Its a shaped foam core like a surfboard but you can use EPS (styrofoam).
And then vacuum a thin heated sheet of plastic over the foam on both sides.
Heres a surfboard as an example with a clear skin.( not mine)
And what you get is a perfectly smooth skin thats fused to the foam.
Weve tried thermoforming over lots of different foam combos,
but weve got the right materials to start making some test boards.
Because its not made of blocks and strips like a commercial bb, you can try different rail shapes. Or concaves, channels, handgrips, or whatever you can shape into a block of foam.
Its as simple as shaping the foam in any design you like, and then the thermoforming takes about 30 minutes in total to do both sides.
The plastic is either ABS, ( the same as car fenders), ASA or Kydex, but theyre all waterproof, UV stable and 100% recyclable. And they come in flat colours, metallic and woodgrains and heaps more.
The boards are light and strong but because the plastic skin is about .5 mm over foam the board is softer than fibreglass. Theres no resins or sanding to make these boards but its still got flex like a standard bodyboard.
Im shaping two boards this week and they should be ready the week after for testing.
