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OUR VACUUM BAGGING CARBON SURFBOARD TECHNOLOGY

Vacuum Bagging Process

All our boards are made using the vacuum bagging process. Each one is composed of an EPS foam core with a density of 35 kg/m3, along with 3k carbon fiber and fiberglass. The vacuum bagging process starts with laying out the ingredients (foam, carbon, and fiber), then a sheet is tightly sealed around the piece. Vacuum is then applied to remove air from the bag, creating a vacuum environment.

The Advantages ?

This technique enables achieving a uniform distribution of resin, enhancing the mechanical properties and strength of the board. Additionally :

Better fiber/resin ratio
Avoidance of air bubbles
Reduction of toxic emissions

View of the carbon fiber with tinted yellow resin

View of the carbon fiber with a blue tinted resin.

View of the hot coat of the carbon fiber with a blue tinted resin and a yellow tinted resin.

At EKAHI, we have developed two innovative technologies based on carbon fiber :

DUAL WEAVE CARBON TECHNOLOGY

We have developed a new Dual Weave Carbon Technology. This innovative approach, combined with our vacuum bagging process, involves utilizing plain weave carbon fiber on the deck for enhanced strength and durability, ensuring your board withstands the toughest conditions. On the bottom, we incorporate twill weave carbon fiber, which provides increased flexibility for a more responsive and dynamic surfing experience. Additionally, we use a high-density EPS foam core and high-quality epoxy resin, optimizing both the durability and performance of our boards, giving surfers the best of both worlds.

CARBON-KEVLAR DUAL TECHNOLOGY

CKD blends the snap of carbon with the impact resilience of Kevlar to deliver a uniquely balanced ride. Carbon layers drive responsiveness and speed transfer, while targeted Kevlar reinforcement shields high-stress zones from dings, heel dents, and abrasion. Paired with our high-density EPS core and premium epoxy resin, this layup increases longevity without sacrificing feel giving surfers a fast, lively board that stays dependable session after session.

CRITERIA	PU POLYESTER (Ref. = 1x)	EPOXY EPS + FULL CARBON + VACUUM BAGGING
Material Cost	1x	3-5 times higher
Labor Cost	1x	2-3 times higher
Durability	Fragile (1x)	Very strong (5-10 times more durable)
Flexibility	More flexible (1x)	Ekahi technology 20% stiffer – Ultra speed
Weight	1x	0.7 to 0.8 (20-30% lighter)
Performance	Standard (1x)	Optimized (2-3 times more performant)
Environmental Impact	More polluting (1x)	Less toxic (2 times less toxic)

Conclusion : PU polyester boards remain more affordable and a bit more flexible, but they wear out very quickly. Because they need to be replaced more often, their overall cost ends up being higher. Plus, a deck covered in heel dents is practically impossible to resell second-hand. PU can be a good choice for professional surfers who constantly renew their quiver without paying for their boards—something that’s not the case for more than 99% of surfers. By contrast, Epoxy EPS + Carbon boards are more expensive to produce, but they offer greater durability, optimized weight, and overall superior performance.