A quick and easy explanation on how the surfboards are made. From hand shaped custom surfboards to molded surfboards, soft surfboards, body boards and injection molded boards. What are the advantages and disadvantages of each construction technique and who is it meant for.

SURFBOARD CONSTRUCTION

There are 4 main methods of constructing surfboards.

• Custom Surfboards Shaping – PU surfboards
• Machine shaped PU surfboards
• Molded Surfboards
• Soft Surfboards
• Bodyboards
• Injection Moulded Boards

Custom Surfboards Shaping

Custom surfboards are shaped from blanks.

What is a blank? Blank is a polyurethane (PU, hard foam) core in the rough shape of a surfboard which is split from nose to tail and a wooden strip, called a stringer, approx. 6mm wide is glued between the 2 halves. The stringer strengthens the board, reducing the risk of the board twisting or snapping.

Shaping a custom surfboard

The blank is then shaped by hand using a variety of tools. First a saw is used to cut the desired outline and then an electric plane is used to take off the hard outer skin of the blank and any large areas of foam that need to be removed. Extra Rocker can also be added using the power plane. A rasping tool (surform) and then sandpaper are used to fine tune the blank and give the custom surfboard its finished shape. Custom surfboard may now be spray-painted using acrylic or other paint prior to laminating.

Laminating a custom surfboard

In the laminating process the surfboard is covered with woven fibreglass cloth. Shortboards usually have 1 layer of 4 oz weight cloth on the bottom and 2 layers on the deck. Longboards often use a stronger 6oz cloth and may have more layers. The cloth is then saturated with polyester or isothalic resin. After this sets and the fins have been attached a coat of sanding resin is applied and when this has hardened it is sanded down to give the final shape. A further coating of resin (the gloss coat) may be given which can then be polished to a high gloss finish.

Epoxy and styrofoam is more and more used instead of polyester and polyurethane foam. Styrofoam makes the boards lighter and epoxy resin makes them stronger so epoxy surfboards are more durable, but they are still not thoroughly accepted.

• PRO: Custom boards can be shaped to the exact requirements of the surfer, they are light and they give a high performance.

• CON: They are expensive and they ding easily.

• WHO RIDES THEM? Custom shaped surfboards are meant for experienced surfers that know what they want.

Machine shaped PU Surfboards

Machine shaped PU Surfboards are basically made the same way as custom shaped surfboards. Again instead of polyurethane foam you can use styrofoam and epoxy.

The difference is that the blank is shaped by a machine. This means that the shaping process is quicker but on the other hand, every board is completely the same. With custom shaped surfboard you can talk to the shaper about what you want, with machine shaped surfboard you can only choose from a range of predesigned surfboard shapes.

• PRO: Light, high performance, can be cheaper than custom made surfboards.

• CON: Still expensive, ding easily, you can only choose from a range of predesigned surfboard shapes.

• WHO RIDES THEM? Machine shaped surfboards come in different shapes and sizes from shortboard to minimals etc. but are generally suited for more advanced surfers.

Surftech surfboards (Tuflite technology)

Tuflite technology is an epoxy sandwich surfboard technology. Surftech is producing the strongest lightweight epoxy surfboards in the world. Blending ultra high performance with maximum durability, TUFLITE technology is revolutionizing the surfboard industry and is being sought after by the best shapers in the world. Tuflite technology was introduced by Randy French in 1992 when he started Surftech. French, a shaper since the late 1960′s has been on the leading edge of surfboard design and evolution for over 30 years. His industry leading windsurf company, Seatrend, set technological and design standards in windsurfing for over 10 years. French has chosen to share his technology with the best craftsmen in our sport. Allowing shapers to replicate their most sought after designs (models / shapes ) and freeing them to work further on the evolution of the surfboard. Surfers can now experience the strongest and lightest performance surfboards ever created. Their boards enjoy a lifespan never before possible, and the chance to repeatedly get the same magic board over and over again. Surf Tech’s are ‘generally’ more expensive than traditional foam and fibreglass surfboards The strongest lightweight epoxy surfboards in the world Characteristics Ultra high performance with maximum durability

• PRO: Lightweight, high performance, maximum durability.

• CON: High price, some surfers also do not like the increased buoyancy of the epoxy surfboards.

• WHO RIDES THEM? Intermediate and advanced surfers.

Salomon S-Core surfboards

Salomon’s new S-core technology was inspired by aeronautic technologies, creating boards which are FLEXIBLE, PROFILED, LIGHT, and STRONG at the same time. The S-core construction method starts with a carbon fiberglass frame base which provides the stiffness necessary for speed and responsiveness. Three Polypropolene foam stringers are then glued to the carbon fiber frame to provide support and dampening. This completes the core structure of the board. The top layers consist of 4oz fiberglass and extruded polystyrene (EPS) foam. The EPS top coat provides a “soft” feeling under your feet, similar to that of a traditional PU board. Once the EPS foam/fiberglass topcoat has been attached to the core, the board is then given to the individual shaper for hand finishing. Once the board is finished by the shaper, it is then hand glassed by the laminator using epoxy resin. The motivation behind creating the s-core surfboard construction method was twofold. Firstly, this method produces a lighter, more durable board. Secondly, this method is much more environmentally friendly. The EPS foam used in producing S-core surfboards is CFC/HCFC free, 100% recyclable, PVC free and non-poluting due to the fact that it is dilutable into water and air. The epoxy resin used in producing these surfboards contains 4x less volatile organic compounds and is less toxic than the polyester resin used in traditional surfboard construction. Salomon is now working with a number of shapers and surfboard companies to construct S-core versions of their original surfboard designs.

