CONCEPT & MATERIALS
It’s essentially the same concept than a standard surfboard –a soft core covered with an outer shell– but with huge differences:
Recycled/recyclable EPS (expanded polystyrene or styrofoam)
Let’s make it clear: EPS IS NOT an eco friendly material. It emits less volatile organic compounds (VOCs) than polyurethane foam, and it’s recyclable. But polystyrene is still a petroleum-based material, made with carcinogenic components; it’s harmless in its final form, but it does not biodegrade for hundreds of years; and remember that those huge plastic islands floating in the Pacific Ocean are full of it! Therefore, we should say recycled EPS foam is far more ecological than PU, but we must find an alternative for this. And the solution might be around the corner.
Vacuum bagged skins
Paulownia wood helps dissipate water vibrations and it doesen’t crack as easily as fiberglass.
Cork rails add more flex to the board. Actually our boards became more responsive and more similar to PU/poly boards since we switched from our previous paulownia rails to cork. They also absorve impacts without deforming and you'll ding them less. Otherwise, dings and scratches are not necessary or urgent to repair, as cork is water resistant. You can also easily repair it yourself with a bit of cork (the classic chipboard cork found in many stores) and PU glue. Cut, glue, polish and varnish. Easy!
Cork deck option for added flex
With the CorkEvolve techonology we're able to control flex: having a hard bottom (paulownia skin) and a soft top of cork allows us to adjust the right amount of flex, even in certain parts of the board.
Also, our CorkEvolve boards can be considered the most ecofriendly soft-boards, and they're also well suited for begginers.
Cork as a natural grip
Under request we can leave the cork exposed and natural in the deck area 'cause when it's wet it's super grippy!
Laminated parabolic rails
The parabolic rails help control flex while adding strength to the eps core. There's a 3mm paulownia strip around the perimeter, and then we cover the rest of the rails with cork (for performance) or paulownia (bulletproof option).
—Cork rails: cork rails are way stronger than you might think, very resistant against impacts but soft enough if the board hits you. Rapairs are super easy and you can make it yourself!
—Paulownia rails: this rails make the board stiffer but super strong and durable. And if they’re dinged, then there is no rush to repair them ‘cause paulownia is water resistant. And if you need to, you can repair with wood paste and a bit of varnish.
D4 Polyurethane glue
The glue foams and expands during the vacuum bagging process and the glue is forced into any pores of the EPS, thus sealing it.
We discovered than when you glue 0,3mm of bamboo veneer at 90º on paulownia, it becomes a bulletproof, super elastic material. We use this technique to strengthen the deck, especially under the feet area.
Polyurethane foam offcuts
Recycled PU offcuts from MontjuichSurfboards production to get a firmer grip of fin boxes and fin plugs.
Wood floor varnish
The same treatement used in the FlamaClassic boards: easy, cheap, practical and you can do it yourself.