Engineering Insights: Gecko Crampon Tensioner Testing

At Gecko Gear, rigorous testing ensures our products meet the demands of real-world use. Below, we share key results from tension buckle testing on our crampons.

Overall this round of testing was extremely successful, and we're very happy with the results. Most importantly, our minimum safety factor on these buckles was 5.13.

In this context, the safety factor represents the ratio between the tested failure load of the tensioner and the maximum load it’s expected to encounter in real-world use. A high minimum safety factor, like the 5.13 achieved in our tests, means the system can handle significantly more stress than it would ever face in typical conditions, ensuring reliability and peace of mind for users in critical situations. 

All testing was done with 3mm kevlar (aramid fiber) 12 strand cordage. There was no slippage observed before failure.

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Test Overview

Objective: Evaluate the performance and reliability of tensioners used in Gecko crampons.
Metrics Assessed:

• Failure point under load (kg)
• Simulated real world load (kg)
• Force multiplication factor (how much mechanical advantage our patent pending attachment system generates exactly)
• Safety factor

Key Results

1. Failure Point Testing:

   • Tensioners were tested to breaking point, with failure occurring between 43–49 kg.
   • This range demonstrates a strong load capacity, exceeding typical field-use scenarios.

2. Hand Tension Efficiency:

   • Manual tensioning loads averaged 1.95–4.0 kg for single-point tension and up to 8.1 kg for two-point deflection, in the way that they would be used on the crampons.
   • This highlights the system’s ease of use while maintaining effectiveness.

3. Force Multiplication Factor:

   • The two-point pull mechanism amplified applied force by a factor of 2.02–3.08, showcasing efficient force transfer for secure fitment.

4. Safety Factor (failure strength over simulated load):

   • Calculated safety factors ranged from 7.16–7.84, far surpassing standard safety thresholds, ensuring reliability under extreme conditions.
   • Minimum safety factor was 5.13, taken from the highest simulated load, and the lowest break point

Summary

These results validate the Gecko crampon tensioners as lightweight yet durable tools, engineered to perform under stress. With high safety margins and efficient tensioning mechanics, Gecko crampons provide adventurers with confidence in every step.