Surfboard Construction Explained
At Circle One Surf Co., we believe a surfboards are precision-engineered performance tools, built for long term enjoyment. Every layer, every material, and every finish plays a role in creating boards that deliver exceptional strength, responsiveness, and durability.
Here’s how we build our boards.
EPS High-Density Pressurised Foam Core
Our boards begin with a high-density pressurised EPS foam core, forming a lightweight yet extremely strong foundation.
This core provides:
- Outstanding buoyancy for easier paddling
- A superior strength-to-weight ratio
- Consistent structural integrity
- Improved long-term durability
By using high-density EPS, we create boards that remain light underfoot while maintaining strength in demanding conditions.
Epoxy Resin: Lightness and Strength
We use epoxy resin across all our boards to maximise performance and longevity.
Epoxy offers:
- Increased structural strength
- Enhanced impact resistance
- Better flex memory
- Reduced weight compared to traditional laminates
- Improved resistance to water absorption
When paired with our EPS cores, epoxy creates a strong, responsive, and reliable construction system.
Premium Porcher E-Glass Fibreglass
We use premium layers of Porcher E-Glass fibreglass for superior performance and durability.
Porcher E-Glass delivers:
- High tensile strength
- Excellent impact resistance
- Consistent resin absorption
- Enhanced structural reinforcement
These premium fibres ensure the board maintains integrity under pressure while keeping overall weight low.
CROSSLINK Deck and Rail Reinforcement
The deck and rails experience the most impact during use. To protect these critical areas, we integrate our CROSSLINK reinforcement technology into our construction.
This system provides:
- Maximum impact resistance
- Improved compression strength
- Reduced pressure dents
- Increased board lifespan
By strategically reinforcing high-stress zones, we enhance durability without compromising flex or performance.
Full-Length 4-Ply Wood Stringer
Every Circle One board features a full-length unidirectional 4-ply wood stringer.
This stringer delivers:
- Controlled and predictable flex
- Added longitudinal strength
- Improved energy transfer through turns
- Enhanced structural stability
The unidirectional design ensures strength where it’s needed while maintaining responsive performance underfoot.
CNC Precision from AKU Files + Hand Shaping
Our boards are first CNC cut using AKU shaping files, ensuring:
- Precise rocker profiles
- Accurate outlines
- Consistent performance templates
- Millimetre-level design accuracy
After CNC shaping, each board is hand finished by experienced craftsmen, combining modern technology with traditional surfboard artistry. This process guarantees both consistency and character in every board we produce.
Hot Coat Durable Outer Finish
To complete the construction, we apply a durable hot coat outer finish.
This final layer:
- Seals and protects the laminate
- Enhances surface durability
- Adds UV resistance
- Provides a clean, professional finish
The hot coat acts as a protective shield, ensuring long-lasting performance in all conditions.
Exceptional Strength-to-Weight Ratio
By combining:
- High-density EPS cores
- Epoxy resin systems
- Premium Porcher E-Glass
- CROSSLINK reinforcement
- Full-length wood stringers
- CNC precision shaping
- Hand finishing craftsmanship
Circle One Surf Co. delivers boards with an exceptional strength-to-weight ratio, engineered for performance, built for durability, and designed for progression.
Built with Precision. Shaped for Progression.
At Circle One Surf Co., our construction philosophy is simple: use the best materials, apply advanced manufacturing techniques, and finish each board with expert craftsmanship.
The result is a surfboard that is light, strong, responsive and ready for serious performance in the water.
Shop our huge range of epoxy surfboards today.
