The main board we produce is for freestyle (we also produce wave boards, but there is not much call for them in the UK). Here is a brief outline of the process we use to make a HT Board.
The outline shape of the board is produced using CAD software.
The outline is then cut out of the CoreCell to form the core of the board.
This is then placed on a pre-made rocker table to form the perfect shape, tip to tip. We use different rocker tables, depending on what shape and size you require.
The CoreCell is then sanded to produce the shape and a smooth surface to make sure there is no imperfections. This also eliminates any marks that will show through the artwork.
The foot strap holes are then cut out of the CoreCell to make sure the fixings sit flush with the top and bottom decks. These are then filled to make sure no epoxy resin can get in whilst applying the composite layers.
The fibreglass is then cut out to size and heated to make sure there is no moisture left in it. The fibreglass fabric is very dense and has a tough weave that can only be formed using the vacuum bag process which draws out all the air to make a perfect layer over the core of the board.
The individually sized layers of fibreglass are then applied to the board with a coating of resin to set the layers. Once applied, all the air pockets are removed with a roller to ensure a smooth finish (this will not be perfect, which is why the vacuum process plays a vital part). Any excess fibreglass around the edges is at this point trimmed off.
Due to the raised 3D top deck the layers are positioned perfectly in conjunction with the designs to enable the perfect hydrodynamics, which will include a concave from tip to tip - this allows for the flex and pop.
The board is then placed into the vacuum to push the layers into place. Once the layers are perfect the board is left to cure over night, then sanded to make it really smooth.
Kiteboards design and technology
The boards produced by HT Boards incorporate different technologies.
Raised 3D top deck board design
CAD software allows to produce a Raised 3D top deck, aligning all the composite layers to give excellent results whilst being pressed under great pressured to allow perfect results each time.
Strong CoreCell foam core
Lightweight CoreCell foam allows the board to be extremely light and buoyant. The CoreCell foam is strategically placed in the centre, thus allowing maximum strength and rigidity.
Flex Zones
With the use of different computer software and rider input, the Raised 3D top deck utilises various thicknesses in different sections of the board. This produces devoted areas of flex where it is needed - on the tips and the centre, which allows great absorption of big hits from waves and landings. These areas also give the rider great pop.
Complete Concave
We use hydrodynamic software, which allows us to find the perfect point to have a concave. With the perfectly formed concave early planing is achieved along with great speed on-the-go, without losing any stability and control.
Vacuum Pressed
HT boards are pressed under great pressure to produce strength and durability. By using this method, the composite layers are aligned perfectly each time. When all the air is pulled out of the vacuum bag, the atmospheric pressure pushes on the layers compressing each one into position and making it into one composite layer.
Firstly, the vacuum removes any unwanted air in-between each layer. Secondly, the pressure compacts the layers to form a strengthened structure capable of withstanding the vigorous forces it is put under whilst being used. Lastly, the whole process makes sure the resin/fibre mix is proportional to what is needed.