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Which Board

Knitted (Fusion) vs Weave

Below is a guide to help explain what material paddleboards are made of, so you can make a more informed decision about what you’re buying and why.

What you need to know

When browsing most paddleboard websites, you’ll often come across terms like Fusion, Weave, Double Laminated, MSL, ESL, Light Technology, Double Walled, Military Grade and other ways of describing materials.

Low-End Paddleboards

Low-end paddleboards (which aren’t always cheaper in price) are typically made from single-skin, low-density material (500 denier substrate with a dropstitch where the strands are further apart). These boards may be marketed under various names such as Light Technology, Military Grade, or Double Walled. They are usually 6” thick and have a maximum construction pressure of 15 PSI, which is one of the only real ways to assess the quality online. When purchased or seen in a shop, it’s easier to spot the cheaper quality—the material is extremely light and rolls up very tightly, so the package will arrive in a smaller box.

There are still a couple of brands that use double-glued materials. These boards are much heavier and more cumbersome to carry, which is a stark contrast to premium fusion boards that, while heavier than a 500 denier substrate board, are still easily manageable to carry.

Premium Paddleboards

More premium boards are made from high-density knitted or Woven material, typically a 1000 denier substrate with a thick laminate coating, often referred to as double laminate. These premium manufacturing techniques allow for a 4.7” dropstitch and 20 PSI construction. When the board arrives, it will come in a larger box, be heavier due to the additional material, and be harder to roll up because the substrate and laminate are thicker. You’ll also usually find that extras like triple rail edges made of thicker materials, carbon rails, and higher quality EVA on the decks contribute to the board’s weight and overall durability.

To give an example of average weight a 10’6 shape, the weight is slightly altered by the rail thickness as the premium boards are 4.7 inches thick so they lose weight because they have less material in the board. Unfortunately, the cheaper brands often do not show true weights on their website so this all does get a bit confusing.

  • 10’6 x 32 x 6” Single skin board weight; 7.5kg
  • 10’6 x 32 x 6” Double Glue board weight; 10.5kg
  • 10’6 x 32 x 5” (4.7”) Double laminate average weight; 9kg
  • 10’6 x 32” x 5” (4.7”) Weave average weight; 7.7kg

What is Knitted (Fusion) Material?

Knitted ‘dropstitch’ material is composed of several elements that come together.

Substrate, the fabric at the top and bottom of the board. The substrate in knitted materials resembles the knit of a jumper under a magnifying glass. The dropstitch—strands that run top to bottom inside the board—are attached to this knit. When the board is inflated, you can see the strands forming diamond-shaped dots.

In cheaper boards, the knit is thinner, while in premium boards, they are thicker. The substrate is coated with a laminate to ensure longevity and keep the board air and watertight.

Cheaper boards often have thinner laminate, while more premium materials feature a thicker laminate (often referred to as double laminate). The thicker laminate makes the board more durable, though it’s the thicker substrate that primarily contributes to this, along with increased airtightness and stiffness. Thinner materials are weaker, less stiff, and less durable, which is partly why they can only be inflated to 15 PSI, and the more premium materials are thicker, more stiff and more durable which is why the material can withstand the higher pressure of 20PSI +.

What is Weave Material?

Weave material has only been around for about five years. It’s more expensive to produce, so you’ll typically only find it in brands that are more technologically advanced. Unlike knitted materials, which can go by many different names, weave is generally just called “weave,” making premium quality easier to identify.

The substrate in weave material is still 1000 denier, like premium knitted (fusion), but because the tensile strength of the weave is higher than the knit, it’s stiffer. As the weave has fewer dips and bumps in the material, when the lamination is placed over the substrate material, less laminate is used, which allows the board to be noticeably lighter. This is why it’s easier to carry.

Because the board is lighter, weave is often used in high-end travel boards as well as by brands that are pioneering hardboard-like performance in 4.7” drop-stitch designs.

Weave is easily identifiable because the drop-stitch is attached to the substrate in such a way that when the board is inflated, the material looks visibly different from the diamond-shaped dots of fusion material. Instead, it appears as many small, indented lines in the laminated top.

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