VESTIGE HANDLE

Skills

Ergonomics, 3D Modeling, Design for Repair

Year

2026

project overview

A modular trekking pole handle designed for easy repair to reduce unnecessary waste. Presented to the Black Diamond design team.

the challenge

Hikers regularly lose high-end trekking poles to a single point of failure: chewed-up handles. Standard cork grips absorb salty sweat on the trail, turning them into midnight snacks for backcountry wildlife while you sleep. Because current manufacturing permanently bonds these grips, users have no way to repair localized damage, forcing them to discard the entire pole assembly.

CURRENT SOLUTIONS

When handles fail, hikers resort to DIY fixes that never restore the original ergonomics, texture, or aesthetic appeal. Because brands don't offer modular replacement grips, users are trapped between messy makeshift repairs and expensive full-assembly replacements.

Duct Tape: Leaves sticky residue and changes grip profile
Ground Cork + Wood Glue: Time-consuming, messy, and high skill required
Handle Bar Tape: Replaces natural cork with foam, changes aesthetics
Full Upper/Pole Replacement: Expensive and wasteful, discards perfectly functional poles

IDEATION & Refinement

Ideation began by 3D-scanning an existing handle to establish accurate hand proportions before transitioning from sketches to CAD and rapid prototyping. To ensure structural integrity during handling, a minimum material thickness constraint of 3/16" was established for the cork grip inserts

Final Concept

Replaceable Cork Grip Modules
Main Handle Body
Internal Indexing Ribs to Prevent Rattle
Trekking Pole
Lateral Assembly Pins

High Fidelity Prototype

Validated through functional prototyping using an FDM-printed core, custom-molded cork grips, and hardware salvaged from a donor pole. The build confirmed that a fully modular mechanical assembly can successfully integrate into a standard trekking pole handle silhouette while proving the concept of low profile lateral retention pins.

conclusion

The Vestige Handle provides a sustainable and serviceable handle for trekking poles. By integrating a modular handle assembly, the design extends the pole's product lifespan and reduces material waste.

Next Steps:

Reinfocement: Testing showed that pure cork lacks the strength needed to hold the grips securely on the lateral pins
Future Updates: Add a thin plastic backing to the cork grips to prevent the pins from tearing through the cork

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