Kitesurf365 – TechCast #27 | Ep. 427
Release Date: March 2, 2026
Host: Adrian Kerr (B)
Guest: Dave Kay (DK/A) – Kite designer, software developer, and founder of Lacuna

Episode Overview

In this episode of the TechCast series, Adrian Kerr is joined by the highly knowledgeable kite designer Dave Kay (“DK”). They dive deep into listener AMA questions on the role of AI in kite design and the technicalities of kite strut configuration. The conversation also touches on material choices in kiteboard manufacturing, and features candid industry reflections along with a blend of humor and insight. The episode is especially valuable for those interested in the intersection of technology and kiteboarding gear development.

Key Discussion Points & Insights

1. Reflections on Andrea’s Iconic Jump (01:39 – 05:45)

• Topic: Andrea’s jump off the A Dubai and the intersection of kitesurfing with spectacle events.
• Key Insight: DK provides both an industry and safety perspective, distinguishing between public perception and engineering realities in kite and paraglider design.
  • Risks vs. Rewards: High-profile jumps attract attention to the sport and sponsors but highlight that kites are not built for BASE-jumping or similar stunts. Paragliders offer more safety redundancy due to their design (multiple load paths), but kites are riskier if a line snaps.
  • Quote:

    “From a product designer's point of view, it… shows our sport in a light that we probably, we don't want that to be a thing. Like you shouldn't be jumping off stuff on your kite. It's not designed for it.” (04:13, DK)

• Memorable Moment: Adrian and DK recall behind-the-scenes footage of similar extreme jumps to underline the perilous nature of launching kites off structures with suboptimal wind.

2. AI in Kite Design – Opportunities and Limits (05:45 – 18:05)

a. Current AI Capabilities (06:20 – 12:12)

• Software Development Parallels:
  DK draws on his daily work using AI (like ChatGPT) in software and highlights why AI is so effective in coding: there’s a massive, public, well-documented data set (GitHub, Stack Overflow).

• Challenges in Kiteboarding Context:

  • Ill-defined Problems: “High-performance” is subjective with qualitative metrics—fast turning, bar pressure, etc.—making AI optimization tough.
  • Lack of Data: Unlike code, kite designs are proprietary and unpublished, offering AI nothing to train on.
  • Quote:

    “No kite designer has ever published anything more than like, nothing... The AI’s got nothing to train on.” (10:26, DK)

• Prognosis:
  AI won’t be revolutionary in kite design without shared industry data. Proprietary secrecy is too ingrained for public datasets to emerge.

b. AI in Jump Height and Scoring (12:12 – 17:45)

• Clarifying “AI”:
  The industry buzzword “AI” is too broad. Most current excitement is about Large Language Models (LLMs), which aren’t suited to tasks like measuring jump height, but other algorithmic solutions have been used for years.

• Jump Height Measurement:
  Devices like WOO already apply advanced algorithms (sometimes dubbed “AI”) to parse accelerometer data. True millimeter accuracy isn’t possible, but devices are impressively close.

  • Quote:

    “What’s already sitting inside, say, a WOO device... could easily be described as AI. It’s already taking a problem that is essentially uncalculatable... and we can agree that it does the job.” (15:06, DK)

• Scoring Assistance:
  AI could assist judges by processing large volumes of video and competition data, but variability, “noise,” and the need for high-quality labeled datasets mean humans are still required.

3. Kite Struts: Design Decisions & Technical Factors (18:07 – 23:38)

a. Strut Pressure, Placement, and Diameter (18:07 – 20:57)

• Modern Limitations:
  All modern kites use a “one pump system,” so strut and leading edge pressures are the same, unlike in certain wings.

• Design Variables:

  • Strut diameter: Small changes yield big effects on stiffness (e.g., half the diameter is 8x more flexible).
  • Strut number & placement: Determined by design goals and manufacturing constraints (seam placement in kite panels).
  • Goal: Reduce weight while retaining canopy stability.

