FULL CUSTOM PRODUCTION ᐅ A Step-by-Step Factory Tour | Duotone Windsurfing

Ever wondered how the new Duotone windsurfing boards are made?

In this new video launched by Duotone Windsurfing. It shows the behind the scenes, "how its made' secrets in the new factory!

Why are they so light and strong?

Due to the new factory, manufacturing processes and quality. In the past two years Duotone have managed to increase the quality but reduce the weight by almost 1kg! 700grams lighter from 2022 to 2023. And another 300 grams from 2023 to 2024!

Almost 1kg in 2 years saved!
300grams from 2023 -> 2024!

Join Duotone Windsurfing ffor a tour of our FULL CUSTOM PRODUCTION process. Ever wondered how your Duotone board is made? We’ll guide you through every step, from CNCing the core to the final product: your finished board from Duotone.

 

 

In comparison to the industry standard, “semi-custom boards” a full custom board

is just as high-end as a handmade custom board from any shaper out there.

 

CNC-shaped EPS cores are not just more accurate as molded cores. For example it also  allow Duotone not to have the massive investment of molds. So whenever Duotone’s teams or Duotone's R&D team gets a better board ,we're able to implement it in the next year's collection.

 

Duotone's full custom boards are 100% handcrafted and take up to 30% more individual work hours on each Duotone board, which give everything for the product a lot of love to make as precise boards as possible. Unique in the industry, this is the same place where we create all of Duotone's prototypes and layup development.

 

That means at the end, the, the customer gets the same board and Technology as Duotone's team and R&D times developed for you. 

 

Welcome to the Duotone factory. We are here close to Bangkok in Thailand where all the magic is happening. From team rider boards to production boards and custom boards for Duotone’s team riders. 

 

Step 1 - CNC Shaped

Every board CNC cut out the EPS blocks - for example, here grip 4 SLS 81 as full EPS block comes on the machine we start to Route the board out of the foam 

 

Step 2 - EPC Core

The board com straight from the CNC go in the track.

Get the production cards registered and go straight to the shaping bay. 

 

Step 3 - EPS Sanding

that's where the shape gets really cleaned out and perfectly match into all the templates

 

Step 4 - PVC Reinforcements

the board is now nicely shaped Mass block is inside some PVC patches also nicely faded in for some additional strength 

 

Step 5 - First Lamination

 

Step 6 - Rocker Stick Library

The Rocker sticks are crucial elements of each board, so Duotone has five copies of each rocker stick for one board. They are labelled nicely and have all the digits so everybody knows which rocker stick fits in which shape.

 

Step 7 - PVC Bottom Process

After checking all the measurements and templates, we will go into the PVC process. First Duotone put first the bottom layer of the PVC with all the extra patches of the matching rocker stick into its board into the vacuum bag.

 

Step 8 - Vacuum Bag

 

Step 9 - PVC Top

After the board comes back out of the vacuum with the bottom layer of the PVC applied. It goes back to the QC inspection. We are checking weight measurements all details on the boards again before we go into the next process - adding the top shelf and all the extra

patches on the deck.

 

Step 10 - Vacuum Bag 2

 

Step 11 - Quality Control After PVC Process

 

Step 12 - Installation Inserts

Next step each windsurfing board gets it’s inserts. There are PVC blocks already in. So the team is cutting out the track, air valve, if it had it and the insert, double screw or single screw with anti-twist system. Matching everything and then going to the lamination process again.

 

Step 13 - Lamination

Before we entering the top lamination. Where you get the production card - its specification and there's everything prepared already for the lamination process they are filling out everything on a table pre- laminate on the table to absorb maximum weight efficiency to get the boards as light as possible.

 

Laminating the fibres on the board going back into the vacuum bag, adding The Rocker stick for extra precision

 

Step 14 - Vacuum Bag 3

 

Step 15 - Hot Coating

 

A nice hot coating is used to seal the surface of the fibers. in its color applied on the deck, and on the bottom, goes back into the sanding room where the guys give it the perfect finish.

 

Step 16 - Sanding Process

After the hot coatin,g the guys give it this final Touch with sanding before we go to the next QC step.

Step 17 - Quality Control 

 

Where the deck and the bottom get perfectly measured again before the board, let's go into the painting section there's a final QC deeply involved in Duotone's technical engineer. Which is closely working together with the factory based in Thailand so we have the specification from each board all the lines get drawn up, the rails get checked, the V gets checked, and everything is specified and controlled until we go to the next section.

Step 18 - Board Finishing 

 

So here's the finishing stage of the board: get the painting applied, the Graphics foot pad, and everything you need to finish it off.

 

Step 19 - Footpad inserts

 

Step 20 - Artwork

 

Step 21 - Packaging in Eco Friendly, plastic-free

 

The final packing you had now the full tDuotone's from CNC the core all the way to y Duotone's finished dreamboard.

Now it's time to pack it in an eco-friendly packing system and ship it straight to you.