Commitment to Manufacturing Excellence

At Circle One, we design and develop every product in the UK and oversee manufacturing in the Far East with a dedicated quality team. Our authentic surf heritage since 1969 and no-compromise approach to quality mean every board, wetsuit and accessory is built to last.

Using only the best materials—Porcher E-Fibreglass for strength, aerospace-grade carbon fibre for performance, and premium limestone CR neoprene for flexibility—our products are crafted to perform in real-world conditions.

When you choose Circle One, you’re investing in over 50 years of trustworthy craftsmanship and gear that helps inspire every step of your surf journey.

Read more about the Circle One story here or read on to learn more about our fascinating Epoxy Surfboard manufacturing process..

CNC Machine Assisted Shaping

In the early years, Jeff shaped every board from scratch, often working through the night to meet demand. Today, that same dedication continues with the support of AKU Shaper CAD software and CNC technology.

Sub-millimetre accuracy: AKU Shaper software allows Jeff and the team to design shapes in 3D with unrivalled precision.

CNC shaping: Each design file is cut from EPS foam on a computer-guided CNC machine, ensuring consistency and efficiency.

More time for creativity: Machine-assisted shaping frees our shapers to focus on refining designs and pushing performance.

Importantly, machine shaping is not mass-produced “pop-out” manufacturing. Circle One boards are still built from foam, fibreglass and resin—not plastic molds. Every board is hand finished, laminated and sprayed by expert craftsmen to achieve the perfect balance of strength, weight and performance.

Hand Finished vs ‘Pop-Out’

There’s often confusion between CNC-assisted shaping and pop-out boards. Pop-outs are cheap, molded plastic composites filled with foam—heavier, less durable, and lacking performance. Circle One has never produced pop-outs.

Our process blends precision shaping with skilled hand finishing. Every rail, tail cut, laminate and spray job is crafted by experienced hands. It’s this attention to detail—backed by over 50 years of shaping heritage—that makes Circle One boards different.

We use only the highest-quality materials, including:

• Porcher E-Fibreglass – for strength, clarity and durability.

• Aerospace-grade 3k carbon fibre – in skimboard ranges.

• Super-durable CR limestone neoprene – across wetsuits and accessories.

Put simply: if you want a board that performs and lasts, what’s underneath matters.

The Board Making Process

Every Circle One board follows a carefully managed 10-stage journey:

Stage 1 – Cutting the *EPS or **PU Blanks

The process starts with a block of EPS (Expanded Polystyrene) or PU (Polyurethane) foam, cut into sections using a hot-wire cutting machine. This produces the “blank”—the raw starting point for every board. Our system can cut up to six blanks at a time, ready for stringers and shaping.

Stage 2 – Adding the Stringer

A balsa wood stringer is inserted through the centre of the blank, running nose to tail. Balsa is chosen for its unique combination of strength and flexibility—it provides controlled flex without adding unnecessary weight. The blank is cut in half, the stringer glued in, and once dry, it’s ready for shaping.

Stage 3 – ‘Shaping’ the Blank

Using AKU Shaper CAD software, each design is programmed with sub-millimetre accuracy. The file is fed into our CNC shaping machine, which mills the foam blank with a circular cutter. This stage ensures consistent, repeatable outlines and rocker profiles—while leaving scope for experimentation and design innovation.

Stage 4 – Hand Shaping

Even with CNC precision, shaping is not complete until the board is refined by hand. Using coarse sandpaper and scrim cloth, skilled shapers smooth out ridges, refine rails, and cut complex tail designs (such as swallow or fish tails) that machines cannot produce. This step preserves the craftsmanship and individuality of each board.

Stage 5 – Inserting the FCS Fusion Finboxes and Leash Plug

Before glassing, FCS Fusion finboxes and leash plugs are installed. Unlike some manufacturers who set them in resin paste, we glass them in using premium Porcher E-fibreglass. This method takes longer but delivers maximum strength and impact resistance, ensuring fittings last as long as the board itself.

We only use genuine FCS Fusion Finboxes in Circle One boards – FCS have a reputation for quality and strength and complement our ethos of using only the best materials possible.  Check out the FCS site for more technical info on Fusion boxes or check out the video below:

Stage 6 – Laminating (Glassing)

The board is layered with fibreglass cloth and epoxy resin in a process known as the “glassing schedule.” Skilled glassers apply multiple layers by hand, ensuring no air bubbles remain. For bamboo construction, a thin bamboo veneer is sandwiched between fibreglass layers—adding natural strength and flex. We only use Porcher E-glass, recognised worldwide for its superior wet-out, strength and clarity.

Stage 7 – Curing

After laminating, boards spend 1–2 weeks in a temperature-controlled curing room. Epoxy resin requires heat to fully harden, reach maximum strength, and deliver long-lasting durability. Proper curing is essential for performance and longevity.

Stage 8 – Sanding

Once cured, the board is sanded by machine and hand using progressively finer grits. This eliminates resin drips, smooths rails and fin areas, and ensures an even finish. Careful rail sanding is especially important for performance. The board is then cleaned and prepped for spraying.

Stage 9 – Spray Room

Each Circle One board receives its finishing design in the spray room. Using precision colour application, decals, and masking techniques, boards are given their unique identity. Colours are carefully selected to balance aesthetic appeal with durability, and once sprayed, boards return briefly to the curing room to harden the finish.

Stage 10 – Hot Coat and Sealer

Finally, a thin “hot coat” of resin is brushed across the board to create a durable outer shield. Once cured, the board is lightly sanded and polished if a gloss finish is required. A specially formulated sealer coat is applied in a dust-free environment, locking in the finish and leaving the board ready for the waves.