Surf Board

September 2008
EuroSIMA Cluster
Villa Casa Mia - 9 rue des acacias
40 130 Capbreton
France
Tel: +33 (0) 558 721 533
Mail: info@eurosima.com
Web site: www.eurosima.com
Market Study - Surfboards Europe

Technology and market
InovEco
Benoît DANDINE
100 rue de Bahinos
64600 Anglet, France
Tel: +00 33 (0) 685 785 156

Mail: bdandine@inoveco.fr
EuroSIMA Cluster | Manufacturing technology for surfboards 1

September 2008
Contents
I. Surfboard manufacturing technology ............................................................................................. 4
A. Characteristics of composite materials ...................................................................................... 4
B. Basic materials............................................................................................................................ 5
1. Resins ..................................................................................................................................... 5
2. Fibre reinforcement ............................................................................................................. 11
3. Foam blanks ......................................................................................................................... 19
C. Types of construction ............................................................................................................... 23
1. Single layer lamination......................................................................................................... 23
2. Sandwich construction ......................................................................................................... 23
3. Hollow boards ...................................................................................................................... 26
D. Lamination methods ................................................................................................................ 27
1. Open contact lamination ..................................................................................................... 27
2. Vacuum molding .................................................................................................................. 27
3. Infusion ................................................................................................................................ 28
4. Preimpregnated fabric ......................................................................................................... 29
E. Conclusions and perspectives .................................................................................................. 30
II. The surfboard market.................................................................................................................... 32
A. Market typology ....................................................................................................................... 32
1. In the United States ............................................................................................................. 32
2. In Europe .............................................................................................................................. 33
B. European production of surfboards ......................................................................................... 35
C. The manufacturers ................................................................................................................... 36
1. Resin and fabrics .................................................................................................................. 36

September 2008
2. Foam blanks ......................................................................................................................... 38
3. Fins and fin plugs.................................................................................................................. 39
4. Specialised Surf suppliers..................................................................................................... 39
5. Shapers................................................................................................................................. 40

September 2008
I. Surfboard manufacturing technology

Nowadays all surfboards are composed of composite materials as these enable boards to be made
that are both very resistant and light. They therefore improve the board’s specific mechanical
performances.
Composite material is engineered from the association of several basic constituents that are
significantly different in nature. There are two basic constituents: the reinforcement and the
matrix, each having a particular function within the material as a whole.
Since the closing down of the largest, worldwide manufacturer of foam blanks (the company Clark
Foam in the United States), a multitude of new materials have appeared and, after a period of nearly
50 years with very little development, a new age has dawned for shapers and surfers who are
enjoying a new Eldorado of innovative technology.
A. Characteristics of composite materials

Mechanical properties of composites cover three fundamental concepts, that is:
• stiffness, expressed by Young’s Modulus (or module of longitudinal elasticity, E),
• mechanical resistance (σ), which measures the breaking point of material under tensile,
compressive and shear stress,
• density (d), less dense than metals with at least the same mechanical performances.
These characteristics comprise the essential parameters of a composite material and guide the
technical choices in their use.
It is possible to use computer technology to model and calculate the physical stress factors affecting
surfboards, which, for the moment, is not common. The arrival of R&D teams, such as the Burton
testing laboratory working for Channel Islands surfboards, will undoubtedly lead to more innovations
and professionalism in the research of new materials.

September 2008
B. Basic materials
There are two basic constituents that make a surfboard: the resin (or matrix) and a reinforcement
fabric. According to the manufacturing technique, a core may be used, in which case one or several
types of foam are used that provide the board with additional mechanical properties.
1. Resins
The resins most used by shapers to manufacture surfboards are thermosetting resins. During their
polymerization these resins acquire an irreversible stiffness. From an initial malleable phase, the
curing process results in a cross-linking of the resin and the formation of a 3-D network of bonds.
Resins are easy to apply and they set in just a few minutes. These resins should not be confused with
thermoplastic resins that may be melted down and recycled. Thermosetting resins have good
mechanical and above all thermo-mechanical performance.
a) Unsaturated polyester resin

To date most surfboards have been manufactured using unsaturated polyester resin. Several
performance ranges exist and for pricing reasons, shapers often use orthophtalic resin. This resin is
relatively fragile and is not entirely hydrophobic which may seem contradictory given its use in water.
Advantages Disadvantages
Good adherence to fiberglass Flammability (except chlorinated resins)
Translucent Resistance to vapor and boiling water
Good chemical resistance Significant shrinking (6 to 15%)
Easy to handle Limited storage in pot
Heat resistant (> 150°C) Emission of styrene
Low cost
Isophtalic resins have more attractive properties and their cost is beginning to diminish. They show
better resistance to shock and are more resistant to humidity. It would be interesting to use this
type of resin more.
The main drawback of polyester resin is the presence of styrene, which is a solvent that has a major
toxicological impact. It is listed as being potentially carcinogenic in certain countries and Average
Exposure Values (AEV) for workers subjected to styrene fumes are very low in Northern European
countries.

September 2008
There now exist Low Styrene Emission (LES) or Low Styrene Composition (LSC) polyester resins that
enable concentrations in the air to be diminished, but nevertheless, even with these resins, it is not
possible to work without general ventilation.
Certain benchmark resins used by shapers are already Low Styrene Composition resins (SILMAR
SIL66BQ-249 resin).
Industrialized Countries AEV (period of 8hrs / ppm
United Kingdom 100
France 50
USA 50
Japan 50
The Netherlands, Denmark 25
Germany, 20
Sweden, Finland 20
Average Exposure to styrene Values that should not be exceeded
b) Light-activated resins
This type of resin hardens when exposed to a ray of light with a specific wavelength. The use of a
peroxide type catalyst is therefore not necessary to ensure the polymerization of the resin. They can
be cured by conventional procedures that avoid technology transfer and changes in usual practices.
These resins must be exposed to ultraviolet lighting, under luminescent tubes (commercial UV,
solarium lamps).
As hardening takes place in the direction the UV rays penetrate, in just a few seconds a hardened
skin forms on the surface that seals the styrene. Therefore, fumes are not diminished during
laminating but rather when the resin is hardened. As soon as the lamps are switched on, a hardened
layer forms on the surface, which is sufficient to prevent the styrene from evaporating.
Today, most standard polyester resins or vinylester resins can be composed in such a way that they
harden when exposed to UV rays. The compositions are, for example, based on aromatic ketones as
UV initiators and are used with amine accelerators (methyldiethanolamine).
In order to ensure good reticulation of the UV resins, it is necessary to observe certain

implementation criteria. Thus, lamps with wave lengths adapted to the product should be used.

