Sanding a shaped foam board blank
How we build · Cixi, Ningbo

A closer look
at the build.

Kayak hulls are molded, cooled, trimmed and assembled. Boards are shaped, sanded, vacuum-laminated and printed. Here is how each one moves through our factory.

The kayak line.
Rotomolded polyethylene.

8 steps

Our kayaks are rotomolded from polyethylene: LLDPE, MDPE or HDPE, matched to the model and how it will be used. The material goes into a closed mold, the mold heats and turns, and the hull comes out as one seamless shell.

Pouring material
Step 01 Pouring material The polyethylene goes into the open mold.
Mold closing
Step 02 Mold closing The mold is closed and clamped shut.
Setting up
Step 03 Setting up The machine is set for the hull. No hand-held flame guns.
Mold heating
Step 04 Mold heating The mold heats and rotates so the material coats every surface.
Cooling
Step 05 Cooling The mold cools before the hull is released.
Off the mold
Step 06 Off the mold The finished shell comes out of the mold in one piece.
Assembling and trimming
Step 07 Assembling and trimming We trim the hull and fit it out by hand.
Packing
Step 08 Packing Each kayak is bagged and packed for shipping.
Material
LLDPE, MDPE or HDPE
Graphics
Mold-in
Colors
Standard and mixed
Lead time
30–45 days (production)
See the kayaks →See the pedal kayaks →

The board line.
Shaped, then laminated.

9 steps

Our soft-top surfboards and paddleboards are built around an EPS foam core, with a fiberglass layer and vacuum-bagged lamination.

Material
Step 01 Material EPS foam blanks, at a density of 24–28 kg/m³.
Shaping
Step 02 Shaping Each blank is cut to its outline and shaped.
Sanding
Step 03 Sanding The shaped blank is sanded smooth.
Embedding
Step 04 Embedding Fin boxes and plugs are set into the blank.
Gluing
Step 05 Gluing Deck and bottom layers are glued to the core.
Vacuum bagging
Step 06 Vacuum bagging Boards are laminated under vacuum, several at a time.
Trimming
Step 07 Trimming Excess material is trimmed from the rails.
Printing
Step 08 Printing Graphics are screen printed onto the deck.
Packing
Step 09 Packing Finished boards are boxed and stacked for shipping.
Deck
IXPE / EVA
Core
EPS
Bottom
HDPE
Fiberglass
2 deck · 1 bottom
Lead time
30–45 days (production)
See the surfboards →See the paddleboards →
The floor

More than 13,000 m²
under one roof.

Both lines run side by side in our factory in Cixi, Ningbo, with molding, shaping, lamination, printing and packing in one place.

We keep investing in the machines behind them. Deck textures, for example, are embossed in house on our own graining machine.

About the factory →
The graining machine that embosses deck textures Graining machine, board line

Want to see a sample?

Tell us which line and model you are looking at. We can talk through materials, graphics and timing for your order.

Start a quote requestTalk to our team →