Not all SUP board construction is equal! Straight Talk About SUP Manufacturing

General

There are several types of SUP board construction available, each with its own unique features and benefits. Here are the most common types of SUP board construction:

• Solid Epoxy: Solid epoxy boards are made from a foam core wrapped in layers of fiberglass and epoxy resin. These boards are lightweight, durable, and provide good performance in a variety of conditions. They are a popular choice for beginner and intermediate paddlers.
• Inflatable: Inflatable SUPs are made from a PVC or similar material that is inflated with a pump to create a rigid board. These boards are lightweight, portable, and easy to store and transport. They are a great choice for travel and for paddling in calm waters.
• Soft Top: Soft top SUPs have a foam core with a soft, non-slip surface on the top. These boards are durable and forgiving, making them a good choice for beginners and for paddling in rough waters.
• Carbon Fiber: Carbon fiber SUPs are lightweight and provide excellent performance in a variety of conditions. These boards are more expensive than other types of construction, but are popular among experienced paddlers who are looking for top-of-the-line performance.
• Wood Veneer: Wood veneer SUPs are made from a foam core that is wrapped in a layer of wood veneer. These boards are lightweight, strong, and provide a unique look and feel. They are a good choice for experienced paddlers who are looking for a high-performance board with a unique aesthetic.
• Carbon/Kevlar: Carbon/Kevlar SUPs are similar to carbon fiber boards but are reinforced with Kevlar, a strong synthetic material. These boards provide excellent performance in rough conditions and are a good choice for experienced paddlers who are looking for a durable and high-performance board.
• Hollow Core: Hollow core SUPs are made from a foam core with a hollow center. These boards are lightweight and provide good performance in a variety of conditions. They are a good choice for intermediate and experienced paddlers who are looking for a high-performance board.

High Performance sup board construction - hard boards

The Outside:

High-performance SUP boards are typically made of lightweight and strong materials, such as carbon fiber, fiberglass, and Kevlar. These materials are layered together with epoxy resin to create a rigid and durable board that can handle more challenging conditions and provide excellent speed, maneuverability, and stability.

Carbon fiber is a popular material for high-performance SUP boards because it is extremely strong and lightweight. It provides excellent stiffness and responsiveness, allowing the board to perform well in a variety of conditions. However, carbon fiber boards can be more expensive than other types of construction.

Fiberglass is another commonly used material for high-performance SUP boards. It is less expensive than carbon fiber but still provides good stiffness and durability. Fiberglass boards can be a good choice for intermediate and advanced paddlers who are looking for a high-performance board that is more affordable than a carbon fiber board.

Kevlar is also sometimes used in high-performance SUP board construction. It is an extremely strong synthetic material that provides excellent durability and impact resistance. Kevlar-reinforced boards are a good choice for paddling in rocky or rough conditions.

Overall, high-performance SUP boards are typically made of materials that provide a balance of strength, stiffness, and weight, allowing the board to handle more challenging conditions and provide top-level performance.

The Inside:

The foam core used in high-performance SUP boards is typically a closed-cell foam that is lightweight and provides good stiffness and buoyancy. There are several types of foam that can be used, but the most common types are:

• Expanded Polystyrene (EPS): EPS foam is a popular choice for high-performance SUP boards because it is lightweight and provides good stiffness and strength. It is often used in combination with other materials, such as carbon fiber or fiberglass, to create a high-performance board.
• Extruded Polystyrene (XPS): XPS foam is another type of closed-cell foam that is commonly used in high-performance SUP board construction. It is denser than EPS foam and provides good stiffness and strength.
• Polyurethane (PU): PU foam is a softer, more flexible foam that is often used in the construction of surfboards. However, it can also be used in SUP board construction to create a more forgiving board that is easier to control in rough conditions.

Overall, the choice of foam will depend on the desired characteristics of the board, such as weight, stiffness, and flex. High-performance SUP boards typically use a combination of foam and other materials to create a board that is lightweight, strong, and provides excellent performance in a variety of conditions.

Sup board construction - inflatable

Drop stitch technology is a popular construction method used in inflatable stand-up paddleboards (SUPs) that allows for a stable and rigid board when inflated. There are two styles of drop stitch used in inflatable SUPs: single-layer and double-layer drop stitch.

