Superfused EPS Foam

We are using ‘Superfused EPS Foam’ from US Blanks. It has a tighter fusion and cell structure due to the moulding process of the blank, this means the blank takes less resin and offers a tighter flex pattern than the standard EPS blanks available on the market. If you weren’t already aware, standard EPS foam has a tighter flex than standard construction boards, so Superfused blanks are a massive step up in that respect. These blanks are around 25% lighter than standard blanks, so with the added flex properties you can see where the added performance comes from when riding the board.

Resin Research Epoxy

When the board is laminated it happens in a heat controlled environment using ‘resin research’ epoxy resin.

‘Resin research’ epoxy is ground breaking stuff, not only is it over 40% bio content it is also the strongest, lightest and brightest epoxy on the market. It isn’t just safer to use and better for the environment, it is also the best performing resin we could get our hands on. Given the characteristics of the foam and the resin, this surfboard as a product uses less resin per foot than standard construction surfboards, meaning the weight is further reduced. It all plays a part in why this construction method is so special.

Hexel S-Glass

Hexel S-glass fibre glass is used to laminate the board along with the epoxy resin. S-glass is pound for pound the strongest woven 4oz cloth available on the market. Offering up to 4x more tensile strength than other available cloths on the market. As standard we apply two layers of s-glass to each side of the board. The strength to weight ratio really is amazing – All the while gaining flex recoil instead of having a stiff, non flexing, pop out feel like some EPS epoxy sandwich construction surfboards have.

Finally the board is heated in a hot box over night at 35 degrees, this ensures curing times are sped up during the first 72 hours of the board’s life. Heat is a really important factor when using epoxy resins, the right temperatures must be maintained in order to exploit the epoxies characteristics.

The Finish

Once the board has been in the hot box, we apply a 100% sand finish to the board which we believe is the strongest and lightest method to finish a surfboard. This finishing process is standard on all of our boards and is a testament to our factory staff that they can use this finish on our epoxy boards as well. Flatter sanding, sharper edges and resin gloss give these boards the Ferrari finish they deserve.

The Result

When you bring everything together to form the Superfused E.S.E construction method you are left with a stronger, lighter more durable board that has better flex recoil compared to standard construction boards….. Is it a wheel re-invention? No – it’s just another way of making a surfboard that characteristically can improve the life span of the board and the enjoyment you get from surfing. Better for longer. We are always looking to offer more options whether that be shapes, materials, construction methods or simply aesthetics…. We want everyone to ride the right board for them.