12 Secrets of Roller Coaster Designers

People ride a spinning roller coaster in the Santa Cruz Beach Boardwalk Park
People ride a spinning roller coaster in the Santa Cruz Beach Boardwalk Park
hanusst/iStock via Getty Images

Back in the early 20th century, engineers attempting to push the limits of roller coaster thrills subjected riders to risky upside-down turns and bloody noses. A century later, coaster designers rely on computer software, physics, and psychology to push the limits of the roughly 5000 rides in operation worldwide. To get a sense of what their job entails, Mental Floss spoke with several roller coaster specialists about everything from testing rides with water-filled dummies to how something as simple as paint can influence a coaster experience. Here’s what we learned.

1. Getting strapped in might be the most exciting part of the roller coaster ride.

Known as a “thrill engineer,” UK-based Brendan Walker consults with coaster manufacturers and parks on the psychology of riding the rails. In his experience, riders getting secured into their seats are at the peak of their excitement—even more so than during the ride itself. “The moment the lap bar is being locked down and you have that feeling of things being inescapable, that you have to suffer the effects of the ride, is the highest moment of arousal,” Walker says. “The actual ride might only achieve 80 percent of that excitement.”

2. Designers test roller coasters with water-filled dummies.

Bill Kitchen, founder of U.S. Thrill Rides, says it can take anywhere from two to five years for a coaster to go from idea to execution. Part of that process is devoted to the logistics of securing patents and permits for local site construction—the rest is extensive safety testing. “We’re subject to ASTM [American Society for Testing Materials] standards,” Kitchen says. “It covers every aspect of coasters. The rides are tested with what we call water dummies, or sometimes sandbags.”

The inanimate patrons allow designers to figure out how a coaster will react to the constant use and rider weight of a highly trafficked ride. The water dummies—which look a bit like crash test dummies, but filled with water—can be emptied or filled to simulate different weight capacities. Designers also sometimes use the kind of crash-test dummies found in the auto industry to observe any potential issues prior to actual humans climbing aboard.

3. Every foot of roller coaster track costs a lot of money.

Thrill seekers go upside-down while riding on the Mind Eraser roller coaster in Agawam, Massachusetts
Thrill seekers go upside-down while riding on the Mind Eraser roller coaster in Agawam, Massachusetts
Kirkikis/iStock via Getty Images

There is absolutely nothing random about the length of a coaster’s track. In addition to designing a ride based on the topography of a park site, designers take into account exactly how much space they’ll need to terrorize you and not an inch more. When England’s Alton Towers park was preparing to build a ride named TH13TEEN for a 2010 opening, they asked Walker exactly how much of a drop was needed to scare someone in the dark. “It was a practical question,” Walker says. “For every extra foot of steelwork, it would have cost them £30,000 [roughly $40,000].”

4. Rollercoaster Tycoon brought a lot of people into the business.

The popular PC game, first released in 1999, allowed users to methodically construct their own amusement parks, including the rides. As a proving ground for aspiring engineers and designers, it worked pretty well. Jeff Pike, President of Skyline Attractions, says he’s seen several people grow passionate about the industry as a direct result of the game. “I remember when the game first got popular, I would go to trade shows and there would be kids looking to get into it using screen shots of rides they designed. The game definitely brought a lot of people into the fold.”

5. Paint makes a big difference in coaster speed.

A group of tin metal cans with colorful paint
scanrail/iStock via Getty Images

For all of their high-tech design—the software, fabrication, and precise measures of energy—a good coaster ride can often come down to whether it’s got too much paint on it. “The one thing that will slow down a steel coaster is a build-up of paint on the track rails,” Pike says. “It softens where the wheel is rolling and hitting the track, which increases the drag.” A good, worn-in track will have gray or silver streaks where the wheel has worn down the paint, making it move more quickly.

6. A roller coaster’s skyline is key.

Brian Morrow, former Corporate Vice President for Theme Park Experience at SeaWorld Parks and Entertainment, says that the looming curvature of coasters spotted as guests drive toward and enter the park is very purposeful. “It’s like a movie trailer in that we want you to see some iconic coaster elements, but not the whole thing,” he says. “You approach it with anticipation.”

7. Some coasters arrive as giant model kits.

Whether a coaster’s theme or design comes first is largely left up to the end user—the amusement park. But for some rides, manufacturers are able to offer pre-fabricated constructions that designers can treat like the world’s biggest Erector Set. “Sometimes I work on rides that have already been built,” Walker says. “They’re produced by a company and presented almost like a kit with parts, like a model train set. There’s a curve here, a straight bit here, and you can pick your own layout depending on the lay of the land.”

