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Project Status: Manufacturing completed; entering trial sales.
Project Objective: An Alternative to Conventional Lightweight Trekking Poles
Project Objective: An Alternative to Conventional Lightweight Trekking Poles
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The objective of this project was to develop a trekking pole with a different structural approach from conventional lightweight designs.
Rather than prioritizing minimum weight, the project explored a solid TC21 titanium shaft with a diameter of 12 mm. The design and manufacturing process focused on material selection, connection design, CNC machining, surface finishing, and final assembly.
The intended users include hikers carrying heavier loads, expedition users, and outdoor users who place particular importance on shaft stiffness. The solid-shaft design comes with a clear trade-off: the completed pole weighs approximately 650 g. It is therefore not intended to compete directly with ultralight trekking poles on weight alone.
The product has entered trial sales. Its practical value will need to be assessed through further testing and feedback from actual users.
1. Material Selection and Structural Design
1. Material Selection and Structural Design
The project uses the following material and structural configuration:
Main shaft
Solid TC21 titanium alloy, Ø12 mm
Tip section
TC4 titanium alloy
Ground-contact tip
Tungsten carbide
Connections
CNC-machined threads
Surface finish
Titanium anodizing
Available lengths
1,100 / 1,200 / 1,300 mm
Total weight
Approximately 650 g
Using a typical TC21 density of approximately 4.5 g/cm³, a solid shaft measuring 1,100 mm in length and 12 mm in diameter has a theoretical mass of approximately 560 g. The estimated mass of the complete pole is approximately 650 g, including the other components.
From the beginning, the design involved a deliberate trade-off: using a solid titanium shaft as the structural foundation while accepting the additional weight.
2. CNC Machining and Threaded Connections
2. CNC Machining and Threaded Connections
Once the material and structural configuration were established, the project moved into component manufacturing.
The connecting sections use CNC-machined threads. In addition to thread dimensions and pitch, the manufacturing process must account for fit clearance, dimensional relationships between components, and actual assembly conditions.
Titanium threads also require attention to friction, wear, and galling during repeated engagement. For this reason, dimensional inspection alone is not sufficient. The assembled connections must also be checked for proper engagement and fit.
The project included the relevant CNC machining and trial fitting of the connecting sections. Machining and assembly were considered together to ensure that the individual components could be assembled into the intended product.
3. Anodizing and Final Assembly
3. Anodizing and Final Assembly
Following component machining, the titanium parts underwent anodizing, and final product assembly was completed.
Titanium anodizing forms an oxide layer on the surface and can produce different colors under appropriate process conditions. Surface finishing must be coordinated with machining and assembly so that the various manufacturing steps work together in the completed product.
The project brought together the TC21 main shaft, TC4 tip section, and tungsten carbide ground-contact tip to complete the trekking pole. Three lengths were specified: 1,100 mm, 1,200 mm, and 1,300 mm.
4. From Manufacturing to Trial Sales
4. From Manufacturing to Trial Sales
Manufacturing is complete, and the product has entered trial sales.
The next step is to gather practical feedback and evaluate aspects such as shaft deformation under different loads, the condition of the connections after repeated use and assembly, and wear at the ground-contact tip.
These findings will help determine whether the current design meets the needs of its intended users and identify opportunities for further development.
5. What This Project Demonstrates
5. What This Project Demonstrates
For Aikerly, this project involved more than producing a titanium trekking pole. Material selection, structural design, CNC machining, threaded connections, surface finishing, and final assembly were coordinated within a single product development project.
Aikerly supplies aluminum and magnesium alloy materials and supports custom manufacturing and engineering projects involving titanium, aluminum, magnesium, and carbon fiber components. Depending on project requirements, we coordinate appropriate manufacturing resources to connect material choices, component processing, and finished-product manufacturing.
This trekking pole is a practical example of that approach. Manufacturing has been completed, while its performance in actual use remains subject to further testing and customer feedback.
From material selection and component machining to the finished product, Aikerly focuses on turning manufacturing requirements into tangible results.
Note: The total product weight is approximate, and the shaft mass is theoretically estimated using a typical reference density. This case study does not claim that load-bearing, durability, or safety performance has been fully validated. Such performance should be established through appropriate testing and actual-use evaluation.
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