September 2008
Generally, these fall within a range of 360 – 420 nm; the speed in which reticulation takes place is
influenced by the strength of the lamp and its distance from the board. It should be noted that it is
possible to use lamps that do not emit short wavelengths, which enables potential hazards to the
eyes or skin to be avoided.
Sun light causes a reaction but is relatively slow and resin that remains in premises that are simply lit
by filament light bulbs remain usable.
Thanks to this type of reticulation, UV polyester resins have numerous advantages over classic resins:
• They have an infinite gelation time as long as they are not exposed to specific UV
wavelengths and this enables resin consumption to be limited during laminating. Excess
resin applied during laminating may therefore be recuperated and used for the next
surfboard.
• Also, the use of UV resins enables the quantities of solvent used for cleaning tools in the
workshop to be considerably reduced as they are cleaned less frequently, which is better for
the environment and uses up less time. Tools, for example, may therefore be cleaned just at
the end of the day, and their lifespan is incidentally increased.
On the other hand, UV polymerization is only possible for transparent systems. When boards are
decorated with thick stickers, a normally catalyzed resin should be used over these precise zones in
order to avoid problems of non-reticulated resins.
Feedback on the use of these resins is good, especially in terms of UV aging. They have been used for
a number of years now and shapers who use them are satisfied with the results.
Few general suppliers offer this type of product and pre-formulated resins should be bought directly
rather than adding a UV polymerization initiator into a classic resin oneself. Indeed, a UV resin
formulated by a manufacturer has the advantage of being more easily replicated for different lots.
Also, the supplier will be able to give details about the lamps (wavelength, strength) to be used in
order to ensure the correct implementation of the product.
The cost of this type of resins is generally much higher than for standard resins (> 3.5 Euros / kg) but
it is possible to recuperate the non-polymerized resin and there is a reduction in the consumption of
solvents.

September 2008
Resins reticulating under UV seem to be, in principle, an interesting technical solution that limits the
emission of styrene during the manufacture of surfboards. According to the situation, it would be
possible to reduce the emission of styrene by 60 g/m². Measurements of styrene were carried out in
workshops using light-activated resin by the association Clean Shaper and results showed a
significant reduction of 20 to 30% in the concentration of air-borne styrene thanks to this type of
resin.
Measurement of styrene concentration during glassing stage (source association ACS)
c) Epoxy resin
Epoxide resins are different from polyester resins in their good mechanical properties, resistance to
temperature, only slight shrinkage and low water absorption. Besides, they show high resistance to
UV when the compounds are stabilized. These resins are generally used in the manufacture of stiff
surfboards. However, sometimes post-curing is necessary in order to stabilize the resin’s properties.
These resins are generally much more costly than polyester resins.
Advantages Disadvantages
Mechanical, thermal, chemical and fatigue resistant High price
Slight shrinkage (1 to 2%) Sensitive to humidity and UV
Excellent adherence on fiber Ages with heat
Self extinguishing Sensitive to shocks
Easy to work, no solvents Time required for polymerization (curing) > polyester

September 2008
Epoxide resins also have certain toxic characteristics particularly through contact with skin. The
epoxide group is very aggressive due to its high reactivity with numerous substances. Resins based
on non-modified bisphenol A do not, in general, provoke dermatoses when in contact with the skin
as their molecules are too large to be able to easily penetrate the epidermis. A long chain resin, for
example a semi-solid, and, in particularly, a solid resin, presents less risk than a liquid resin.
Particular attention should be paid to:
• reactive diluents, the molecule of which is shorter than that of bisphenol A based resins
(because of this, increased vigilance is required for diluted resins than for non-modified
resins).
• certain amine cross-linkers (hardeners), such as TETA (triethylenetetramine) have very low
viscosity, which is likely to lead to contact allergies.
• above all, solvents that lower the viscosity of resin and carry the resin molecule under the
skin after having destroyed the epidermis’ protective sebum secretion.
Resins used to manufacture surfboards are generally very fluid, and therefore it is necessary to be
extremely attentive to risks of allergy. Any solvents that may be used to wash arms and hands in the
workshop should be banned. On the other hand, it is strongly recommended to frequently wash
hands using special soaps (for example, acid soaps when handling basic hardeners such as aliphatic
amines). It is also recommended to equip workbenches with paper towels that are renewed each
day, so that the paper towels are thrown away after use (and therefore, rags are not used that
remain impregnated with chemicals, which may contaminate the skin).
Wearing safety glasses and protective gloves is obligatory not only in critical points within the
workshop, but also at moments when certain dangerous operations are carried out. If necessary, it is
possible to contact the resin suppliers’ specialist advisor in order to obtain advice on health and
safety. If these recommendations are not respected, there is risk of irritation of the ocular and
respiratory mucous membranes and sensitive areas (face). This risk is even greater in people prone
to allergies, in particular when handling amine aliphatic type hardeners.
In addition, particular vigilance is required in the use of certain amine hardeners which may be
carcinogenic (request Safety Data File from the supplier and obtain information from the
occupational doctor).
However, the use of new products, which are amines compounded on epoxy resin frames, has
theoretically reduced the risk of dermatoses.

September 2008
d) Vinylester resin
This resin can be considered as a polyester variant, produced from acrylic acids and shows good
resistance to fatigue and corrosion. Vinylester resin has greater mechanical characteristics than
classic polyester resins and is less expensive than epoxy resin.
The major disadvantage lies in its color, which is brown or beige. Today, very few surfboard
manufacturers use this resin because of this inconvenience.
e) « Ecological » resins
New vegetable-based resins are appearing on the market. One of them is especially marketed for
the manufacture of surfboards (www.suscomp.com). It is composed of 96% vegetable products and
4% UV light initiators. VOC measurements have been carried out on this resin and have shown that
there is no trace of VOC. On the other hand, both the technical file and safety data file for this
product are very evasive; breakdown tests by a specialized laboratory are necessary in order to
determine if styrene has been substituted by other toxic components.
Besides, the resin in question does not yet have satisfactory mechanical properties in terms of
resistance to shock and compression, which explains why this resin is not used on a large scale in the
manufacture of boats.
International offers for biocomposite materials are regularly updated on www.biopolymer.net

