I spent the last 6 years of my life developing a precision-shaped aluminum honeycomb surfboard technology. This was the subject of my senior design in Materials Science & Engineering at UPenn. Over the years, I was able to work through all of the technical challenges by collaborating with aerospace and motorsports advanced composites fabricators in Southern California. Below is a picture of a cross section of the board and more can be found on my company’s website www.varialsurfboards.com and the Facebook page that’s linked to at the bottom.
Honeycomb is extremely stiff through the core, but is very flexible in bending. The theory is that the core provides much more stability for the fiberglass skins than foam, preventing the skins from buckling before they reach their compressive strength. Honeycomb doesn’t add any bending stiffness to the structure, so we can dial in whatever flex the rider wants using computer analysis.
I know they experimented with honeycomb in surfboards in the 1970’s with the Wave Corporation and Aquajet boards. However, as I understand it they were just using those materials in a thin layer under the skin of the board and that the core itself was mostly hollow. Our design uses shaped honeycomb through the entire core of the board.
We are just now starting to publicly tell people about our technology. I’m excited to hear what all of you think.