“All our foil boards are produced in our 100% carbon fibre construction”
Our foil boards are well thought out and unique in the foil industry. Not only in their shape, but especially in their construction. We use our own production method. This is possible because we have our own production facility. We can control the process from start to finish. All custom boards are available in different strength and weight options, all the info on this can be found here.
50K CLOSED CELL FOAM
It all starts with the core and every board we make starts with a foam core of our very own 50K closed cell foam. This foam is formalized exclusively for us, it is not used in any other board in the market.
The foam can withstand 50.000 kg per square meter, while staying very light, and most of all very flexible. Another plus of our 50K foam is that it is closed cell, meaning that the foam will not take in water, and the board will not blow out when it gets hot. Any small crack or ding does not need immediate repair. Eventually a repair is advised, but you can first finish your well deserved session or trip!
50K foam is not easy to shape, all commercially available shaping machines will have great trouble shaping it and hand shaping is not possible. At Appletree Surfboards we use our own shaping machines that we built and control ourselves. This way we can not only shape the foam, but we can also create channels and extreme contours, straight from the machine.
100% CARBON FIBER CONSTRUCTION
All our foil boards are produced in our 100% carbon fiber construction. You want carbon fiber in a foil board for its stiffness and strength. A stiff board will give you the best control and response from the foil. Also stiffness will make pumping the foil much more effective. With carbon fiber we are able to make the board extremely strong while really light at the same time.
The most stress in a foil board is in the connection of the foil to the board. So this is where we put extra care and attention to make it the strongest connection available. The foil mount is CNC cut with the board, for the highest precision. We only use FUTURES oneshot boxes as they are the strongest in the industry. The boxes are placed in a panel of ultra high density PET honeycomb. This PET honeycomb itself is sandwiched in carbon again. Meaning there is carbon fiber both inside the board and outside. The honeycombs open structure ensures a solid connection between inside and outside, fusing everything together into a solid block.
Our lamination is completely different as well. We use a vacuum technique developed in house, where we layer all the carbon fiber, and reinforcements on the board dry. Then we extract all the air from the bag and inject the epoxy resin under pressure. This results in the tightest lamination possible, with the best ration between fiber and epoxy. It also gives 100% connection to the core so the boards do not delaminate. Extra patches under the feet prevent heel denting.
Inserts in our foil range are made from blocks of high density material. And can be customized position wise. These blocks are also fused to the core so they never pull out.