September 2008
2. Fiber reinforcement
The fiber is comprised of a greater or lesser number of filaments; carbon fiber, for example, is usually
comprised of 1,000 filaments and sometimes up to 10,000 filaments.
Fiber is used, in the first place, as it enables the likelihood of fracture to be reduced. Risk of sudden
fracture is closely linked to the size of the defect in the material. Since the surface is reduced, fibers
show greater resistance to fracture than solid materials, while preserving the same main
characteristics.
According to the application and the anticipated mechanical properties, fiber reinforcement can
represent between 30 and 70% of material volume. For « High Performance » manufacture, a high
level of reinforcement is necessary.
Fibers can be used in the form of threads, lines of fibers, strands or be semi-transformed. They are
essentially mats and fabric. Distribution of mats is uncertain and fiber volume is generally lower than
that of fabric, which implies lesser mechanical characteristics.
Fibers are characterized by certain data, in particular their linear mass density (which is the mass in
grams per 1,000m length expressed in “tex” or “denier”) and their mechanical properties (strength
and stiffness). The mass of reinforcement to the square meter is evaluated by the areal weight. The
breaking point of a thread under traction is called the tenacity (expressed in Newton N).
The highest performing fibers are thus the finest fibers. The diameter of usual fibers is typically from
5 to 15 µm.
The orientation of fibers in the most solicited

directions result in the elaboration of
anisotropic materials, i.e. materials whose
properties are not identical in all directions.
The fibers have more interesting properties
lengthwise (parallel to the direction of the
fibers) rather than crosswise (perpendicular to
the fiber).
One way in which the mechanical properties of

surfboards may be improved is by better
understanding their conditions of use. Some
areas on the surfboard are subject to greater external constraints than others (foot rest areas, rail
shock, etc.) and consequently compromise the performance of the whole unit. This behavior can be
improved by reinforcing these sensitive zones.

September 2008
These properties are used in the manufacture of skis and snowboards but, at the moment, not for
surfboards.
Classification of reinforcement fibers according to their origin
a) Fiberglass
Textile fiberglass was really produced on an industrial scale in the 1930s. First used as an insulation
material for electrical conductors, the first applications with resin followed several years later. When
taking all types into account, fiberglass is without doubt the most used material in composites in the
world at this time, and especially in the manufacture of surfboards. Not only is this material
extremely flexible to use, fiberglass has an excellent mechanical performance and is good value
If the different fiberglass categories have varied qualities, fiber production is, at least, common to all.
This process has five main stages:
1. Refining at 1,500 °C: the mixture is heated and becomes first viscous (around 800°c), then
liquid and finally it vitrifies. At 1,500°C it is homogenous and the last bubbles of impurity
disappear.
2. Continuous filament by drawing: the molten glass is transformed into threads by being
stretched at high speed; spinning of glass threads is very much like the classic procedure to
produce textile yarn. This glass thread is then wound round a spool.
3. Filament coupling: drawing and winding is not sufficient to join, on a permanent basis, the
hundreds of filaments into one thread (the glass is too smooth to agglomerate). Filament
coupling consists in adding a protective binder in order that the filaments may be
agglomerated and facilitate integration into the polymers.
4. Finishing: the thread is then wound onto a spool or cut according to final use.

September 2008
5. Oven drying: the threads are finally dried at temperatures of between 600 to 700°C.
In adjusting the composition of this mixture, it is possible to vary the properties of the glass
• E-glass is most used in the manufacture of textile glass fibers,

• R-glass (or S) is also called aeronautic glass, and is used in high performance applications
• D-glass, which has good dielectric properties, is used in electronics
• C-glass, is resistant to acids and is used as surface material
Comparison of different forms of glass fabric
b) Carbon fiber
Carbon fiber is comprised of extremely fine fibers, between 5 to 15µm in diameter, and is mainly
composed of carbon atoms. The carbon atoms are arranged in microscopic crystals that are more or
less parallel to the length of the fiber.
The alignment of the crystals makes the fiber incredibly resistant in relation to its size. Many
thousands of carbon fibers are wound together in order to form a thread that may be used as such or
woven.
Carbon fibers are characterized by their light density, high tensile strength and resistance to
compression, flexibility, good electrical and thermal conductivity, heat resistance and chemical
inertia (except oxidation).
Carbon fibers have a theoretical resistance of 20,000MPa and maximum stiffness is evaluated at
1,200,000MPa. For other materials, these values are clearly lower (for example, high performance
fiberglass has theoretical resistance of 4,400MPa and maximum stiffness of 86,000MPa).
Carbon fiber is therefore more stiff and resistant than fiberglass. In equal quantity, it is able to bear
greater stress and distorts very little. It is lighter but it also breaks more easily as it does not bend
under stress. Therefore attention should be paid to the risk of being cut by a broken carbon
surfboard (carbon fiber splinters should also be avoided). To compensate for this shortcoming, it

September 2008
may be associated with Kevlar© but the manufacturing price of such a surfboard then becomes
prohibitive.
Carbon tends to absorb more resin than an equivalent fiberglass fabric, and it is for this reason that it
is advisable to carry out glassing in a vacuum if the aim is to save on weight. It is also necessary to
use a high performance epoxy resin in order not to diminish the mechanical advantages of the
carbon.
Moreover, as the density of carbon, which is more resistant, is 1.4, and that of fiberglass is 2.4, for
the same resistance under continuous stress, fabric that is two times lighter (3oz instead of 6oz) may
be used, thus giving rise to an interesting saving in weight.
Application of carbon on the rails (as for RT

Surfboards or Bourton surfboards) aims at keeping
the rail in good condition for longer, especially
around the tail, which is indeed a very important
but fine area subject to multiple stress factors
(bearing down hard for snaps and cutbacks, impact
landing on air maneuvers, etc.)
The use of « parabolic » rails has recently appeared; these rails are situated on the surfboard rails
and no longer in the central part. Now most large scale manufacturers of foam blanks have a range
of blanks with parabolic rails (whether for PU or EPS blanks).
The company Firewire (see following page) even has a system of balsa rails with carbon tubes that
are linked from the board’s tail to its fins. According to this company, the reactivity, trajectory
precision and flex of these boards is incomparable.