• Single-layer drop stitch: This style uses a single layer of drop stitch material, which consists of thousands of nylon threads that are tightly woven together and encased in a PVC coating. The threads are connected by thousands of small polyester fibers, creating a pattern of diamond-shaped pockets that are filled with air when the board is inflated. This design provides a lightweight and flexible board that is easy to roll up and transport, but it may not be as durable as double-layer drop stitch.
• Double-layer drop stitch: This style uses two layers of drop stitch material, with the second layer placed perpendicular to the first layer. This creates a stronger and more rigid board that can withstand higher pressures and more abuse. Double-layer drop stitch is heavier and less flexible than single-layer drop stitch, but it is more durable and ideal for riders who want a board that can handle more challenging conditions.

Both single-layer and double-layer drop stitch can produce high-quality inflatable SUPs, but the choice ultimately comes down to the rider's preferences and needs. If you prioritize portability and ease of use, a single-layer drop stitch board may be the better option. But if you want a board that can handle rougher conditions and last longer, a double-layer drop stitch board may be the way to go.

SUP board construction highlights

Sandwich epoxy: 

This style of board is durable, light, and buoyant. A wood or bamboo veneer is applied at the bottom and deck. Bamboo is stronger than steel and more durable than most hardwoods. This style includes a stringer made of wood or fibreglass inserted along the length of the board. 

Key considerations:

1. Quality varies from mid to high depending on the manufacturer.
2. Consider this sandwich epoxy construction for wave surfing, freestyle, flat water, or all-around board.   

Explanation of sandwich epoxy board

Carbon:

This construction style can feature additional layers of fibreglass. Carbon is used for its lightweight, strong and rigid attributes. This board is reinforced with PVC.

Key considerations:

1. Again, quality varies from mid to high depending on the manufacturer.
2. Consider carbon construction for wave surfing, freestyle, flat water, or all-around board.   

Review for a carbon construction board in the following video.

Board Quality

Pay attention to the level of quality for SUP board construction

Traditional board manufacturing in Taiwan has long been known for quality and for hand-crafted boards. To keep up with increasing demand, companies in China have been contracted to produce boards more quickly. These boards generally cost less, and in most cases you get what you pay for. If you come across wildly low prices it probably means corners have been cut during manufacturing. There is obviously a market for low cost boards since consumers are purchasing them. Simply put, be aware, and ask plenty of questions. 

There are some smaller manufacturers in the U.S. and Canada who offer superior custom board manufacturing.

FOAM CORE FOR SUP BOARD CONSTRUCTION

Polyurethane (PU): 

PU is the original foam inside most fibreglass boards, along with polyester resin. This was standard until about 2005, when Expanded polystyrene (EPS) came on the scene. 

Expanded polystyrene (EPS): 

EPS foam is about 60 percent lighter than PU and is always combined with epoxy resin. These boards are also stronger and more buoyant than PU. EPS foam core is now used for most stand up paddle board construction. High quality EPS reduces water absorption (it is water resistant, not water proof). 

The EPS board will outlast the PU board, however some wave surfers prefer PU because it allows for more flex. 

HAND SHAPING

The following video explains the hand shaping process from a "blank."

by shaper Paul Carter

COMPUTER SHAPING

The following video gives an interesting explanation of the computer shaping process.

by Blue Planet Surf

FIBERGLASS CLOTH and RESIN FOR BOARD CONSTRUCTION

Cloth:

The amount and weight of the cloth fibreglass applied will influence durability strength. Typically, more fibreglass is placed on the deck side of the board to give more strength in the standing area, although depending on the board style it could be applied to other areas as well.

Resin:

Either epoxy or polyester resin is used to keep the fibreglass cloth in place. Epoxy resin is lighter than polyester resin, and epoxy boards are stronger, lighter and stiffer than polyester boards. 

NOTE: the quality of fibreglass and resin used can vary. It can be matte or clear gloss, light or heavy. If you have questions about these details, contact the manufacturer.

Vent plugs:

A vent plug is installed on EPS foam boards to release gas buildup when the board is exposed to heat or extreme altitude changes. The ability to vent gas discourages potential delamination. Some vent plugs need to be physically removed and screwed back on before the next ride. A newer style of vent can release the gas on the water, without letting the water in.

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