What are Surfboards Made of?

Last Updated on November 29, 2023 by Matt Hapgood

For surfers, the surfboard is THE most important piece of equipment.

Period.

Choosing the right board can make all the difference out in the surf. And while factors like length, width, and shape impact performance, the materials used in a surfboard’s construction also play a key role.

So what exactly are surfboards made of? From polyurethane foam to EPS and epoxy resins, let’s take a deep dive into the composition of modern surfboards.

TL;DR (too long didn’t read)

A Brief History of Surfboard Materials

Surfers have been catching waves for centuries, with the earliest surfboards made from wood. Polynesian islanders shaped solid boards called olo from the wiliwili tree. Early 20th century Hawaiian surf legends like Duke Kahanamoku often rode heavy koa wood boards that could weigh up to 100 pounds!

The development of fiberglass cloth in the 1940s was a game-changer for surfboard construction. By layering sheets of fiberglass over a wooden core, builders could create lighter and more durable boards. Polyester resin was used to saturate the fiberglass fabric. These early fiberglass boards still had wooden skeletons.

By the 1950s, builders pioneered the first full foam surfboards. Polyurethane foam had become widely available after WWII, providing an alternative to wood cores. Plastic became popular for fins around this time too. The shortboard revolution of the late 60s saw more experimentation with materials like epoxy resin.

Today’s high-performance surfboards continue to utilize advanced materials and construction techniques.

The Anatomy of a Modern Surfboard

Before diving into specific materials, let’s look at the components that make up a contemporary surfboard:

• Deck – The top surface of the board where the surfer stands.
• Bottom – Underside of the board that faces the wave.
• Rails – The board’s edges between the deck and bottom.
• Nose – Front tip of the board.
• Tail – Back end of the board.
• Fins – Attached at the tail for stability and drive.
• Core – Internal structure of the board.
• Skin – Outer layer that coats the core.

Now let’s explore how different materials are used for these parts!

Polyurethane Foam Cores

The core material forms the inner skeleton of most modern surfboards. Polyurethane foam is the predominant choice for core construction. The development of polyurethane foam was a revolution for surfboard design.

Polyurethane is created from two liquid chemical components – a polyol resin and an isocyanate. When mixed together, an exothermic reaction occurs, expanding the liquid into a bubbled plastic. Varying the chemical composition allows polyurethane foams of different densities and flex patterns. A surfboard blank can be shaped from a block of high-density polyurethane foam.

Polyurethane offers several advantages that make it ideal for surfboard cores:

• Lightweight – Polyurethane foam is much lighter than solid wood. This allows for smaller, more maneuverable boards.
• Custom shaping – The foam blank can be easily shaped with saws and planers into different designs.
• Flexibility – The flex and rigidity of the foam can be adjusted during production. Stiffer foam is used for longboards, while softer foam works for shortboards.
• Resilience – Closed-cell polyurethane foam is waterproof and resilient, maintaining its structure over years of use.

While polyurethane dominates board construction today, some alternative core materials include:

• Polystyrene – More rigid and dense than polyurethane. Used for longboards.
• Wood – Basswood, balsa, or redwood provide a traditional feel. Composite wood decreases weight.
• Hollow – Empty space inside can lower weight. Not as durable long-term.

Fiberglass Cloth and Resin Skins

The production process laminates sheets of fiberglass cloth to the shaped polyurethane core using resin. This creates the deck and bottom outer skins of the surfboard. Fiberglass and resin allow surfboard builders to waterproof the foam and add strength.

Fiberglass Fabrics

Fiberglass contains thin strands of glass fibers woven into a cloth. It is categorized by the orientation of the glass strands:

• Woven – Fibers woven perpendicular at 90o angles for even strength.
• Unidirectional – Fibers oriented parallel for rigidity in one direction.
• Biaxial – Fibers woven in a +- 45o pattern for flex and strength.

Resins

Two main types of resin are used to adhere fiberglass to the foam and cure it into a hard shell:

Polyester Resin

• Most common and affordable option.
• Provides good rigidity for less flex.
• Environmental issues asVOCs evaporate during curing.

Epoxy Resin

• Clear epoxy creates a glossy finish without additional polish.
• Bonds strongly for a lighter, thinner coat.
• More flex and impact resistance than polyester.
• Low VOCs and less styrene emission.
• More expensive than polyester.

In addition to the fiber orientation and resin chemistry, factors like the number of fiberglass coats and weight/oz of the cloth impact flex, weight and strength. Most boards use a combination of different fiberglass types, tailored to the desired performance.

Modern Surfboard Fin Materials

Fins help surfers generate speed and direct the board. While fins were once made of solid wood or plastic, today’s options aim to balance durability, flex, and hydrodynamics.

