![]() ![]() They are made from foam, fibreglass and resin which means we produce a product superior in durability and strength to weight ratio. Boards produced in this way are typically much heavier and lack any true performance characteristics. ![]() The term ‘pop-out’ actually refers to the cheapest way to make a surfboard which involves making the hard outer layer of a board (usually a plastic composite) from a mold and then filling it with expandable foam. The use of CAD programs such as AKU and CNC machine is often (wrongly) associated with ‘pop-out’ boards. It is designed to help shapers keep their direct relationship with surfers and protect surfing from the loss of personalisation we’ve seen in other sports.” “The AKUshaper system was created to preserve the art of the custom surfboard. We believe all boards are precision instruments and should excel in function: that is why we have invested in the benefits of the AKU system. The move to machine shaping allows for efficient production and more time spent on the actual design and development of Circle One board shapes. Circle One have invested in two CNC machines installed by Mike Rickard, Director at AKU Shaper. The software produces a ‘file’ for each shape which is programmed into a state-of-the-art AKU Shaper CNC (Computer Numercial Control) machine which shapes the surfboard from a block of EPS foam using a circular cutter. The AKU software allows sub-millimetre accuracy to be achieved representing a revelation for creativity and experimentation. ![]() These days, the process of achieving shaping excellence is transformed by the use of industry-renowned CAD software ‘AKU Shaper’, which enables Jeff to ‘shape’ boards using a 3D software interface. As demand grew, Jeff worked around the clock to shape all boards to his own exacting standards. In the early days, Jeff Townsley, Circle One founder and shaper shaped all boards from scratch by hand. Read more about the Circle One story here or read on to learn more about our fascinating Epoxy Surfboard manufacturing process. You can be sure when you purchase a Circle One product you are investing in years of manufacturing expertise and heritage. All Circle One products are precision-cut and hand finished to exacting standards using only the best materials such as superior strength Porcher E-Fibreglass in our surfboards, hi-tensile aerospace grade 3k 220g/m3 carbon fibre in our carbon skimboard ranges and 360° super-stretch eco-friendly Japanese YAMAMOTO limestone neoprene across our Wetsuit and Neoprene Accessories range. We know that our reputation is only as good as the last Board, Wetsuit or Accessory we produce which is why we employ a team on the front-line to quality check production and maintain a no-compromise commitment to manufacturing excellence. At Circle One we’re passionate about riding the wave of innovation, developing and designing all our products in the UK and manufacturing in the Far East. ![]()
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