September 2008
Board with carbon rails linked to fins (www.firewiresurfboards.com )
It should be noted that the cutting out of fabric and sanding of carbon fibers is not difficult when
compared to Kevlar© and Dyneema© fibers that are extremely difficult to cut without specific tools.
Carbon fibers have a certain number of disadvantages that should not be forgotten: recycling is
difficult (especially the shredding stage), electrical conductivity may pose a problem during storms,
and its structure is close to that of asbestos – precautions should therefore be taken when working
with this material.

September 2008
c) Aramid fibres
Aramid fiber was invented by the company DuPont and, from 1971, was marketed under the brand
name Kevlar©. These synthetic fibers possess exceptional tensile strength and resistance to
elongation. Only spider webs (3 times stronger) and nanotubes (100 times stronger and 6 times
lighter) can better its performance.
Its advantages:
• Good tensile strength
• Light density (1.45)
• No thermal dilatation
• Vibration absorption, shock absorption
• Excellent resistance to shocks and fatigue
Its disadvantages:
• Low resistance to UV rays
• Low resistance under pressure
• High humidity absorption (4%)
• Weak adherence with infusion resins
• Very difficult to machine (especially cutting and sanding)
The main interest in using aramid fibers is therefore down to their capacity to absorb vibrations.
This ability means that they are, for example, very resistant to impacts (hence their use in bullet-
proof vests), but above all they allow a certain “comfort” in boards in
case of choppy waves.
For example, under a top-of-the-range snowboard it is possible to

put two bands of Kevlar around the base edges and therefore absorb
certain high frequency vibrations that are barely perceptible by the
user but which may cause the rider to fall.
It is therefore interesting to put in Kevlar reinforcement on the

surfboard bottom; putting it on the top however would be pointless.
« Titanium Series » surfboard with Kevlar reinforcements from the

company Proctor (www.proctorsurf.com )

September 2008
d) Fabric derived from renewable resources

Natural fibers (hemp, linen, jute, cotton, kenaf, etc.) have numerous advantages over synthetic fibers
(low cost, derived from renewable resources, biodegradable, specific mechanical properties). Using
them is one way to reduce the impact of surfboard manufacture on the environment.
After different trials (testing density, hardness, and flexural strength) carried out on composites that
had been reinforced by these fibers, it may be concluded that the mechanical characteristics of
composites reinforced by linen, hemp and basalt fibers are inferior to those reinforced by fiberglass,
which explains the limited development of these fibers in the field of composites. These types of
fibers can be used to reduce costs, as they are less expensive than resin, but not to improve the
mechanical characteristics.
Comparison of Young’s modulus according to type of reinforcement used (source CARMA Matériaux)

September 2008
It is clear that for contact lamination, the mechanical properties of renewable source fabrics are
widely inferior to those of glassfiber.
Other inconveniences can be holding back the development of these organic materials, such as the
difficulty in reproducing the working method (non industrial), non-homogeneous physical properties
(the quantity and quality of the fibers depends on the environment and humidity). Therefore these
fibers are currently being developed.
Most suppliers of these fibers are situated abroad, mostly in Germany and Holland. These two
countries seem to be quite advanced in terms of potential use of natural fibers in composite
materials. In France, there are very few suppliers of natural fibers. Some French companies
specialize in bamboo and linen fibers.
Composites reinforced with natural fibers are still little used and they are being developed. Large
scale development is currently concentrating on:
• Setting up production and distribution networks to meet the industry’s needs;
• Increased knowledge of these materials (performance, handling, biodegradability,
identification of these complex structures, etc.)
• Setting up recycling networks (dismounting and waste management)
• Further developing biopolymers at a competitive price
• The development of industrial technologies in order to transform these vegetable fibers (as
can be already be done for the textile, paper and wood industries)

September 2008
3. Foam blanks
a) Polyurethane
Polyurethane foam can be used in the manufacture of surfboards with polyester or epoxy resin as
this foam is able to support both types of matrix. It is a mixture between two main constituents:
isocyanates and polyols. Foam blanks available may be classified according to the type of isocyanate
used (TDI or MDI).
TDI (toluene diisocyanate) contains Toluene which has a “Toxic +” rating, and it is vital that people
working in factories handling this substance be protected (general ventilation and individual
protection). It is easy to imagine that work conditions are not always the same in each of the
manufacturing countries (United States, Brazil, China…)
There is also a risk at the time of pre-shaping and shaping the board when levels of isocyanate may
be released according to the quality of the foam. Studies are necessary in order to determine the
level of exposure experienced by workers when handling this type of foam.
Certain companies now offer foam blanks with MDI (methylene diphenyl diisocyanate) replacing the
TDI. The constituents are less dangerous than the toluene and therefore present less of a health and
environmental problem. Nevertheless, it is still a product listed as being “harmful if inhaled” and an
“irritant”.
Some companies have even succeeded in incorporating vegetable material in the foam composition
by substituting the polyol derived from petrol by a vegetable polyol. This is a true step forward in
eco-design since the foam components are both less dangerous for health and the environment as
well as being derived from renewable resources (from 30% to 40% of the foam constituents are
derived from vegetable matter, the rest coming from petrol).
(www.homeblown.co.uk ) (www.iceninefoamworks.com )

September 2008
However, this type of foam is not completely ecologic as it is not recyclable and for the moment
there is no recuperation network other than incineration with subsequent energy recuperation or
burying in an adapted waste site.
b) Polystyrene
This foam is being used more and more as it is lighter and floats better than polyurethane foam.
Polystyrene (PS) is only used with epoxy resin, which has good shock resistance qualities and lasts
over time. It is therefore possible to make boards that are lighter, float better and are more shock
resistant.
Manufacturing costs for a polystyrene-epoxy surfboard are higher than for polyurethane-polyester
boards as epoxy resin is more expensive than polyester resin and it is also more problematical to use.
PS is recyclable and a collection system exists on both a national and international scale with PS
manufacturers who recuperate polystyrene off-cuts from companies using this material or waste
management units in order to remanufacture polystyrene. It is therefore a more ecological material
than polyurethane foam but it should not be forgotten that the main constituent of PS is styrene
(listed as being potentially carcinogenic in some countries).
According to the manufacturing process of foam blanks, the density and therefore the quality of the
blank may not be homogeneous. Indeed, there is a great difference between a foam blank
manufactured in a mould with a precise density and a foam blank manufactured from a block of
polystyrene foam that has just been cut by a hot wire into a pre-shape. The distribution of air is not
homogeneous in the latter and certain fragility in the blank is to be expected. Therefore, polystyrene
blanks should be manufactured from a mold.
Examples of companies manufacturing molded EPS blanks:
(www.markofoam.com ) (www.usblanks.com )