Common fin materials include:

• Fiberglass – Glass cloth and resin fins blend rigidity and flex for control and release from turns.
• Carbon fiber – Light yet rigid carbon fiber fins maximize acceleration and responsiveness. Costlier but popular for performance boards.
• Glass foam composites – Fins with a foam core wrapped in fiberglass sheets. A blend of flex, drive and snap.
• Plastics – Affordable fins made from nylon, acetal or polycarbonate. Offer budget friendly durability.
• Rubber – Flexible rubber fins awesome for big wave surfing when snap release is essential.
• Wood – Traditional solid wood or wood veneers create vintage aesthetic. Dense woods like teak add rigidity.
• 3D printed – New advances allow fully customizable, hydrodynamic fin shapes.

Pro surfers may have multiple sets of fins for different conditions. Beginners can start with sturdier plastic or composite fins until skills progress.

Eco-Friendly Surfboard Materials

Many standard surfboard construction materials have raised environmental concerns. Fiberglass production creates tiny airborne particles during sanding and cutting. Polyester and epoxy resins emit styrene vapors as VOCs during curing. And old boards can end up in landfills.

In response, eco-conscious surf brands are pioneering greener materials and production methods:

• Bio-based resins – Resins derived from plants like flaxseed oil or tree sap reduce petroleum reliance.
• Expanded polystyrene (EPS) foam – Contains recycled polymer pellets and avoids polyurethane chemicals.
• Recycled polymer skins – Upcycled plastic bags or fishing nets can be pressed into boards instead of fiberglass.
• Wood pulp composites – Plant-based epoxies bind recycled wood pulp in surf core blanks.
• Hollow wood – New pressed wood techniques eliminate foam, while retaining performance.
• Carbon neutral manufacturing – Brands like Firewire offset emissions and plant trees during production.
• Repurposed foam – Some companies will reshape your old board’s foam core into a fresh new ride!

While eco boards represent a small (but growing) share of surfboard construction currently, they highlight promising techniques that could become mainstream in the future.

How Long Should a Surfboard Last?

With proper care, the typical lifetime of a quality surfboard is 5-10 years. However, there are many variables that impact longevity:

• Usage – A frequently ridden board in heavy surf may only last a couple years before needing a replacement.
• Storage – Keep boards out of direct sunlight and extreme temperature swings to avoid material breakdown.
• Repairs – Fixing dings and fractures right away will extend a board’s lifespan.
• Skill level – Beginner boards tend to receive more damage that requires repair.
• Travel – Airline and road trip wear and tear takes a toll over time.
• Material quality – Higher grade materials shaped by master builders typically endure longer.

Even pros need to replace their boards every few years as dings accumulate or technology improves. With some TLC, most recreational surfers can get 5+ years from their trusty ride before it’s time to upgrade.

Surfboard Materials Impact Performance

When shopping for a new surfboard, materials matter. Construction techniques utilize different materials to fine-tune attributes like:

Weight – Heavy, dense woods sink into waves, while EPS foam floats easily. Traveling surfers need lighter options.

Flex – Stiff boards hold an edge in critical turns, while flexible boards generate speed in the flats. Variable flex accommodates different riding styles.

Strength – Bomber epoxy and carbon fiber constructions withstand heaviest impacts during big wave charging.

Responsiveness – Advanced composites with fiberglass, foam, wood, and carbon fiber achieve the ideal reflex and spring.

Style – From retro wood designs to glossy epoxy, materials influence aesthetic.

Sustainability – Eco-friendly builds satisfy environmental preferences.

Price – Material selection drives cost considerations, from budget boards to high-performance.

Only by understanding how materials impact these factors can a surfer find the ideal magic carpet to match their ability, wave conditions, and budget. While technology keeps advancing, the soul of surfing remains catching waves on boards borne from nature’s bounty, from trees to sand.

The Evolution Continues

As surfing has grown from ancient Polynesian pastime to global professional sport, surfboard materials have evolved remarkably in parallel. What started as solid slabs of wood has transformed into sophisticated composites of foam, fiberglass, carbon fiber, and resins. Innovation continues today with 3D-printed fins, recycled polymers, and environmentally-friendly resin chemistries.

Yet whether riding antique kook boxes or shredding on cutting-edge rockets, the surfboard remains deeply connected to nature. Surfing arose from the oceans, and surfers will always share an innate bond with the forces that sculpt their equipment from raw materials.

As surfers, being mindful of how our boards are built allows us to progress our skills and advance the sport while also protecting the waters that give so much.

So next time you wax down a new board, take a moment to appreciate the technological achievement under your feet. Yet never forget that a surfboard is more than just the sum of its parts. In the water, it becomes an extension of our dreams, allowing access to endless possibility, adventure, and stoke.

What our boards are crafted from pales in comparison to the emotions they unlock within in us. By understanding that, we can nurture the origins of surf culture, while still pioneering future innovation.