Behind the Scenes at Red Paddle Co: Production & Innovation

Rueben from SUPboarder meets with Red Paddle Co in this two-part series. He’ll be speaking with George Shillito, the Commercial Director, and Phil Hawthorne, the Head Designer, to discuss all things Red Paddle Co.

In this first video, we will explore the production process, quality controls, and the MSL material they use. We will also delve into the differences between welded and glued rails, focusing on their Tech Air process. There’s a lot of fascinating information to cover, so let’s get started.

To begin with the basics, how can you make an inflatable paddleboard? Inflatable paddleboards are made from a material called drop stitch. Drop stitch refers to the manufacturing technique where threads are woven between two layers of fabric, creating a strong, air-tight structure. This material arrives on a roll from a large machine and is then cut into the shape of a board. To make the board airtight, a tape is added around the edges, along with a valve, forming the core of a modern inflatable paddleboard.

There are various qualities of materials that brands can use in their manufacturing process. At Red Paddle Co., we specify the exact materials, their grades, densities, and compositions to ensure consistency and performance. Initially, we used off-the-shelf materials, but they did not meet our standards. Materials are dynamic and can expand, compress, shift, or twist, so we needed to control and specify them to achieve the desired performance.

We have been fortunate to learn and refine our material specifications over the years, ensuring that we know exactly what goes into our boards. This is crucial because, in some factories, materials might change without the brand’s knowledge, leading to inconsistencies. At Red Paddle Co., we maintain strong relationships with our suppliers and visit them regularly to ensure transparency and quality.

In terms of material construction, inflatable paddleboards can be single-layer or double-layer. Single-layer boards are made from a textile material coated with plastic to make it airtight, but they lack structural integrity. Double-layer boards add a second layer of material, providing extra strength and durability but at the cost of increased weight. To address this, we pioneered the MSL (Monocoque Structural Laminate) technology, which bonds the layers together at the manufacturing stage, resulting in a lighter, stronger, and more durable board.

Now, let’s talk about the bonding process for the rails and making the board airtight. While some brands use welded rails, we use a gluing process. Welding is a strong method but requires precision, and any mistakes can render the board unusable. Our gluing process, developed through extensive research and testing, ensures a robust bond that withstands the rigors of use.

Quality control is paramount at Red Paddle Co. We work closely with chemists to test the adhesives and ensure they meet our high standards. We control factors such as humidity, temperature, and the timing of glue application to maximize adhesion. This meticulous approach ensures our boards are durable and reliable.

Regular visits to our manufacturing partners in Asia allow us to maintain oversight and ensure our processes are followed. Even when not physically present, we implement stringent quality control measures to catch any potential issues.

Our commitment to quality and innovation has allowed us to refine our processes continually. For instance, our compact range uses unique materials specified to our requirements, which did not exist before we began our development.

Innovation at Red Paddle Co. is driven by a desire to enhance the paddling experience. Whether it’s reducing board weight for better performance or developing new materials, our goal is to create the best possible products. While some ideas remain on the cutting room floor, many have shaped the industry and improved paddleboarding for everyone.

In the next video, we will explore what sets Red Paddle Co. apart from other brands.