September 2008
(1) Expanded polystyrene

Expanded Polystyrene (EPS) is obtained from a mixture of gas and translucent polystyrene. Before
concerns for the ozone, Freon, a CFC (chlorofluorocarbon), was used. Since the 90s this has been
replaced by butane or pentane.
Molecular structure of polystyrene
EPS is interesting foam to use in the manufacture of surfboards but the macro-polystyrene balls that
have been bound together give the board a sensation of resonance in rippling waves that most
surfers do not appreciate.
Expanded polystyrene has, however, a certain memory of shape, i.e. instead of remaining
permanently dented, it returns to its initial form, after being crushed for example. Therefore, it has
excellent resistance to fatigue due to repeated flexions and it allows for inner shear stress (hence the
flex) without premature fatigue, unlike polyurethane.
Once laminated, it shows good resistance to delaminating thanks to greater resin penetration.
(2) Extruded polystyrene

To compensate for the phenomenon of resonance in choppy waves, it is possible to use extruded
polystyrene foam (XPS).
Extruded polystyrene has a harder aspect as well as being more regular and homogeneous than
polyurethane foam and it does not swell in water. However it is much more subject to delaminating
as it still contains, in its closed cells, the gases used in its manufacture. These gases are liberated
during hot spells and lead to increased risks of delaminating.
It is for this reason that some companies effect a series of micro-holes when glassing the board in
order to let the gas evaporate (Thermovent© technique patented by the company Epoxy
Surfboards). Foam in closed cells does not imbibe water, so therefore there is no risk of increased
heaviness in the board.

September 2008
The monolayer laminated construction allows the board to conserve all its flexibility and the epoxy
resin limits denting.
Examples of companies using XPS foam blanks :
(www.fcdsurfboards.com ) (www.epoxysurfboards.com )

September 2008
C. Types of construction
1. Single layer lamination
a) The principle
Single layer lamination is the technique used by most shapers as it is quick and relatively easy to
master. It involves impregnating one or two layers of reinforcement fabric, which have been laid on
a core, with resin.
A single layer of fabric enables the board to be very light and therefore very easy to handle. Most
world class surfers use this type of construction but there is a price to pay in the considerable
number of broken boards.
Indeed, such a composite is not at all solid since there is hardly any reinforcement fabric.
b) The costs
This is the quickest and cheapest method in terms of raw materials. The boards are very easily
repaired at very low cost, which provides shapers with an additional source of revenue.
2. Sandwich construction
a) The principle
In order to improve the mechanical characteristics of surfboards, it is possible to use a sandwich
construction, which consists in reinforcing the core material with “skins” that are highly stiff yet thin.
Sandwich construction requires the use of vacuum lamination techniques in order to obtain
homogeneous material.

September 2008
EPS sandwich construction from the company Surftech (www.surftech.com )
Polyurethane sandwich construction from the company Bic (www.bicsportsurfboards.com )
EPS sandwich construction from the company Bic (www.bicsportsurfboards.com )

September 2008
Some companies have specialized in the manufacture of High Technology boards with very advanced
mechanical characteristics. These companies have developed specific cores composed of high
performance materials (use of aluminum honeycomb, high density foam) linked to high performance
resins and carbon/Kevlar reinforcement fabric.
Aeroflex foam blank from the company HydroEpic (www.hydroepic.com )
Hydroflex foam blank technology developed and used by the company Bufo Surfboards
(www.bufo-boards.com )

September 2008
3. Hollow boards
In the 1930s, surfboards known as « hollow »boards were developed. Indeed research to find lighter
and higher performance boards than the balsa boards widely available at that time was rapidly
directed towards an empty structure filled with air, which enabled the board to be lighter and float
more easily.
Not having a core considerably lightened the board, but this can hamper some surfers who are used
to having boards displaying certain inertia. Materials used to make the shells are High Performance
materials (carbon reinforcements, high performance epoxy) and that implies higher board durability.
The sale price is often calculated as follows: “the board lasts twice as long so I’ll sell it for twice as
much”. But with a high sale price, some companies, such as Salomon with the S-Core, did not
succeed in finding their market niche, and this should lead to some serious thinking about “high
tech” boards.
2-piece folding board from the company Pope Bisect (www.bisect.com )
« Full Carbon » surfboard from the company Aviso (www.avisosurf.com )

September 2008
D. Lamination methods
1. Open contact lamination
a) The principle
Open contact lamination consists in applying resin on layers

of reinforcement fabric (stack manufacture). This is an easy
and quick technique but the mechanical performances
obtained are low and work conditions are difficult (exposure
to strong concentrations of solvent giving rise to respiratory
and skin problems).
b) The costs
It is the least costly in terms of time, consumables and investment and therefore still represents 80%
of water sports equipment manufacture.
2. Vacuum molding
a) The principle
This technique first appeared in the manufacture of windsurf boards and was developed to improve
board resistance and lighten the floaters. It was adapted to the manufacture of surfboards by
companies, especially French companies such as Waves Surfboards (François PACOU www.waves.fr ).
It consists in creating a vacuum in the membrane covering the surfboard that has just been
laminated. It allows ideal resin impregnation of the reinforcement fabric and also facilitates
successful glassing as the quality of glassing is less dependant on external factors (less handling,
humidity, ambient temperature, etc.)
b) The costs
On the other hand, more time is required to make one of these boards and the cost price of the
board is therefore much higher. Companies such as Cobra in Thailand use this technology as labor
costs are lower.

