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.