• Quote:

  “All comes down to the designer and their iteration process ... Struts are just one part of thousands of options you can change on a kite.” (19:54, DK)

b. Three vs. Five Strut Debate in Big Air Kites (20:57 – 23:38)

• Conventional Wisdoms:

  • 0–1 strut: Light wind, foiling
  • 3 strut: All-rounder
  • 5 strut: Big air, high-end wind range

• Design Tradeoffs:

  • More struts → more stability in high wind, but more weight and rigidity.
  • Fewer struts → lighter and faster turning, may require tweaks in kite profile for stability.

• Quote:

  “The number of struts has been used to determine what style of kite it is… but you can’t just point at a kite, go, ‘oh, it’s three struts, it’s X.’ It doesn’t work like that.” (22:46, DK)

c. Advanced Materials – The “Aluula Effect” (23:38 – 24:57)

• Stiffness Is Key:
  New materials (like Aluula) enable designers to reduce tube diameters without sacrificing rigidity, maintaining performance and reducing weight—a significant leap for kite responsiveness and longevity.

4. Kiteboard Construction: Wood vs. Foam Cores (24:57 – 33:29)

• No Plywood Used:
  No modern boards use plywood cores. Plywood is engineered for construction, not board dynamics.

• Industry Standard – Vertical Laminated Paulownia:

  • Why Vertical Lamination? Multiple strips glued edge-to-edge yield better strength, consistency, and resource usage than one big piece or plywood.
  • Benefits: More predictable flex and resilience, and better pop for riders.

• Comparison with Foam Cores:

  • Polyurethane Foam: Used in wakeboards but too soft/flexible for thin, high-performance kiteboards.
  • Cross-linked PVC Foam: Stronger but eventually failed under more aggressive riding styles (e.g., kite loops).
  • Paulownia Wood: Light, strong, lively response—became industry standard after foam’s limitations were exposed.

• Quote:

  “The big difference between riding a foam cord twin tip and riding a wood chord twin tip is how quickly that board returns to shape when you load it up… what a rider would describe as pop, what a designer would describe as reflex. Paulownia wood cores give you a much stronger board with a much more lively ride.” (32:23, DK)

Notable Quotes & Memorable Moments

• On Kites and Danger:

  “You shouldn’t be jumping off stuff on your kite. It’s not designed for it. Thirty meter jumps over water... is dangerous enough.” (04:13, DK)

• On AI’s limits:

  “No kite designer has ever published anything more than like, nothing... The AI’s got nothing to train on.” (10:26, DK)

• On Strut Number:

  “You can’t just point at a kite, go, ‘oh, it’s three struts, it’s X.’ It doesn’t work like that.” (22:46, DK)

• On Wood Cores:

  “Paulownia wood cores give you a much stronger board with a much more lively ride, a much better pop than if we use foam. And that’s why it’s become the dominant core material across the industry.” (32:23, DK)

Key Timestamps

• 01:39 – Andrea’s jump and the gear danger discussion
• 05:45 – Listener AMA segment: AI’s role in kite design
• 10:26 – Why AI can’t solve kite design (data limitations)
• 12:12 – Accuracy and future of jump height measurement with AI
• 16:18 – AI for competition scoring
• 18:07 – Strut design: pressures, placements, diameters
• 20:57 – Three vs. five struts in big air kites
• 23:48 – Impact of Aluula and modern materials
• 24:57 – Kiteboard manufacturing: plywood vs. vertical laminated wood vs. foam
• 32:23 – Advantages of vertical laminated paulownia wood
• 33:29 – Wrap-up and sign-off

Summary & Takeaways

This episode offers a high-definition look behind the curtain of kite design and board construction, mixing practical engineering insights with strategic reflections on industry trends. Dave Kay’s depth of expertise and Adrian’s thoughtful questioning make this a must-listen for anyone chasing the “why” behind their gear’s feel and performance—from diehard kiters to technology geeks. The initial optimism around AI is tempered by pragmatic realities, while the segment on materials showcases the continuous experimentation and innovation that drives the sport forward.

To stay current on future AMA sessions, send in your pressing gear questions, and be sure to follow the show for more deep dives and tech insights from kiting’s leaders.