AFS and AFS Advanced board construction

When constructing a board, the recipe is always the same; it’s the ingredients that change. A board is composed of several essential elements: the foam, the outer shell, the reinforcements, and the inserts.

The manufacturing process is generally the same: a low-density foam (EPS) core is created and then wrapped in a rigid shell.

Materials

What changes the properties of the board are the materials used and the order in which they are positioned. Here are the different materials that can be found in a board:

EPS Foam

This is a foam of varying low density that makes up the core of the board, also called the foam blank. It provides rigidity and buoyancy to the board while remaining light. The density of the foam has a significant impact on the final weight of the board.

Glass Fiber

Fiberglass is a strong material that allows for the construction of durable boards. It is denser and less rigid than carbon but is much more affordable, making it an asset in the construction of rigid and financially accessible boards.

Carbon

The ratio of rigidity to density of this material makes it one of the most used materials in high-performance construction worldwide. It can be used for the entire outer shell of the board or simply for reinforcements in strategic areas. There are various grades of carbon rigidity, allowing for pushing the limits of glide while ensuring rigidity and responsiveness of the equipment.

PVC

This PVC foam is generally four times denser than the EPS core. It comes in sheets of various thicknesses depending on its use (deck, US rail, etc.). The combination of this PVC foam with fiberglass or carbon fabric forms a sandwich material. It conforms to the shape of the core to reinforce and stiffen it while ensuring maximum lightness.

Epoxy Resin

It binds all the elements together and ensures the board’s waterproofness.

Construction basics

Let’s delve a bit deeper into the construction of the boards: The core forms the base of the board. There is a direct relationship between the choice of density and the construction around it according to the desired final product weight. The denser the foam used, the heavier but more resistant it will be to compression and impacts. A denser (heavier but stronger) foam allows for a lighter shell with more rigid materials like carbon.

It’s a matter of balance and compromise depending on what is expected from the final product. This is where the concept of sandwich construction comes in.

Sandwich construction

Firstly, the sandwich structure offers great impact resistance and results in durable constructions.

PVC Sandwich Glass

For PVC sandwich constructions, the principle is to enclose PVC sheets between multiple layers of glass or carbon to benefit from the mechanical properties of the fibers while limiting weight, thus ensuring unmatched strength. The PVC Sandwich Glass structure offers great impact and wear resistance. It is suitable for all levels of practice, from beginner to advanced. These are versatile and durable boards, offering excellent value for money.

PVC Sandwich Glass Carbon

This follows the same construction process as the PVC Sandwich Glass with the addition of carbon reinforcements in certain areas depending on the intended use of the board. The density of the core can also change to ensure slightly lighter boards. It’s an ideal compromise to have a fairly light and strong board – a low-density core and a glass sandwich construction with added carbon reinforcement strips. At AFS, the Whitebird best represents this type of construction. The PVC Sandwich Glass Carbon construction is particularly suitable for riders looking for a high-performance, light, and durable board while remaining affordable.

PVC Sandwich Carbon

In this construction, the sandwich fiber and PVC manufacturing process are still used, but the envelope fabric changes. Instead of fiberglass, it is made entirely of carbon. On each side of the EPS core, multidirectional carbon fiber fabric is applied. This material, known for its rigidity-to-density ratio, reinforces the board while optimizing its weight. This technique allows for optimizing the distribution of forces in the board, thereby improving its rigidity in all directions and overall responsiveness.

Triaxial Carbon Construction

AFS Advanced Construction

Triaxial Carbon is a weave of carbon fiber along three different axes, offering exceptional resistance and rigidity for minimal weight. In this type of construction, we choose to use a denser EPS core than usual. To ensure a light, strong, and rigid board, a Carbon/PVC sandwich reinforcement is located in the deck’s foot zones and around the US rail boxes. Additionally, carbon stiffeners along the board provide more responsiveness. These technical elements combined form a compromise that maximizes the lightness, resistance, and rigidity of our boards.

The manufacture of a board in Triaxial Carbon is a complex and meticulous process that requires artisanal know-how and advanced technologies, which is why this manufacturing technology is implemented in the same facilities where we make the foils in France.

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