8. Wooden roller coasters are weather-sensitive.

If you’ve ever been on a wooden coaster that seems a little shaky from one trip to the next, check the forecast: It might be because of the weather. Pike says that humidity and other factors can shrink the wood, affecting how bolts fit and leading to a slightly shakier experience. “The structure itself can flex back and forth,” he says. It’s still perfectly safe—it just takes more maintenance to make sure the wood and fasteners are in proper operating condition. A well-cared-for wooden coaster, Pike says, can usually outlast a steel model.

9. The time of day can affect the coaster experience.

“A coaster running in the morning could run slower when cooler,” Morrow says. “The wheels are not as warm, the bearings are warming up. That could be different by 2 p.m., with a slicked-up wheel chassis.” Coasters experiencing their first-ever test runs can also be slightly unpredictable, according to Pike. "Those first trial runs [during the testing phase] can be slow because everything is just so tight," he says. "A lot of coasters don't even make it around the track. It's not a failure. It's just super-slow."

10. Roller coaster designs can come from unusual places—like Jay Leno’s chin.

The twisting, undulating tracks of coasters can often be the result of necessity: Pike says that trees, underground piping, and available real estate all inform designers when it comes to placing a ride in a specific park. But when they have more freedom, coasters can sometimes take on the distinctive shape of whatever happens to be around the designers at the time of conception. “We had a giant piece of land in Holland that just had no constraints, and we were sitting around talking," Pike says. “And we started talking about Jay Leno’s chin.” The ride was a “loose” representation of the comedian's jaw, but “it is there.”

11. Roller coaster riders double as performers.

A woman taking a ride on a rollercoaster at Oktoberfest in Munich, Germany
A woman taking a ride on a rollercoaster at Oktoberfest in Munich, Germany
exithamster/iStock via Getty Images

For Walker, the best advertising for a coaster is having spectators watch riders de-board after an exhilarating experience. “It’s all about that emotion,” he says. “A spectator basically asks, ‘What’s making them so aroused? What’s giving them such pleasure?’ The line for the ride is the audience. Imagining yourself on the structure becomes a very powerful thing."

12. The future of coasters is vertical.

Biggest, fastest, longest—coasters are running out of superlatives. Because rides can only be designed with so many drips, rolls, or G forces, some companies are looking to the sky for their next big idea. Kitchen has been overseeing design of the Polercoaster for years: It’s a sprawling, skyscraper-esque ride that uses electromagnetic propulsion to carry riders upwards instead of across horizontal tracks. “We want to put it in places where land is very expensive, like the Vegas strip,” he says. “You can only do that if it takes up a lot less space.” The project is set to exceed the 456 feet of the current tallest ride, Kingda Ka at Six Flags in New Jersey. “It’ll be the world’s tallest—and hopefully the most fun.”

This list first ran in 2017.

10 Products for a Better Night's Sleep

Amazon/Comfort Spaces
Amazon/Comfort Spaces

Getting a full eight hours of sleep can be tough these days. If you’re having trouble catching enough Zzzs, consider giving these highly rated and recommended products a try.

1. Everlasting Comfort Pure Memory Foam Knee Pillow; $25

Everlasting Comfort Knee Pillow
Everlasting Comfort/Amazon

For side sleepers, keeping the spine, hips, and legs aligned is key to a good night’s rest—and a pain-free morning after. Everlasting Comfort’s memory foam knee pillow is ergonomically designed to fit between the knees or thighs to ensure proper alignment. One simple but game-changing feature is the removable strap, which you can fasten around one leg; this keeps the pillow in place even as you roll at night, meaning you don’t have to wake up to adjust it (or pick it up from your floor). Reviewers call the pillow “life-changing” and “the best knee pillow I’ve found.” Plus, it comes with two pairs of ear plugs.

Buy it: Amazon

2. Letsfit White Noise Machine; $21

Letsfit White Noise Machine
Letsfit/Amazon

White noise machines: They’re not just for babies! This Letsfit model—which is rated 4.7 out of five with nearly 3500 reviews—has 14 potential sleep soundtracks, including three white noise tracks, to better block out everything from sirens to birds that chirp enthusiastically at dawn (although there’s also a birds track, if that’s your thing). It also has a timer function and a night light.