September 2008
Cobra factory in Thailand (www.cobrainter.com)
3. Infusion
a) The principle
Infusion is a technique that comes from the water sports industry. It consists in creating a vacuum
within a bag surrounding the surfboard then allowing the resin to flow through ports that imbibe the
reinforcement fabrics in ideal proportions.
The mechanical properties of the surfboard are again improved but this technique is still at the
experimental stage and presents major inconveniences for craft production: very long preparation
time for each board and the use of numerous non-reusable consumables.
Diagram showing the principle of mold infusion
In theory, it enables work conditions to be improved as the quantity of solvent released into the
atmosphere is limited or even non-existent.
September 2008
b) The Costs
The infusion technique uses up a lot of time and consumables per board; a project is underway in the
Aquitaine Region that is looking into how these factors may be diminished and is being carried out by
a research laboratory Rescoll (www.rescoll.fr ), a design office specialized in composites Lof Tech
(www.lof-tech.com ), a local resin manufacturer CIRON( www.ciron.com ) and the association Clean
Shaper (www.cleanshaper.com) .
4. Preimpregnated fabric
a) The principle
The principle of lamination with preimpregnated fabric consists in draping the object to be laminated
with fabric preimpregnated with resin then placing the
object in an oven (kiln) to be cured; this improves the
technical characteristics of the object.
The process of draping these prepregs without adding any

additional resin can be summarized as follows:
- Compacting under a vacuum bag or press

- Use of a kiln
- Curing / polymerization: the flexibility of the resin
systems enables polymerization at 82°C for 12 to
15 hours or polymerization at 120°C for 30 minutes.
Autoclave belonging to the company Cameron Aircraft that produces surfboards made using preimpregnated
fabric (http://cameronaircraft.com/surf/index.htm )

September 2008
Preimpregnated aramid fabric is often used for hulls since it enables the structures to be lightened
and results in greater shock and deterioration resistance. Preimpregnated glassfiber is used to
produce thick, shock-resistant pieces at a reasonable price.
b) The costs
Apart from the investment in an autoclave, production costs are almost the same as those for classic
lamination but the finished product has far greater mechanical properties and the work conditions
are much improved.
E. Conclusions and perspectives

Concerning the Technical part, several paths of development should be explored:
- Reinforcement fabric: study and analysis of the stress to which a surfboard is subjected
when standing on it should enable the most called-upon parts of the board to be reinforced
with suitable fabric (multi-axial, carbon or aramid fabrics). Technological monitoring should
also be carried out on vegetable-based reinforcement fabrics that have, for the moment,
inferior mechanical properties compared to classic fiberglass. However research is currently
being carried out in laboratory programs in order to find high performance bio-fabrics such
as preimpregnated linen fabric (www.lineo.eu).
- Resins: orthopthalic polyester resin should no longer be used as its mechanical properties are
too low in relation to the solidity required by consumers. Resins such as isophtalic resins,
vinylester resins or DPO polyester should be studied and applied in order to increase
surfboard resistance. Caution should be shown with regards to so-called “ecological” resins,
the toxicity of which has not really been studied and described in safety notices.
- Foam blanks: TDI polyurethane foam blanks should be abandoned due to their toxicity both
in production and sometimes during shaping (isocyanate release). Extruded polystyrene
should be given priority due to its potential for recycling and also because this foam does not
absorb water when cracked or when the resin breaks (which is the contrary to expanded
polystyrene).
- Laminating techniques: open contact lamination should be limited due to both the
toxicological risks incurred by the shapers and the minimal mechanical properties of such a
construction method. “Vacuum” methods (vacuum or infusion lamination) are interesting
but require increased preparation time per board and this will penalize the craftsmen’s
output. Use of preimpregnated fabric adapted to the manufacture of surfboards seems to be
an interesting technological path to follow for craftsmen if a collective project is set up in
order to invest in an autoclave and if manufacturers of preimpregnated fabrics design a
suitable fabric-resin mixture.

September 2008
The field of thermoplastics should also be explored as these composites have very good
shock-resistance characteristics and are easily recyclable. On the other hand, the use of
molds means that a made-to-measure consumer service is not possible and this is a
contradiction to the craft approach to surfboard manufacture.
To date, there is no « miracle » surfboard that possesses all the characteristics that interest a surfer:
shock resistance, flex maintained throughout its lifespan, reactivity, aesthetic appearance, non-toxic
for shapers and the environment…
For the moment, the following analogy can be made to compare polyurethane/polyester boards with
polystyrene/epoxy boards. The polyurethane/polyester board is like an apple – it has a dense and
homogeneous core with a fine and fragile skin whereas the polystyrene/epoxy board is like an
orange with a delicate and heterogeneous core and a thick and stiff skin. Ideally, the flex properties
of the core should be combined with more solid lamination.
Numerous projects are under way in order to improve the mechanical and ecological properties of
surfboards. We can cite:
• Work carried out by the association Clean Shaper, working on improving work conditions and
conducting tests on new lamination resins (UV bio-resin, vinylester resins, low emission
epoxy resins, bio-fabrics, optimization of UV lamination, development of locally-produced
XPS foam…)
• The « Styrene Free » project led by Rescoll, Loftech, Ciron and ACS for the development of an
infusion lamination technique.
• Work carried out by the company UWL (www.uwl-surfboards.com ) on the manufacture of

an eco-design surfboard (Eurosima award 2008)
• Other projects are being carried out by private structures that, for the moment, have chosen
not to divulge the details of their work.

September 2008
II. The surfboard market

A. Market typology
1. In the United States

A study was carried out by the American Surfing Magazine at the end of 2007 into the breakdown of
surfboard sales according to their typology (P/U, Sandwich, High Tech and Epoxy). This study was
based on a sample of 15 surf shops representative of the American market and on 22,804 boards
sold.
P/U: 70 %
The majority of boards sold by the surf shops in the study are classically constructed boards in
polyurethane/polyester. Even if sales of boards made using other technology have increased since
the closure of Clark Foam, the use of polyurethane foam blanks is by far the most common type. The
“Top 44” effect surely has something to do with this. Polyurethane foam blank manufacturers have
filled the gap left by Clark Foam and competition has played an important role in the development of
innovations.
Molded Sandwich (Surftech, Placebo, NSP…): 23 %

The market for molded boards is increasing each year and they are attracting more and more surfers.
The company Surftech is banking on using the names of recognized shapers, the increase in the
durability of the board through the use of epoxy resin and an impressive marketing plan to develop
even further their breakthrough into this market. The offer has grown over the whole range from
beginner boards (such as NSP) to boards with incisive shapes for the most demanding consumers

September 2008
(these brands are manufactured in the same Cobra factory in Thailand by companies such as Surftech
or Global Surf Industries).
High Tech (Firewire, Aviso, TL2…): 1 %
So-called « High Tech » boards use high performance materials and construction techniques which
result in high prices. For the moment, they only represent a very small percentage of surfboards
sold. The company Salomon even had to stop production when faced with the small quantity of
boards sold, in spite of using very promising coreless board technology. Imports into the USA of
traditional Australian surfboards, which are well-known but less expensive (DHD, JS and Chilli), are in
direct competition with the High Tech up-market boards.
Epoxy (craftsmen shaper, EPS or XPS): 6%

