surfboards made from natural materials that perform better and last longer
Flexframe minimizes the impact of surfers on the environment by leading a transition from polluting surfboards to an alternative that is better for the planet and more fun to surf. The buildup of the Flexframe construction provides many advantages over traditional surfboard constructions.
This way of building boards is completely different from the traditional shaping, glassing, sanding method and relies heavily on the the use of our specialised machines.
The boards are built up from a super light EPS core with 2cm of bendy plywood rails that function as parabolic stringers. This combination makes the board extremely ding resistant on the rails while keeping it light and springy.
The deck is laminated with natural fibers, high-bio content Epoxy resin and a layer of cork, because of it's grip and compressive capability.
The bottom is laminated with a thin layer of flax and high-bio content resin with a 2.5mm paulownia skin, that is both lightweight and water resistant.
The board is then finished with a vented leashplug, finboxes and eventually coated with natural paint and hard-wax. There is no more resin or glassing on the outside of the board.
The cork deck gives these boards their lively flex and a soft, natural grip under your feet. These boards are prone to some footprints development.
For models where a bit more stiffness is ideal, we use a paulownia wood skin on both deck and bottom. This construction offers a stiffer flax pattern and keeps the board looking and performing great for many years.
Usually we recommend a cork deck on boards under 7 foot, and a wood deck on boards over.
After a couple of years of hardcore surfing, the cork decks may have received a fair amount of beating. Flexframe boards have the ability to be refurbished when given to any producer of Flexframe. The process starts by removing the dented deck skin. The deck will be reshaped and laminated with a new fiber and cork skin. These boards don't loose their flex and can be surfed again as a new board.
Materials used
Cork
Cork is used for the deck. It's lightweight, flexible, watertight and naturally grippy, making it ideal as top deck layer on surfboards. It enables the deck to compress, provides traction and eliminates the need for wax.
Paulownia Wood
Paulownia is a lightweight, water-resistant and fast growing hardwood. It is the lightest wood after balsa and grows up to 4.5m per year. Paulownia woods are known to be extremely efficient and effective at capturing carbon.
Using Paulownia as a bottom skin adds strength, durability, and natural flex while maintaining low weight. We use paulownia wood inserts as support for the finboxes so they don't pop out.
EPS
We use locally produced EPS for our board cores and ensure all offcuts are recycled. While it’s a step in the right direction, we're actively exploring plant-based alternatives and are committed to making the switch as soon as performance and sustainability align.
Meanwhile we found that classic foam cores are produced overseas and inefficiently shipped across the globe. By using locally produced foam we found that the CO2e impact becomes relatively low.
Organic Hemp and flax fibers
We use a combination of hemp and flax fiber beneath our cork and wood decks as a natural alternative to fiberglass. It adds strength, maintains flexibility, and durability delivering high performance with a lower environmental impact.
Natural Oils and Hard Wax
We use a natural coating system to protect the wooden bottoms of our boards. Rubio Monocoat seals and hardens the timber, while Osmo Polyx adds a tough, water-resistant, hydrophobic finish boosting durability and making the boards faster through the water. As colours we use both powder pigments an Osmo natural paints.
Epoxy resin with high bio-content
Our resin is approximately 30% plant-based, offering a more sustainable option with a reduced carbon footprint. It binds all materials together while providing strength and flexibility for lasting performance and ensuring water tightness.
We're regularly looking into even more eco-friendly alternatives while ensuring the performance and durability of the boards.