Buy it: Amazon

3. ECLIPSE Blackout Curtains; $16

Eclipse Black Out Curtains
Eclipse/Amazon

According to the National Sleep Foundation, too much light in a room when you’re trying to snooze is a recipe for sleep disaster. These understated polyester curtains from ECLIPSE block 99 percent of light and reduce noise—plus, they’ll help you save on energy costs. "Our neighbor leaves their backyard light on all night with what I can only guess is the same kind of bulb they use on a train headlight. It shines across their yard, through ours, straight at our bedroom window," one Amazon reviewer who purchased the curtains in black wrote. "These drapes block the light completely."

Buy it: Amazon

4. JALL Wake Up Light Sunrise Alarm Clock; $38

JALL Wake Up Light Sunrise Alarm Clock
JALL/Amazon

Being jarred awake by a blaring alarm clock can set the wrong mood for the rest of your day. Wake up in a more pleasant way with this clock, which gradually lights up between 10 percent and 100 percent in the 30 minutes before your alarm. You can choose between seven different colors and several natural sounds as well as a regular alarm beep, but why would you ever use that? “Since getting this clock my sleep has been much better,” one reviewer reported. “I wake up not feeling tired but refreshed.”

Buy it: Amazon

5. Philips SmartSleep Wake-Up Light; $200

Philips SmartSleep Wake-Up Light
Philips/Amazon

If you’re looking for an alarm clock with even more features, Philips’s SmartSleep Wake-Up Light is smartphone-enabled and equipped with an AmbiTrack sensor, which tracks things like bedroom temperature, humidity, and light levels, then gives recommendations for how you can get a better night’s rest.

Buy it: Amazon

6. Slumber Cloud Stratus Sheet Set; $159

Stratus sheets from Slumber Cloud.
Slumber Cloud

Being too hot or too cold can kill a good night’s sleep. The Good Housekeeping Institute rated these sheets—which are made with Outlast fibers engineered by NASA—as 2020’s best temperature-regulating sheets.

Buy it: SlumberCloud

7. Comfort Space Coolmax Sheet Set; $29-$40

Comfort Spaces Coolmax Sheets
Comfort Spaces/Amazon

If $159 sheets are out of your price range, the GHI recommends these sheets from Comfort Spaces, which are made with moisture-wicking Coolmax microfiber. Depending on the size you need, they range in price from $29 to $40.

Buy it: Amazon

8. Coop Home Goods Eden Memory Foam Pillow; $80

Coop Eden Pillow
Coop Home Goods/Amazon

This pillow—which has a 4.5-star rating on Amazon—is filled with memory foam scraps and microfiber, and comes with an extra half-pound of fill so you can add, or subtract, the amount in the pillow for ultimate comfort. As a bonus, the pillows are hypoallergenic, mite-resistant, and washable.

Buy it: Amazon

9. Baloo Weighted Blanket; $149-$169

Baloo Weighted Blanket
Baloo/Amazon

Though the science is still out on weighted blankets, some people swear by them. Wirecutter named this Baloo blanket the best, not in small part because, unlike many weighted blankets, it’s machine-washable and -dryable. It’s currently available in 12-pound ($149) twin size and 20-pound ($169) queen size. It’s rated 4.7 out of five stars on Amazon, with one reviewer reporting that “when it's spread out over you it just feels like a comfy, snuggly hug for your whole body … I've found it super relaxing for falling asleep the last few nights, and it looks nice on the end of the bed, too.” 

Buy it: Amazon 

10. Philips Smartsleep Snoring Relief Band; $200

Philips SmartSleep Snoring Relief Band
Philips/Amazon

Few things can disturb your slumber—and that of the ones you love—like loudly sawing logs. Philips’s Smartsleep Snoring Relief Band is designed for people who snore when they’re sleeping on their backs, and according to the company, 86 percent of people who used the band reported reduced snoring after a month. The device wraps around the torso and is equipped with a sensor that delivers vibrations if it detects you moving to sleep on your back; those vibrations stop when you roll onto your side. The next day, you can see how many hours you spent in bed, how many of those hours you spent on your back, and your response rate to the vibrations. The sensor has an algorithm that notes your response rate and tweaks the intensity of vibrations based on that. “This device works exactly as advertised,” one Amazon reviewer wrote. “I’d say it’s perfect.”

Buy it: Amazon

This article contains affiliate links to products selected by our editors. Mental Floss may receive a commission for purchases made through these links.

Meet Ice Cream Scientist Dr. Maya Warren

Maya Warren
Maya Warren

Most people don’t think about the chemistry in their cone when enjoying a scoop of ice cream, but as a professional ice cream scientist, Dr. Maya Warren can’t stop thinking about it. A lot of complex science goes into every pint of ice cream, and it’s her job to share that knowledge with the people who make it—and to use that information to develop some innovative flavors of her own.