Some key features regarding the S core:

• The S core surfboard is 10% stronger than a PU board,
• S-Core surfboard has 20% more flex and damping than a PU board,
• S-Core surfboard is made from extruded polystyren and is “blue”

At this point you can not get a fully personalized board, but in the future you will be able to. The S core is not an Epoxy sandwich board (like Surf Tech). S core has a growing number of shapers joining the team. S core uses FCS, Future Fins, Red X and speed fin systems.

• PRO: More responsive, lighter, stronger and faster than a traditional PU shortboard.

• CON: High price.

• WHO RIDES THEM? Advanced surfers.

Molded Surfboards (Pop outs)

Molded surfboards are also called Pop-Outs. The name Pop Out implies how they are made. Pop outs are not shaped but they pop-out of a mold that duplicates hundreds or thousands of surfboards. Molded surfboards construction process is the following: a female mold of a surfboard in two halves, top and bottom, is fibre glassed. The two halves are then brought together and liquid polyurethane foam is allowed to expand to fill the void in the center. The join line is later cleaned up and finished with a strip of special tape.

Molded surfboards are durable and hard to damage, the are shaped for the beginner surfers, so you can pick up waves easily.  They are the surfboards that take you from a complete novice to basic level of surfing. The downside of the durability is weight - they are heavier than a custom board. This can cause problems for smaller and weaker surfers. Molded surfboards come in a range of shapes  and sizes from shortboards to longboards, they are designed with lots of width, thickness and volume so they are stable and catch waves easily. Molded surfboards manufacturers: BIC, NSP, South Point.

• PRO: Molded boards are cheap and durable, they are perfect for progressing from novice surfer to intermidiate surfer - these boards are long, wide and thick so they are easy to paddle and catch waves easily.

• CON: Moulded boards are heavier than custom boards and are unsuitable for high performance surfing. If dinged (which happens rarely) they can soak up water and become very heavy.

• WHO RIDES THEM? Perfect for beginner surfers.

Injection Molded Surfboards

Injection Molded Surfboards look very similar to pop-outs but are stronger and more important - lighter. They are also more expensive. The construction process is the following:

The core of the surfboard or a blank if you will is made in a mold with expanded polystrene foam (E.P.S.). Expanded polystrene foam is very light and at the end gives only about 10% of the total weight of the surfboard. EPS core is sometimes hand shaped to remove any iregullarities, then it is laminated with multiple layers of fiberglass and epoxy resin. At the end, the surfboard is again placed into a mold where the thermoformed (P.V.T.) top sheet material is heat pressed to the top and bottom of the surfboard. Heat causes the top sheet to bond with the epoxy and for the epoxy to cure.  This is the final addition that makes these surfboards extra strong and because of the light core not much heavier that ordinary custom surfboards.

Again these surfboard also come in a range of shapes and sizes from shortboards to longboards. In comparison to pop-outs they are more performance shaped and aimed at better surfers. Manufacturers that make them are pretty much the same that make pop-outs.

• PRO: Injection molded boards are lighter and offer better performance than a pop-outs, still they keep great durability and are available at a very good price in comparison with custom shaped surfboards. They are fast and easy to paddle.

• CON: They are more expensive than pop outs.

• WHO RIDES THEM? They are aimed at intermediate surfers.

Soft Surfboards

These are made from a semi-rigid inner foam core blown in a mold which is covered with a soft foam exterior. They are very user friendly, they come in a variety of shapes and sizes and the Soft top surfboards are probably the most ideal surfboards to start on. They are shaped to have lots of volume and stability so you can catch lots of  waves and be more stable when you are trying to stand up. They soft deck reduces the risk of accidents and injuries. All these are the reasons that soft surfboards are widely used in surf schools.

But if you are considering buying your own surfboard then perhaps a slightly more progressive surfboard would be more suitable. You can outgrow a soft surfboard quite quickly.

• PRO: Soft boards are extremely safe and generally very durable. They inspire great confidence in beginners. Soft surfboards are big, float well and you catch waves easily.

• CON: Sof surfboards are heavier than a traditional custom surfboards and progression with them is limited, they are only suitable for performing basic manoeuvres.

• WHO RIDES THEM? First time surfers, children, surf schools.

Bodyboards

These are made in a similar fashion to softboards but are under 5ft in length and are designed to be ridden lying down or whilst crouching on one knee. They are ideal for beginners and experts alike and can be used in all types and sizes of waves.

Related posts:

1. HISTORY OF THE SURFBOARD
2. SURFBOARD DESIGN
3. SURFBOARD TYPES