Even with companies like Channel Islands, Lost or Rusty offering a complete range of epoxy
surfboards, surfers have not yet made the conversion to epoxy boards (Rusty Preisendorfer has a
range of boards using 40% EPS). To date, surfers are showing more interest in molded epoxy
sandwich boards developed by companies such as Surftech and Placebo.
This study is interesting insofar as it shows the current stakes involved in different surfboard
manufacturing techniques. The purchase price of High Tech boards seems to be an obstacle for most
surfers. They will rather buy well-known brand boards that are both traditional and less expensive
(P/U) or a little more resistant but not too expensive (Surftech).
The same type of study could be carried out in Europe in order to have a better understanding of
consumer developments and to see if traditional construction still has a bright future.
2. In Europe
A study was carried out by EuroSIMA Cluster as part of it economic observatory on the surf market in
specialized independent multi-brand surf shops. Nearly 115 shops were questioned as part of this
study between October 2007 and February 2008.
It was clear from this enquiry that Bic molded surfboards are by far the most sold brand in these
shops, followed by the brands Surftech and NSP who also market molded sandwich boards.
The customers in these shops are generally not experienced surfers; they are more likely to be
occasional surfers who are looking either for a beginner’s board or for a board that is more solid that
they will not have to repair regularly.
Craft shapers are generally not well-known to this type of public and the idea of having a made-to-
measure board can be off-putting to customers who believe that the sale price will be much higher if
it is a customized craft-made board.
The study showed that Spanish surfers buy Spanish-made Pukas boards in the shops, thus
demonstrating a certain pride and confidence in this brand, while Italian surfers buy imported brands
such as Al Merrick or JS boards.

September 2008
The study indicated that the sale of surfboards has increased by less than 10% in relation to the
previous year. Over the last few years, a slight increase in sales has been regularly noted, which is
understandable given the growth in the number of people surfing.
The study also showed that the brand Al Merrick is the hottest brand, i.e. it is the brand most
requested by customers. The figures show a contradiction between the wish to buy a “hot” brand
like Al Merrick and the reality of buying a low cost and solid board (Bic) since the facts show that it is
indeed the latter type of board that is most often bought. Other hot brands are Pukas, Lost, MOS
and Surf Factory.
It is interesting to note that MOS boards manufactured in Asia benefit from a positive consumer
image (no doubt thanks to an impressive communications campaign in the specialized press and on
internet web sites) and that even Surf Factory boards also enjoy a “hot” image.
There are no French craft made brands in the « hottest » top 3 boards, which demonstrates the lack
of consumer awareness for French craft brands. This lack of awareness stems from a number of
factors, such as the lack of communication from the shapers themselves, their almost inexistent mail
order sales, exclusion from shop distribution networks, impossibility of financially sponsoring
professional surfers who could act as a “shop window”, globalization with imports being exchanged
between all countries of the world, a strong €uro inhibiting exports, etc.
Finally, nearly 120 surfboard brands were named in the study by European consumers, while 56
swimwear brands were mentioned, 30 wetsuit brands and only 17 watch brands. It can be seen that
for markets that are greater in number, there is less competition, which also explains the fact that
shapers have difficulty in selling their products.

September 2008
B. European production of surfboards

September 2008
This map is based on a survey carried out between July 2007 and September 2007 on different sector
targets (shapers, suppliers and foam blank manufacturers).
It follows from this survey that around 45,800 surfboards are sold each year in Europe. Nearly a third
of these boards are industrial (molded) boards. There is no official indication of the number of
boards manufactured in Europe but cross-checks were made between different suppliers who know
their market.
It is also estimated that American, Australian and Asian imports (Surftech, NSP, etc.) represent at
least 15,000 to 20,000 extra boards in Europe. Today, it is very difficult to have precise figures as
there are a number of distribution networks for these boards (imports via Portugal and England) and
importers do not communicate the number of boards that have been brought in.
The number of imported boards increases each year due to the fact that numerous surf shops place
group orders (as is the case for the 25-strong collective Ministry Of Surfing shops) or through
specialized importers (Hoff, GSI, etc.)
In 2008, numerous developments are taking place amount the main European surfboard
manufacturers and after a difficult start to the season in terms of number of boards sold, it appears
that sales are picking up again at the end of the season.
C. The manufacturers
In order to better know the surfboard market, it is indispensible to identify the market’s actors.
1. Resin and fabrics

Name Internet website
Axon www.axon.com
Ciron www.ciron.com
Cray Valley www.crayvalley.com
DSM www.dsm.com
Hexcel www.hexcel.com
Interplastic Corporation www.interplastic.com/silmar_TR.html
Reichhold www.reichhold.com
Resoltech www.resoltech.com
SF Composites www.sf-composites.com
Sicomin www.sicomin.com

September 2008
Few of these manufacturers develop products that are specific to the manufacture of surfboards but
it is important for the shapers and shapers’ suppliers to monitor the technology shown on these sites
in order to discover new resins or procedures.
It would be interesting for European shapers to benefit from a trial laboratory where they could
come to test their products. A grouping of companies would therefore be interesting in order to
motivate resin and fabric manufacturers to regularly propose new products.

