Kitesurf365 TechCast #23: Directional Boards
Episode #401 | August 11, 2025
Host: Adrian Kerr
Guest: Dave “DK” Kay (product designer & ex-Cabrinha/Airush)
Episode Overview
Adrian Kerr and Dave Kay continue their special TechCast series, this time covering the fascinating world of directional boards in kiteboarding. Building on previous deep-dives into where kites and twin tip boards are made, this third installment explores the factories, construction technologies, regional logistics, and evolution of directionals—including surfboards, foil boards, and their connections to surfing and windfoiling. DK offers insights from his vast industry experience, recounts unique stories, and explains key technological innovations, quality differences, and the quirks of the factory landscape behind the sport’s favorite boards.
Key Discussion Points & Insights
1. Directional Boards Manufacturing—Why and Where?
(00:54–04:18)
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Diversity of Suppliers: Unlike kites and twin tips, directionals are produced in a variety of specialist factories around the globe.
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Logistics Challenges: Logistics and shipping costs play a huge role in factory selection; there’s rarely one location that suits all a brand’s needs.
- Quote: “Your best supplier for a particular technology tends to be in quite a different global location to where your best supplier for another technology is.” — DK [02:11]
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Separation from Standard Surfboard Factories: While surfboard manufacturing know-how is relevant, kite directionals require different, much stronger construction to withstand the loads put on by kitesurfing.
2. Surfboard Construction vs. Kite Directionals: The Durability Problem
(04:18–08:56)
- Kiteboards often draw from traditional surfboard construction but must be much more robust.
- Short Lifespan of Surfboards: Standard surfboards are almost “disposable” due to their short riding time and lighter construction.
- Quote: “Traditional surfboard construction I describe as disposable… the boards are designed to have a very short lifespan… the total number of rideable hours that you get on a surfboard… is pretty low.” — DK [06:23]
- For directionals, brands may use surfboard factories but must specify much stronger laminates or add tech not standard in surfing.
3. Are Directional Kiteboards Ever Hand-Shaped?
(08:56–15:56)
- CNC Shaping vs. Handcraft: Nearly all modern kiteboards (and high-end surfboards) use CNC machines for consistency and quality, but there's a philosophical debate about artistry and technology in shaping.
- Personal Anecdote: DK’s friend (Roger Hall, renowned NZ shaper) shifted from hand-shaping to CNC after seeing its power for precise, repeatable incremental changes.
- Quote: “The reason DK kiteboards got a CNC machine was not to make boards faster. It was to be able to make boards more accurately and to be able to record what we were making… change it by half a millimeter… That’s the power of CNC machining.” — DK [12:51]
- Modern shapers can still infuse artistry; CNC tech is a tool to enhance, not replace, craftsmanship.
4. Key Factories & Construction Methods
A. Playmaker (Taiwan)
(15:56–19:49)
- Innovation Origin: Originally made rackets, then wakeboards, moved into directionals.
- Unique Process: Expanded polystyrene (EPS) core, then thermally formed thin plastic top/bottom sheets in aluminum molds; yields durable, value-oriented boards.
- Brands Served: F-One and Naish use this method for portions of their lineup—notably more robust, heavier boards versus the ultralight high-performance segment.
- Quote: “I'm a really big fan of that process. It's kind of like, it's this perfect mix… between what I love about my, about twin tip process and compression molding… but with a much higher volume, lighter weight core and also makes a really durable board.” — DK [17:36]
B. Heiwan (Zhuhai, China)
(19:49–24:28)
- Niche Focus: CNC-machined EPS foam cores, vacuum-bagged lamination, significant hand finishing—especially sanding!
- Market Role: The headline Chinese source for kite directionals; many global brands have or do work with Heiwan.
- Scale & Quality: Even with many surfboard factories in China, few reach Heiwan’s standards for kiteboards.
C. Cobra International (Bangkok, Thailand)
(24:28–34:06)
- Industry Giant: Traditionally a windsurf board maker since the 1970s; now the global benchmark for "sandwich" construction (EPS core, fiber/foam/fiber layering).
- Secret Tech: Unique, secretive process to make molded EPS cores using composite molds—years ahead of competitors, allowing cores that require almost no sanding/machining, straight to lamination.
- Quote: “Cobra have a technology where they can expand EPS foam into molds made of composite so made of fiberglass and resin rather than being made machined from metal… As far as I know, Cobra to this day are still the only company that has that process.” — DK [31:14]
- Premium Supplier: The go-to for high-performance, best-quality boards; not the cheapest, but the best.
D. Apple Tree Surfboards (Portugal)
(34:06–41:15)
- European Disruptor: Pioneers in using extruded polystyrene (XPS) foam (not EPS); superior water resistance, more difficult to process but yields higher-tech boards.
- Vacuum Infusion Process: Lays all reinforcement dry, sucks resin through under vacuum for light, strong, chemically fused boards with minimal voids or excess resin.
- Quote: “AppleTree use a different style of polystyrene called extruded polystyrene… which cannot absorb water. So it’s significantly… advantageous. It is more difficult to work with.” — DK [36:32]
- Shared R&D: AppleTree produces for both their own and other brands, spearheading this process in Europe.
5. Finishing and Quality
(39:34–41:15)
- Vacuum Infusion Boards: Still require finishing, but labor is lower and result is unique and clean.
- Playmaker’s Molded Boards: Achieve nearly perfect surface finish out of the mold; less laborious finishing.
6. Listener Questions and Future TechCasts
(41:15–42:47)
- Adrian teases an upcoming episode dedicated to answering listener questions (AMA) about board manufacturing, materials, and new tech/processes. Listeners are encouraged to submit questions via the forum or Instagram.
- “An AMA for next month I think would be excellent… If there was any questions about that [new printing processes, factories, etc.], please fire them through.” — DK [42:16]
Memorable Quotes
- “Traditional surfboard construction I describe as disposable.” — DK [06:23]
- “CNC machining… makes you a more powerful board shaper.” — DK [13:54]
- “Cobra have a technology where they can expand EPS foam into molds made of composite… As far as I know, Cobra to this day are still the only company that has that process.” — DK [31:14]
- “AppleTree use a different style of polystyrene called extruded polystyrene… which cannot absorb water. So it’s significantly… advantageous.” — DK [36:32]
- “The reason DK kiteboards got a CNC machine was not to make boards faster. It was to be able to make boards more accurately…” — DK [12:51]
Timestamps of Key Segments
- 00:54 — DK’s manufacturing backgrounds & limits of current involvement
- 02:11 — Logistics and global distribution of board factories
- 04:18 — Why you can’t just use off-the-shelf surfboards for kiting
- 06:23 — Durability & lifespan of traditional surfboards
- 09:00 — Evolution of hand shaping vs CNC shaping
- 13:54 — The art and innovation in board design with CNC
- 15:56 — Playmaker, Taiwan: process and brands
- 19:49 — Heiwan, China: how the process works
- 24:28 — Cobra, Thailand: the global gold-standard for sandwich construction
- 31:14 — The secret core-molding tech at Cobra
- 34:06 — Apple Tree (Portugal): XPS and vacuum infusion tech
- 36:32 — Benefits of extruded polystyrene
- 41:15 — Upcoming AMA, invitation for listener questions
Conclusion
This episode provides an in-depth exploration into the intricate, globalized world of directional kiteboard manufacturing—revealing why certain factories dominate, how technology and artistry blend, and what truly sets premium directionals apart. DK’s first-hand stories, technical explanations, and candid asides paint a vivid picture of a surprisingly complex yet essential facet of the kite industry.
Next Up: AMA episode. Send your most burning questions about kiteboard (or kite) construction to the team!