Surfboards are made from (and Greenlight sells) two types of foam blanks.
1. EPS Foam Blanks - EPS stands for Expanded Polystyrene. EPS foam is lighter and stronger than Polyurethane foam blanks. It consists of small beads of polystyrene expanded with steam and fused together under high pressures. Greenlight's EPS blanks are engineered with a special high energy bead-bond formula for the optimal strength, flex, and shape-ability of the blank. There is a growing demand for EPS surfboards in the world due to its superior strength to weight ratio.
The stock EPS blanks are rectangular in shape supplied with a rocker and foil. You can create any outline shape you want with EPS blanks. There are no limitations.
We also specialize in manufacturing custom surfboard blanks per your AKUShaper File to reduce the labor and dust produced when shaping a surfboard. We're mixing machine and software technology with hand shaping so there's still a sense of pride and ownership in the boards but with much less work, less dust and high accuracy. We've eliminated the power planer from the shaping process and made board building attainable for all surfers, regardless of experience with tools or the process.
Greenlight is a huge proponent of EPS surfboards and has been developing, manufacturing and selling EPS blanks for over 15 years.
NOTE: EPS foam must be glassed with EPOXY resin! Polyester resin will melt the foam!
2. PU Blanks - PU stands for Polyurethane. It has been the traditional surfboard core for over 60 years. PU blanks can be glassed with either polyester resin or epoxy resin (epoxy becoming more popular due to its superior strength). PU blanks are molded in the general shape a surfboard to reduce the amount of excess foam. Your surfboard shape outline still must be drawn on the blank and cut out.
- EPS Surfboard Blanks are stronger than Polyurethane Surfboard Blanks
- EPS Surfboard Blanks are lighter than Polyurethane Surfboard Blanks
- EPS Surfboard Blanks are more environmentally friendly than Polyurethane Surfboard Blanks due to EPS recyclability
- EPS Foam must be fiberglassed with Epoxy Resin. Polyurethane Foam can be fiberglassed with either epoxy resin or polyester resin
- EPS Surfboard Blanks are fully customizable and there are no limitations to the surfboard shape. Polyurethane surfboard blanks are limited in the shape's width and thickness and require more labor and make more dust when shaping.
- EPS Surfboard Blanks do not require a stringer as the foam's strength and glassed with epoxy resin provide adequate strength for surfing. Carbon fiber reinforcements can be included in the fiberglassing process to stiffen the board and control flex patterns. PU foam surfboard blanks require a stringer as they tend to be weak and floppy when surfing without a stringer.
- EPS Surfboard Blanks tend to absorb water more than Polyurethane foam.