Process
Manufacturing Process
From raw material to sea-ready SUP —every step under our control
Unlike brands that outsource production to third-party factories, Afarer owns and operates its entire manufacturing chain. This vertical integration allows us to maintain strict quality control at every stage, respond quickly to custom requirements, and deliver consistent product quality batch after batch. Here is how a SUP board is built in our facility.
Material Receipt & Inspection
Every incoming batch of PVC fabric, fiberglass mat, resin, and hardware is inspected against specification. Fabric samples are tested for tensile strength, thickness uniformity, and UV resistance before release to production. Non-conforming materials are quarantined and returned.
Automatic PVC Cutting
<p>Approved fabrics are laid on the automatic CNC cutting machine and cut with sub-millimetre accuracy. Computer-optimised nesting arranges panels to minimise waste —typically below 5%. Cut panels are labelled by SUP model and chamber, then bundled for transfer to the welding workshop.</p>
Tube Heat Sealing & Welding
Panels are tacked and bonded using heat sealing machines with hot-air welding at controlled temperatures of 200–300 °C. Main seams are reinforced with RF dielectric welding for airtight, high-strength joints. Completed chambers are inflated to 18.0 PSI for an initial airtightness check ahead of the 24-hour retention hold.
Drop-Stitch Core Bonding
SUP board drop-stitch cores are bonded to outer PVC laminates using heat lamination. Thousands of internal polyester threads connect top and bottom layers, creating a rigid structure at 12-15 PSI. Rail bands are triple-layer fusion bonded for edge strength.
SUP Printing & Decoration
SUP board deck graphics are applied using digital printing for full-colour photo-quality designs, and screen printing for durable logos and repeating patterns. Prints are cured and sealed for UV and abrasion resistance.
Final Assembly & Fitting
Valves, D-rings, handles, fin boxes, and deck pads are installed on the assembly line. Each board follows a 100-point assembly checklist with mandatory sign-off at each stage.
Quality Testing & Inspection
Every completed board undergoes mandatory quality gate: chamber air-retention test, hardware function check, fastener torque verification, and cosmetic inspection. Custom and prototype builds also receive in-water trials covering stability and handling.
Packing & Shipping
Boards are deflated, folded per procedure, packed in heavy-duty woven bags or retail boxes, and loaded for shipment. Each package is labelled with model, serial number, and destination. We coordinate with freight forwarders for FCL and LCL container shipments worldwide.
Inspection Evidence
Every Stage Leaves a Record — Photos & Reports
Below are the actual inspection photos and test-report dossiers from our seven controlled quality gates. Each PDF is a real bilingual record you can download and audit — the same records that back every batch in the 10-year ERP traceability archive. See the full 7-stage flow on /quality.
PPM — Project Quality Planning
The pre-production meeting locks scope, the golden sample and the Quality Inspection Plan before the line starts. Unresolved items block production release.
Download QIP (PDF)
IQC — Incoming Material Inspection
Every incoming batch of PVC, fabric and hardware is checked against the approved spec. Non-conforming lots are quarantined and rejected before release to the line.
Download IQC reports (PDF)
IPQC / FAI — In-Process Control
The first article is verified against the locked baselines and every shift keeps patrol checks on the line. FAI approval version-locks artwork, dimensions and BOM.
Download IPQC reports (PDF)
Inflation & Air-Tightness Testing
100% of completed boards — not a sample — get a 24-hour pressure hold at 18.0 PSI with automatic reject above a 0.50 PSI drop. One record per chamber.
Download air-tightness reports (PDF)
FQC — Final Product Inspection
Finished boards are measured against drawing tolerances and cosmetically graded under D65 daylight lamps against the approved golden sample.
Download FQC reports (PDF)
PSI — Packaging & Pre-Shipment Inspection
The packed kit is checked 100% against the customer-approved BOM — barcode scan (Grade ≥ B), carton markings and ISTA-1A drop test before loading.
Download PSI reports (PDF)
Shipment Release & Traceability
Quality signs off the batch only when all six previous gates are closed. Serial numbers are mapped to the batch and the dossier is handed over with the shipment.
Download release reports (PDF)See our equipment and machinery
Explore the industrial-grade equipment behind every Afarer SUP board.
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