Unlike many people’s idea of a typical scientist, Warren isn’t stuck in a lab all day. Her role as senior director for international research and development for Cold Stone Creamery takes her to countries around the world. And after winning the 25th season of The Amazing Race in 2014, she’s now back in front of the camera to host Ice Cream Sundays with Dr. Maya on Instagram. In honor of National Ice Cream Month this July, we spoke with Dr. Warren about her sweet job.

How did you get involved in food science?

I fell in love with science at a really young age. I got Gak as a kid, you know the Nickelodeon stuff? And I remember wanting to make my own Gak. I remember getting a little kit and putting together the glue and all the coloring and whatever else I needed to make it. I also had make-your-own gummy candy sets. So I was always into making things myself.

I didn't really connect that to chemistry until later on in life. When I was in high school, I fell in love with chemistry. I decided at that point I should go to college to become a high school chemistry teacher. One day I was over at my best friend's house in college, and she had the TV on in her apartment. I remember watching the Food Network and there was a show on called Unwrapped, and they go in and show you how food is made on a manufacturing, production scale. In that particular episode, they went into a flavor chemistry lab. It was basically a wall full of vials with clear liquid inside them. They were about to flavor soda to make it taste like different parts of a traditional Thanksgiving meal. So you had green bean casserole-flavored soda, you had turkey and gravy-flavored soda, cranberry sauce soda. And I was like, "Oh my gosh, like how disgusting is this? But how cool is this! I could do this. I'm a chemist."

I love the science of food and how intriguing it is, and I had to ask myself, "Maya, what do you love?" And I was like, "I love ice cream! I’m going to become one of the world’s experts in frozen aerated deserts." I found a professor at UW Madison [where I earned my Ph.D. in food science], Dr. Richard Hartel, and he took me under his wing. Six and half years later, I’ve become an expert in ice cream and all its close cousins.

How did you arrive at your current position?

I didn't actually apply for the job. Six years ago, I was running The Amazing Race, the television show on CBS. After I was on it, a lot of publications reached out wanting to interview me. I did a couple of interviews and someone from Cold Stone found my interview. They noticed that I’m a scientist, and they were looking for someone with my background, so they reached out to me. I was actually writing my dissertation, and I was like, "I'm not looking for a job right now. I just want to go home and sleep."

I originally told myself I wasn't going to work for a year because I was so exhausted after graduate school and I needed some time off. But I ended up going to their office in Scottsdale for an interview. At that time, I still wasn't sure if was going to do it or not because I didn't want to move to Arizona. It's just so incredibly hot. I ended up being able to work something out with them where I didn't have to move Arizona. I came on board back in 2016. I started as a consultant at first because I didn't want to move. But then I proved I could make this work from afar.

What does your job at Cold Stone Creamery entail?

I'm the senior director for international research and development for Cold Stone Creamery. A lot of what I do is establishing dairies and building ice cream mixes for countries all across the globe. Dairy is a very expensive commodity. Milk fat is quite pricey. Cold Stone has locations all over the world, and they all need ice cream mixes. But sometimes bringing that ice cream from the United States into that country is extremely expensive, because of conflicts, because of taxes, different importation laws. A lot of what I do is helping those countries figure out how they can build their own dairies, or how can they work with local dairies to make ice cream mixes more affordable.

The other part of what I do is create new ice cream flavors for these places. I look at a local ingredient and say, "I see people in this country eating a lot of blank. Why don’t we turn that into ice cream? How would people feel about that?" I try to get these places to realize that ice cream is so much more than a scoop. In the States, we have ice cream bars, ice cream floats, ice cream sandwiches. But many countries don’t see ice cream like that. So getting these places to come on board with different ideas and platforms to grow their business is a big part of my job.

Ice cream scientist Maya Warren.
Maya Warren

What’s your favorite ice cream flavor you made on the job?

I made a product called honey cornbread and blackberry jam ice cream. Ice cream to me is a blank canvas. You can throw all kinds of paint at it—blue and red and yellow and orange and metallic and glitter and whatever else you want—and it becomes this masterpiece. That's how I look at ice cream.

