This blog post comes from the surfboard protection specialists FARO Board Bags in collaboration with AkuShaper surfboard design software. Surfing enthusiasts understand the connection between a surfer and their board. Surfboarding is an art that starts with the cutting of a surfboard blank. These blanks are the canvas for surfboard shapers to work their magic, sculpting them into sleek, hydrodynamic shapes that glide effortlessly through the waves. As the core of a surfboard, keeping these blanks safe before they get fiberglassed is extremely important. In this blog post, we break down the science behind CNC surfboard blanks and ways you can protect them.

CNC Cut Surfboard Blanks

CNC-cut surfboard blanks are the raw material used by surfboard shapers to craft custom boards. These blanks are pre-shaped foam blocks that serve as the foundation for creating any surfboard design.

Surfboard blanks come in various sizes, densities, and materials, catering to different riding styles and skill levels. Shapers carefully select the best blank based on factors like weight, buoyancy, flex, and performance characteristics desired in the final board.

Shaping Blanks Using CNC

The process of CNC-cut surfboard making involves using advanced surfboard design software to shape surfboard blanks precisely. Board makers use CAD/CAM software to design the board, ensuring accuracy in every detail. Once the design is finalized, it is sent to the CNC machine for cutting.

The CNC machining allows for intricate cuts and consistent shapes, resulting in high-quality surfboard blanks that are close to perfection. This automated process speeds up the production process, not only increasing efficiency but also drastically reducing weight.

Common Materials

The most common materials used for CNC-cut surfboard blanks include high-density foam cores, such as EPS or polyurethane, which are known for their lightweight and buoyant properties. These materials offer the base for surfboard shaping and laminating, and add to its overall strength and performance.

Picking the Best Blank For You

When you're picking out a surfboard blank, consider the type of waves you'll be riding and your what skill level is. Thicker blanks are ideal for beginners or small wave conditions, providing more flotation and stability. On the other hand, thinner blanks are better suited for experienced surfers tackling larger waves with greater maneuverability.

The material of the surfboard blank also plays a significant role in performance. EPS foam is lightweight and durable, making it popular among shapers looking to create high-performance boards. PU foam, on the other hand, offers a classic feel favored by many surfers for its responsiveness on waves.

Choosing a surfboard blank comes down to your personal preference and its intended use. Experimenting with different shapes, sizes, and materials can help you find out what works best for your surfing style.

Factors Affecting Surfboard Blanks

CNC-cut surfboard blanks are the foam core before the fiberglass is laminated to the core. It is the lamination process that gives a foam board all of its strength, so protecting the board before this process happens is important. There are a number of factors that can cause damage to these foam blank cores during transit.

#1 Exposure to Sunlight

Prolonged exposure to sunlight can lead to discoloration, degradation of foam materials, and delamination of laminates on the surface of the surfboard blanks. UV radiation from the sun can weaken the molecular structure of the foam, causing it to become brittle and easy to damage.

#2 Humidity and Moisture

Excessive humidity and moisture can seep into the foam core of surfboard blanks, leading to waterlogging and potential delamination. This can affect the blanks' buoyancy and structural integrity, affecting their overall performance and lifespan.

#3 Temperature

Extreme temperature variations, especially rapid changes, can cause thermal expansion and contraction of the materials, leading to stress fractures and warping of the surfboard blanks.

#4 Mishandling During Transportation

Improper handling and transportation of surfboard blanks during traveling can result in dents, dings, or scratches, affecting the blanks' overall smoothness.

#5 Impact Damage

Accidental impacts or collisions with hard surfaces can cause the blanks' structure to weaken or crack.

#6 Storage Issues

Storing your board blank improperly, such as stacking heavy objects on top of the blanks or storing them in confined spaces before they get fiberglassed, can cause compression damage and distort the blanks' shape.

Moonlight Glassing - San Diego, California

Is It Important to Safeguard Your CNC-Cut Blanks?

It's essential that you protect your CNC-cut surfboard blanks to maintain their performance in the water. Since these blocks are what makes the core of a surfboard, any compromise in the blanks integrity can lead to decreased buoyancy, stability, maneuverability and overall performance of the surfboard.

Tips to Protect Your Surfboard Blanks

By putting in effective protection measures, you can ensure that your surfboard blank remains unharmed before getting fiberglassed.

Pressure or Stress

Avoid putting too much pressure or stress on your CNC-cut storage blanks, which can lead to deformation or structural damage. Take care to support the blanks evenly and avoid applying extensive pressure on them.

Storage Locations

When selecting a storage location for surfboard blanks, consider factors such as humidity levels, temperature stability, and exposure to sunlight. Put your blank in an indoor storage area or climate-controlled space. Ideally, the storage area should be dry, well-ventilated, and shielded from direct sunlight and temperature extremes. Storing the blanks in a horizontal position can alleviate stress on the materials.

Surfboard Bags

Using durable protective covers or bags specifically designed for surfboard blanks provide an additional layer of defense against dust, moisture, and impact damage. These covers can safeguard the blanks during storage and transportation, reducing the risk of surface abrasions or dings before the blank gets fiberglassed. By investing in a high-quality surfboard bag, you can ensure your blank stays in optimal condition for a long time.

FARO offers a long line of surfboard bags and covers to protect your CNC-cut surfboard blanks from damage. These surfboard covers are made from durable materials that offer water resistance and padding to safeguard against impacts during transport or storage.

Whether you're heading to a surfboard factory to get your blank fiberglassed or just storing your it at home, using FARO’s surfboard protectors can help maintain the quality of your CNC-cut surfboard blank.

Handling and Transportation

To prevent your CNC-Cut blank from getting damaged during transit make use of proper handling and transportation practices. If you plan on traveling with your CNC-cut blank, cover the blank in a canvas bag and securely attach it inside of your vehicle. In case you're traveling by air, pack your surfboard blank in a well padded surfboard case for protection during transit. Securing the blanks with straps or restraints to prevent movement and shifting can minimize the risk of damage caused by sudden stops or turbulence.

Photo courtesy of AkuShaper - Nick Hodgkinson, San Diego, California, 2019

Conclusion

Protecting your CNC-cut surfboard blanks before they get the chance to be fiberglassed is indispensable for maintaining their quality, performance, and longevity. With proper care and maintenance, you’ll be able to transform your surfboard blank into a surfboard that's perfect for you!

How to Protect Your CNC Cut Surfboard Blanks