surf board

September 2008

EuroSIMA Cluster | Manufacturing technology for surfboards 1

EuroSIMA Cluster

Villa Casa Mia - 9 rue des acacias

40 130 Capbreton

France

Tel: +33 (0) 558 721 533

Mail: [email protected]

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: [email protected]

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

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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.

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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

Translucent

Good chemical resistance

Easy to handle

Heat resistant (> 150°C)

Low cost

Flammability (except chlorinated resins)

Resistance to vapor and boiling water

Significant shrinking (6 to 15%)

Limited storage in pot

Emission of styrene

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.

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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

France

USA

Japan

The Netherlands, Denmark

Germany,

Sweden, Finland

100

50

50

50

25

20

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.

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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

Slight shrinkage (1 to 2%)

Excellent adherence on fiber

Self extinguishing

Easy to work, no solvents

High price

Sensitive to humidity and UV

Ages with heat

Sensitive to shocks

Time required for polymerization (curing) > polyester

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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.

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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

Name Country (head office of

manufacturing site) Internet website Foam blanks

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.

surf board

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