining:

  • Reclaimed skis and snowboards
  • Recycled TV diffuser panels

Each piece represents a true circular approach, turning multiple waste streams into functional, long-lasting design.

Built to Last

Unlike mass-produced lighting, every Upcycled Skis piece is:

  • Handcrafted in Colorado
  • Structurally sound and engineered
  • Designed as both art and function

No two pieces are the same, but every piece follows the same commitment to quality and sustainability.