Prototype Workshop

Where design becomes reality

The workshop is equipped for simultaneous fabrication of panels, drop-stitch cores, and rails. This parallel-workflow approach cuts prototype lead time to 7–12 days from engineering release. When your application demands a specialised solution, we can move from concept to on-water validation in under three weeks.

Workshop capabilities

The prototype journey — step by step

1. Engineering handover — The design package (3D model, FEA report, bill of materials, panel lay plan) is formally reviewed by the workshop lead and the project engineer. Any manufacturing concerns are flagged and resolved before cutting begins.
2. Panel production — The board is built according to the engineering specification. Panels are CNC-cut, the drop-stitch core is laminated between PVC skins, and the deck and hull are assembled with the approved material stack.
3. Welding — Panels are RF-welded into the full board shape. The chamber is inflated to test pressure and left for 24 h for initial stabilisation.
4. Assembly & finishing — Deck pad, graphics, handle, leash plug and fin boxes are fitted. All fittings are installed and verified against the specification.
5. Static tests — Before the board touches water, it undergoes: inflation cycling, air-retention hold test, deck deflection measurement at rated pressure, and hardware torque checks.
6. On-water test programme — 10 hours of in-water testing, detailed below.
7. Prototype review — A formal sign-off meeting is held with engineering, production, and quality teams. Any required design changes are documented and incorporated into the production release.

Custom prototyping for unique applications

The Prototype Workshop is where we solve the problems that standard production boards cannot address. Recent examples include:

• A 14'' touring board for a European endurance paddling brand, with a recessed cargo deck and reinforced nose — prototyped, fitted, and tested at our facility.
• A 10'6'' yoga board with a full-length traction deck and extra thickness for stiffness, validated across a 4-week rental season trial.
• A white-label fleet board with custom deck graphics and dual handles, where the prototype was used to validate colour, logo placement and packaging before the client committed to a container.

Our prototyping team

The workshop is staffed by eight multi-skilled production technicians, each cross-trained in at least two of the three core disciplines (cutting, welding, fitting). The team lead is a master craftsman with 16 years of experience spanning custom one-off builds to production series. Every prototype is assigned a dedicated project engineer who serves as the single point of contact for the client throughout the build and test process.

Client involvement

We actively encourage our clients to attend key milestones during the prototype build — particularly the initial fit-out review and the on-water test. Your operational feedback during these stages is invaluable in fine-tuning the board before it enters production. We do not build in a vacuum; we build in partnership with you.

The on-water test programme is also an opportunity for your team to familiarise themselves with the board's handling and maintenance requirements, ensuring a smooth transition to production when the final boards are delivered.