September 2008
2. Foam blanks
Country (head office of
Name Internet website Foam blanks
manufacturing site)
Atua Cores France www.atuacores.com EPS
Bennet Oz Australia www.dionchemicals.com TDI, HydroFlex
Bufo Germany www.bufo-boards.com Hydroflex
Burford Blanks Australia www.burfordblanks.com.au TDI
Core Industrues Australia www.coreindustries.com.au TDI
Drilead Sports Equipment China www.chinasurfboards.com XPS
Echo Tech US www.echotechusa.com MDI
Elova Fiam Argentina www.elovafoam.com TDI, MDI
Epoxy Foam US www.epoxyfoam.com XPS
Eskimo Foam US www.eskimoindustries.com TDI
Gudang Compagny China www.gdsurfboard.com XPS
Holfoam France MDI
Home Blown UK www.homeblown.co.uk MDI
Ice Nine Foam US www.ice-ninefoamworks.com MDI
Just Foam US www.justfoamblanks.com TDI
King Mac Foam Mexico www.kingmacfoam.com TDI
Marko Foam US www.markofoam.com EPS
Ocean Foam Australia www.oceanfoam.com.au TDI
Pacifica Foam US www.pacificafoam.com TDI, MDI
Pro Foam US www.fusreps.com EPS
Rhyno Foam Brazil www.rhynofoam.com TDI
S Foam US www.sfoam.com EPS
Safari Foam South Africa www.safarifoam.com TDI
South Coast Australia www.southcoastfoam.com.au TDI
Surfblanks America US www.surfblanksamerica.com TDI
Surfblanks Australia Australia www.surfblanksaustralia.com TDI
Surfblanks South Africa South Africa www.surfblanks.co.za TDI
Teccell Foam Brazil www.surfteccel.com.br TDI, polyols polyester
Tech Blank Foam Spain www.viralsurf.fr TDI
White Hot Foam US www.prowall.com EPS
WNC US www.wncsurf.com EPS
XTR Foam US www.epoxysurfboards.com XPS
X-TRA Foam South Africa www.xtrafoam.com TDI
Numerous foam blank manufacturers are trying to change from TDI to MDI or announce that there is
no higher performing technology than TDI. The offer for EPS or XPS is steadily growing. Even

September 2008
traditional producers of TDI have invested in EPS production lines. The presence of new materials
like Hydroflex©, the license for which belongs to Volkswagen, should also be noted.
3. Fins and fin plugs
Name Web Site
FCS www.surffcs.com
Fins Unlimited www.finsunlimited.com
Future Fins www.futuresfins.com
LokBox and www.lokboxfins.com
O'Fish'L www.ofishl.com
ProBox www.proboxhawaii.com
Rainbow Fin Co www.rainbowfins.com
Red X www.redxfins.com
Surf Co. Hawaii www.surfcohawaii.com
True Ames www.trueames.com
Turbo Tunnel www.turbotunnel.com
Most fins sold in the world are FCS fins; some companies are developing by proposing plugs that are
more practical for the shapers and more resistant.
4. Specialized Surf suppliers

Name Country Internet website
Fiberglass Hawaii US www.fiberglasshawaii.com
Sea Base UK www.seabase.eu
Shapers Australia Australia www.shapers.com.au
Viral Surf France www.viralsurf.fr

September 2008
These specialist Surf suppliers propose equipment and material that is adapted to the manufacture
of surfboards. Sometimes they reformulate resins, have specific foam blanks manufactured, find
high performance principal material… they are, in a way, providing a “monitoring” service, even
“research and development” for surfboard manufacturers.
5. Shapers
There is no European shapers directory and the exact number of companies in this sector is therefore
difficult to establish. In France, there are about 80 shapers who, for the most part, are to be found in
the south west. The number of shapers in Europe has not been estimated.
In France, the internet websites www.shaper.fr and www.shapers.awprod.com list shapers in

mainland France.

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September 2008

Market Study - Surfboards Europe

Tel: +00 33 (0) 685 785 156

EuroSIMA Cluster | Manufacturing technology for surfboards 1

A. Characteristics of composite materials ...................................................................................... 4

2. Fibre reinforcement ............................................................................................................. 11

3. Foam blanks ......................................................................................................................... 19

C. Types of construction ............................................................................................................... 23

1. Single layer lamination......................................................................................................... 23

2. Sandwich construction ......................................................................................................... 23

3. Hollow boards ...................................................................................................................... 26

D. Lamination methods ................................................................................................................ 27

1. Open contact lamination ..................................................................................................... 27

2. Vacuum molding .................................................................................................................. 27

4. Preimpregnated fabric ......................................................................................................... 29

E. Conclusions and perspectives .................................................................................................. 30

II. The surfboard market.................................................................................................................... 32

A. Market typology ....................................................................................................................... 32

1. In the United States ............................................................................................................. 32

B. European production of surfboards ......................................................................................... 35

C. The manufacturers ................................................................................................................... 36

1. Resin and fabrics .................................................................................................................. 36

EuroSIMA Cluster | Manufacturing technology for surfboards 2

2. Foam blanks ......................................................................................................................... 38

3. Fins and fin plugs.................................................................................................................. 39

4. Specialised Surf suppliers..................................................................................................... 39

EuroSIMA Cluster | Manufacturing technology for surfboards 3

I. Surfboard manufacturing technology

A. Characteristics of composite materials

• stiffness, expressed by Young’s Modulus (or module of longitudinal elasticity, E),

EuroSIMA Cluster | Manufacturing technology for surfboards 4

a) Unsaturated polyester resin

Good adherence to fiberglass Flammability (except chlorinated resins)

Translucent Resistance to vapor and boiling water

Good chemical resistance Significant shrinking (6 to 15%)

Easy to handle Limited storage in pot

Heat resistant (> 150°C) Emission of styrene

EuroSIMA Cluster | Manufacturing technology for surfboards 5

Industrialized Countries AEV (period of 8hrs / ppm

United Kingdom 100

The Netherlands, Denmark 25

Average Exposure to styrene Values that should not be exceeded

In order to ensure good reticulation of the UV resins, it is necessary to observe certain

EuroSIMA Cluster | Manufacturing technology for surfboards 6

EuroSIMA Cluster | Manufacturing technology for surfboards 7

Measurement of styrene concentration during glassing stage (source association ACS)

Mechanical, thermal, chemical and fatigue resistant High price

Slight shrinkage (1 to 2%) Sensitive to humidity and UV

Excellent adherence on fiber Ages with heat

Self extinguishing Sensitive to shocks

EuroSIMA Cluster | Manufacturing technology for surfboards 8

Particular attention should be paid to:

EuroSIMA Cluster | Manufacturing technology for surfboards 9

International offers for biocomposite materials are regularly updated on www.biopolymer.net

EuroSIMA Cluster | Manufacturing technology for surfboards 10

The orientation of fibers in the most solicited

One way in which the mechanical properties of

EuroSIMA Cluster | Manufacturing technology for surfboards 11

Classification of reinforcement fibers according to their origin

EuroSIMA Cluster | Manufacturing technology for surfboards 12

• E-glass is most used in the manufacture of textile glass fibers,

Comparison of different forms of glass fabric

EuroSIMA Cluster | Manufacturing technology for surfboards 13

Application of carbon on the rails (as for RT