Epoxy Surfboard Technology | Premium Standard construction methods

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

When the board is laminated it happens in a heat controlled environment using Resin Research Epoxy resin.

Resin research Epoxy is ground breaking stuff, not only is it over 40% bio content it is also the strongest, lightest and brightest Epoxy resin on the market. It isn’t just safer to use and better for the environment, it is also the best performing resin we could get our hands on. Given the characteristics of the foam and the resin, this surfboard as a product uses less resin per foot than standard construction surfboards, meaning the weight is further reduced. It all plays a part in why this construction method is such an awesome product. Epoxy surfboards are getting more widely used every day. We are at the forefront of that drive for more surfers to utilise the benefits of Epoxy Surfboards.

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

Finally the board is heated in a hot box over night at 39 degrees, this ensures curing times are sped up during the first 72 hours of the board’s life. Heat is a really important factor when using epoxy resins, the right temperatures must be maintained in order to exploit the epoxies characteristics.

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

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

FX1 Construction is lightweight, strong, dent proof, and has a natural flex pattern to ensure performance in a wide range of conditions. When you have epoxy surfboard technologies that have very strong impact resistance, usually it will have stiff flex patterns that feel chattery on the face of a wave and be hard to control, especially at higher speeds. The FX1 construction method rivals the compression strength of sandwich construction epoxy surfboard alternatives but adds a better natural flex pattern to allow for ease of use in a wider range of conditions.

The main core of the epoxy surfboard  technology is super fused EPS foam, then it’s cut in half and inserted with a PU foam central flex dampener which gives you a core that has liveliness to it and loads of flexy spring. This is then wrapped in two layers of glass on the bottom of the board using a unique tiered lap which gives you unreal flex recoil and a tensile strength 20% stronger than a standard 4oz cloth. A sandwich laminate of 4oz and innegra cloths are used to form a layer over the deck of the epoxy surfboard to give you a compression strength completely unrivalled from any other hand glassed surf board on the market.

The surfboard is laminated with an epoxy resin that contains a bio content of 48% and is finished with a 240 grit dry sand finish to ensure it has optimum strength to weight ratios. The FX1 offers you an epoxy construction that will perform in a large range of conditions, remain strong, light and feel new forever, while being an eco-friendlier option compared to a standard construction surfboard.

FX1 epoxy surfboard technologies are 10% lighter than standard construction surfboards, 20% stronger in tensile strength, 50% stronger in compression strength and have a flex pattern that doesn’t feel like you are riding a rigid epoxy surfboard pop out.

The core of the blank is super-fused EPS, which has two high density polyester flex controllers running through it. These act as integral dampeners when powering through turns, adding control, and taking away some of the natural float of an out-and-out EPS core board.The flex controllers are angled from tail to nose, at the same tow as the side fins. This loads the torque directly towards your fins through turns, meaning at lower speeds, your projection will carry you with effortless glide, and at higher speeds, you can load up and accelerate out.

When the epoxy surfboard is laminated it happens in a heat controlled environment using Resin research epoxy surfboard specific resin.

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

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

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

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

The Flex-Lite construction ticks all the boxes from strength, flex, control, feel, weight and most importantly, versatility. When it comes to understanding flow, drive, control and speed, Fourth looked at flex patterns and torque levels at different speeds. The aim was to ensure that you can load up and release energy through turns using the curves of your surfboard that will keep your rails engaged with the face of the wave. The versatility of the Flexlite construction is unrivalled in performance when it comes to epoxy surfboard technologies