SUP Technology

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Carbon Sandwich

Our Carbon boards make use of the latest technological developments and manufacturing processes used to build premium light weight Carbon Sandwich construction paddle boards. Leaning on our extensive composite experience, we took those build processes and tailored and refined them to meet our expectations in performance, weight and durability for all our Zeal Surf products. We carefully calculated our laminate specifications to enhance the desirable flex-reflex characteristics of our boards, and underwent further refinements through prototype testing until we had a product that exceeds international standard, and of which we are proud to put our name on.

All Zeal Surf products are designed, made and tested in Cape Town South Africa. We have the added advantage of manufacturing our own boards in a hand-made, low volume environment where we can pay special attention to the build and quality of the product.

Our Carbon Tech boards are built using a very light weight expanded polystyrene blank (EPS) that is shaped using a computer numerical controlled (CNC) machine with a accuracy of up to 0.5mm. Once shaped, we lay down strategically placed high quality light weight glass and carbon fiber reinforcing and wrap the deck hull and rails with a 3mm high density PVC core that has excellent shear properties in composite construction and great impact resistance. We then wrap the entire boards in off axis +- 45 biaxial carbon fiber. This adds huge strength to the board, without compromising the desirable flex- reflex characteristics that generate huge amounts of speed and drive. We use Carbon Fiber for all of our reinforcing: this provides unmatched strength and weight savings. The board is then placed into a vacuum bag to consolidate all the layers of material and remove excess resin, following which the board is placed in a temperature controlled environment to post cure the resin and finish the composite structure.

 

Wood Sandwich

Our Wood sandwich boards make use of the more traditional manufacture processes where cost is of more importance that having the lightest board on the water. Having said this, due to cleaver laminate spec calculations and build processes, our Wood sandwich boards are on average lighter than equivalent spec boards on the market.

All Zeal Surf products are designed, made and tested in Cape Town South Africa. We have the added advantage of manufacturing our own boards in a hand-made, low volume environment where we can pay special attention to the build and quality of the product.

Our Epoxy Tech boards are built using slightly denser expanded polystyrene blank (EPS) in comparison to our Carbon tech boards, this offers a more robust final product with a slight added weight penalty. The blank is shaped using a computer numerical controlled (CNC) machine with an accuracy of up to 1mm. We laminate the fin boxes and leash plug into the board using biaxial carbon fiber for added strength and weight savings. From there we Lay down 2 layers of E-glass on the bottom, and have a wood sandwich construction (sustainable sourced 0.6mm bamboo veneer) on the deck. The veneer not only add a huge amount of strength and impact resistance especially in the standing area, it also gives the board a beautiful wood finish that complements the classic flowing lines of the board. The board is then placed into a vacuum bag to consolidate all the layers of material and remove excess resin, following which the board is placed in a temperature controlled environment to post cure the resin and finish the composite structure.

Have a question or need a custom board built?

Contact us at hello@zealsurf.com or +27 (0)72 257 9980

We deliver anywhere in South Africa.