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How Surfboards Are Made: Artistry meets scientific precision.


Surfing, an exhilarating dance with the ocean's waves, has been a source of joy and challenge for enthusiasts around the world for centuries. While the heart-pounding experience of riding a wave may seem effortless, the creation of the surfboard that makes this possible is a meticulous and intricate process that merges artistry with scientific precision.

The Evolution of Surfboards

Surfboards have evolved significantly over time. From ancient Hawaiians carving boards out of native koa or wiliwili wood to the modern-day sleek, high-performance boards made from innovative materials, the journey of the surfboard is a testament to human ingenuity and technological advancement.

The Crafting Process

1. Designing the Shape

Every surfboard begins with a design phase. Surfboard shapers, often regarded as artists, meticulously sketch and shape the outline, rocker (the curve from nose to tail), and rails (sides of the board) based on the intended use and rider's preferences. Computer-aided design (CAD) software or traditional hand shaping tools aid in this process.

2. Materials Selection

The core material of most modern surfboards is foam, typically made of expanded polystyrene (EPS) or polyurethane (PU) foam blanks. These blanks are cut according to the design specifications. Other materials include fiberglass cloth, resin, and sometimes carbon fiber or kevlar for added strength and flexibility.

3. Shaping the Blank

The shaping process involves cutting and carving the foam blank to match the design. Shapers use various tools such as planers, sanders, and rasps to sculpt the foam, meticulously refining the board's contours and dimensions. Traditional bespoke shapers will cut blanks by hand where as larger production boards are cut precisely using large C&C routing machines. 

4. Fiberglassing

Once the foam core is shaped, the next step involves covering it with fiberglass cloth. This cloth is saturated with resin and carefully layered onto the board. Multiple layers are applied to ensure strength and durability while maintaining flexibility. boards designed for more performance will generally have less or l""ighter" layers of glass where as heavier boards such as Logs or longboards will have more layers for added weight and streanth.

5. Lamination and Finishing

After the fiberglassing process, the board undergoes lamination, where excess resin is removed, and the board is vacuum-sealed or left to cure. Finishing touches like sanding, polishing, and adding decals or artwork complete the board, giving it its final aesthetic and functional qualities.

Innovation in Surfboard Construction

In recent years, advancements in materials science have led to the development of alternative materials like epoxy resins, bio-based foams, and recycled materials, aiming for more sustainable and eco-friendly surfboard production.

Moreover, the introduction of computer-aided shaping machines has revolutionized the industry, allowing for precise replication of designs and reducing the reliance on hand shaping, though many traditionalists still prefer the hands-on approach.


Crafting a surfboard is an art form that harmonizes creativity with technical expertise. Whether it's the traditional craftsmanship passed down through generations or the cutting-edge technology driving innovation, each surfboard embodies the spirit of riding the waves and reflects the passion of the shapers who bring them to life.

As surfers paddle out into the endless blue, their boards, a result of meticulous craftsmanship and innovation, serve as the bridge connecting them to the dynamic energy of the ocean, inviting them to carve their own stories upon the waves.

Surfboards are more than just tools for riding waves; they are a symbol of human connection to nature, creativity, and the relentless pursuit of adventure on the rolling, ever-changing canvas of the sea.

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Exit Surf Store
1020 Ferry Rd, Ferrymead,
Christchurch, New Zealand