Surflight boards use technologies that have roots in surfing, snowboarding, and bodyboarding.

What you see and feel in a Surflight board, the outer part of our boards, is made with a flexible foam, similar to bodyboard foam.  Like a conventional hard surfboard, the foam is custom shaped.  The shaped-blank is covered with a tough TPE (plastic rubber) skin.  The rails and seam are sealed, hand sanded, and coated with a smooth and tough urethane finish, providing a high performance rail with tuned edges.

The heart of our technology is a composite structure inner core surrounded by the flexible foam.  Imagine a snowboard within a flexible foam surfboard.  Like a snowboard, the Surflight inner core is made of a composite of epoxy resin, carbon fiber, fiberglass cloths, and foam, formed under high pressure and cured with heat for high strength and light weight.  The inner core is layered and contoured to give the right amount of flex and spring.  Like a snowboard, it acts as a "torsion box" to reduce twist.  The core functions as a "composite structure" because the pressurized forming of the materials causes them to function as one melded structure, much like modern snowboards, skis, and tennis rackets.

The combination of these foam, finish, and core technologies has taken years of research and development to achieve the right flex, weight, and strength.  Fortunately, Hawaii is a great proving ground for both performance and durability.

Over the years, we have developed a good understanding of how boards should flex to improve performance by working with some of the world's best riders and shapers in waves from Waikiki to Waimea and Peahi (Jaws) to Teahupoo.  Making the inner core light and strong with the right flex has been a rewarding challenge.

Our current boards have remarkable performance, and in our view, they are superior to conventional high performance surfboards.  Pros have told us that our boards have "mind-blowing performance," that it is "like surfing with radial tires," and that they are "the future of surfing." What they are feeling is the flex and spring that is engineered into our boards.  Our boards also have excellent strength for their weight.


Our approach to making surfboards with better flex is certainly more radical and seems strange to most surfers. Why make the board soft? Why not go with some modified hard board, like Firewire? We think our approach is superior for a couple reasons.

First, we can make a board with more flex, it bends further under the same force, than any of these other constructions. But, that is not always a good thing. It depends on what you want. There are circumstances where a lot of flex works great. And we can do that where nobody else can.

More importantly, we have separated the shape of the board from the flex. Any construction that uses the outer skin to control the flex, is limited by the shape of the board. Make it a little thicker, or wider, and you lose flex. Change the curvature of the deck, and you change the flex. Change the shape of the rails, boxy versus tapered, and you change the flex. Ours is the only technology that allows for shape and flex to be independent. We can make two boards with very different shape have the same flex, or two boards with the same shape have different flex. We do it all the time.

We continue to explore the potential of our engineered flex technology to further improve both the performance and durability of Surflight boards, so watch for future developments.

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Cutting Foam

Cutting Foam

Wetting out glass

Laying fabrics on core

Inserting core

In the vacuum bag

Post cure oven

Surflight blanks




Fin installation

Spraying adhesive


Sealing seams

Making a Surflight

Factory visit videoShop_visit_video.html