For my final project, I'll build ski's. So I started designing them in Illustrator which is a software package I have been using for ages now... At the top of the image on the left you'll see the spacing (in mm) for the profile I designed after in Rhino (see pictures below). The central part is flat (the 100 and 180mm), to accomodate the fixations for the shoes, and will have a 10mm thickness. The tips are 2mm thick (the 110mm), and between the main part and the tips there simply are slopes. The total lenght of the ski's is based on me and my proficiency (and for someone my height and level 1700 to 1800mm are normal) and the running lenght you'll see in the picture is the distance between the part where the tip and the tail touch the snow. You'll note that in the middle the ski curves up. We call this camber (my ski's will have 8mm camber) and serves to give the ski's a little 'pop', meaning it will be easier to jump up out of the snow to turn in deep powder. Reverse camber, meaning the ski curves up, we call rocker. Check the ski profiles below.

Above left you can see the profiles for the mold I'm making. I machined these pieces out of 16mm plywood with the shopbot, and assembled them to shape the two molds between which I'll press the materials for the ski's together... Check the picture below for that. Files for everything, by the way, are ot the bottom of this page.

To the left you'll see how I modeled the core for the ski's (the part that will be wood with Ptex sidewalls) in Rhino. I imported the outline (top of the pic) extruded it (2nd piece from top) modeled the side view profile with the 8mm camber (3rd piece from top) and did a boolean between the two extrusions to obtain the ski profile (bottom piece).

Above left the first test (in MDF) that I machined for the ski profile.. came out super nice, no need for a finishing pass, just a roughing with a 4mm flat tip. Directly above you'll see the pieces for the molds that I machined in plywood and to the left you'll see I covered the bottom mold with a thin sheet of aluminium.