Ice cream starts out with a white base that's full of milk fat and sugar and nonfat dry milk. It’s plain, it’s simple. For this flavor, I thought, "Why don’t I throw cornbread in ice cream mix?" I put in some honey, because that’s a good sweetener, and a little sea salt, because salt elevates taste, especially in sweeter desserts. And why don’t I use blackberry jam? When you’re eating it, you feel the gritty texture of cornbread, which is quite interesting. You get that pop of the berry flavor. There’s a complexity to the flavors, which is what I enjoy about what you can do with ice cream.

What is the most rewarding part of your job?

One of the most rewarding things is being able to produce a product and see people eat it. The other part of it is being able to have a hand in helping people in different countries get on their feet. Ice cream isn’t a luxury for many people in America, but there are people in other countries that would look at it that way. Being able to introduce ice cream to these countries is fascinating to me. And being able to provide job opportunities for people, that sincerely touches my heart.

The last part is the fact that when I tell people I’m an ice cream scientist, it doesn’t matter how old the person is, they can’t believe it. I’m like, "I know, could you imagine doing what you love every day?" And that’s what I do. I love ice cream.

What are some misconceptions about being an ice cream scientist?

When I tell people what I do, they automatically think I just put flavors in ice cream. They don’t know that there’s a whole other part of it before you get to adding flavor. They don't think about the balancing of a mix, the chemistry that goes into ice cream, the microbiology part that goes into ice cream, the flavor science that goes into ice cream. There’s so much hardcore science that goes into being an ice cream scientist. Ice cream, believe it or not, is one of the most complex foods known to man (and woman). It is a solid, it’s a gas, and it’s also a liquid all in one. So the solid phase comes in via the ice crystals and partially coalesced fat globules. The gas phase comes in via the air cells. Ice cream usually ranges from 27 to 30 percent overrun, which is the measurement of aeration in ice cream. You also have your liquid phase. There’s a semi-liquid to component to ice cream that we don’t see, but there’s a little bit of liquid in there.

People don’t think about ice crystals and air cells when they think about ice cream. They really don’t think partially coalesced fat globules. But it’s really fun to connect the science of ice cream to the common knowledge people have about this product they eat so much.

If you weren't doing this, what would you be doing?

If I wasn’t an ice cream scientist, I think that I would have been a motivational speaker. When I was a kid, my parents would send me to camp, and I remember having a lot of motivational speakers that would come in and talk to us. I always wanted to do that as a kid. So it’s either between that or a sport medicine doctor, because that was the track I was on in college. So if I didn’t figure out food science, I probably would have gone back to sports medicine. But I’m glad I didn’t go down that path, because I think I have one of the coolest and sweetest jobs—pun intended—that exists on planet Earth.

You’ve been hosting Ice Cream Sundays on Instagram Live since May. What inspired this?

At the beginning of quarantine, I was like, "What am I going to do? I can't travel anywhere. What am I going to do with all this extra time?" I was on Instagram, and I started seeing people at the very beginning of this make all this bread. And I was like, "I need to start talking about ice cream more. Ice cream can’t be left out of this conversation."

I started making ice cream and posting here and there, and people would ask me about it, and I would ask them, "Do you have an ice cream maker?" I put a poll up and 70, 80 percent of people who replied did not have ice cream makers. So I was like, "How am I going to make people happy with ice cream if all I do is show photos and they can’t make it?" Then I decided to make a no-churn ice cream. That’s not how you make it in the industry, but it’s how you make it at home if you don’t have an ice cream machine. I think it was around May 3, I decided I was going to do an Instagram Live. I’m going to call it Ice Cream Sundays with Dr. Maya, and I’ll just see where it goes from there.

I did one, and from the beginning, people were so in love with it. Then I thought, "Whoa, I guess I should continue doing this." I’ve made a calendar. People really attend. People make the ice cream. People watch me on Live. I’ve always wanted to have a television show on ice cream. I figured, if I can’t do a show on ice cream right now on a major network, I might as well start a show on Instagram.

What advice do you give to young people interested in becoming ice cream scientists?

My advice is: If you want to do it, do it. Don’t forget to work hard, but have fun along the way. And if ice cream isn’t necessarily the realm for you, make sure whatever you do makes your heart flutter. My heart flutters when I think about ice cream. I am so intrigued with it. So if you find something that makes your heart flutter, no one can ever take away your desire for it. If it is ice cream, we can get down and dirty with it. I can tell them about the science behind it, the biology, the microbiology that goes into ice cream itself. But I just encourage people to follow their heart and have fun with whatever they do.

What’s your favorite ice cream flavor?

If we’re talking just general flavors, I love a good cookies and cream. I’m an Oreo fan. I also make a double butter candy pecan that is my absolute jam.