05Process & QC

Twelve stations, then the holding bay.

A board is glued, welded, pressed and sprayed before it is allowed to rest.

01Holding rules

Nothing ships on the day it is made.

Time is part of the spec. Every board sits through the same rests, and a batch holds pressure for 48 hours before it is released.

  1. 01 100% of boards get the seam spray test.
  2. 02 Every board rests 24 hours after lamination, then 24 hours again after finishing.
  3. 03 Nothing is cleaned or packed until it has rested 12 more hours.
  4. 04 Batches hold stack pressure for 48 hours before release.

02Main line

Twelve stations in order.

Edge buffing on the line.

01 Station

Edge buffing

A buffing wheel roughens the airtight edge and the drop-stitch skin so the adhesive keys into the surface.

Rail band cutting on the line.

02 Station

Rail band cutting

The inner sealing PVC band is measured against the outline of the board and cut to the curve.

Rail band glue on the line.

03 Station

Rail band glue

Polyurethane adhesive is brushed on by hand and left to open for a set time before the band goes down.

Inner rail bonding on the line.

04 Station

Inner rail bonding

A hot-air gun reactivates the glue and a steel hand plate presses the band down in sections.

First inflation on the line.

05 Station

First inflation

The sealed blank is inflated for the first time so rocker, symmetry and structure can be checked on shape.

Outer rail welding on the line.

06 Station

Outer rail welding

A high-tensile PVC rail goes over the seam and is hot-air welded, which is where the impact and tear margin is added.

Seam trimming on the line.

07 Station

Seam trimming

Under pressure, a scraper lifts the overflow glue so the rail line reads clean to the hand.

Leak test on the line.

08 Station

Leak test

Boards are inflated to working pressure, stacked, and sprayed with water mist seam by seam to read the bubbles.

Deck pad glue on the line.

09 Station

Deck pad glue

Masking tape holds the pad boundary while a wide brush spreads adhesive clear of the handle and valve bases.

Roller pressing on the line.

10 Station

Roller pressing

The board runs through a roller line under constant pressure, which drives out the last trapped air.

Final cleaning on the line.

11 Station

Final cleaning

In the clean area, QA wipes deck, pad, fin box and rails with a residue-free cleaner before the board is signed off.

Folding and packing on the line.

12 Station

Folding and packing

Air is pulled out, foam goes on the fold points, and the board is rolled and strapped.

03Moving record

Four stations, filmed in the room.

Edge buffing, pad glue, batch trimming and packing, each paused on its first frame until you press play.

Edge buffing Station 01: the buffing wheel roughens the seam edge before glue goes on.
Deck pad glue Station 09: adhesive is brushed inside the taped pad outline.
Batch trimming Detail: boards on the pressure rack are trimmed edge after edge.
Bagged and stacked Detail: folded boards go into dust bags and stack by batch for cartoning.

04Details

Ten more passes the camera caught.

Corner work, batch trimming and the pressure walk that closes a batch out.

Rail alignment on the line.

E01Rail alignment

Outer rail close-up on the line.

E02Outer rail close-up

Corner detailing on the line.

E03Corner detailing

Batch trimming on the line.

E04Batch trimming

Stacked holding on the line.

E05Stacked holding

Pressure check on the line.

E06Pressure check

Masking on the line.

E07Masking

Handle and D-ring glue on the line.

E08Handle and D-ring glue

Bagged and stacked on the line.

E09Bagged and stacked

Roller line, wide on the line.

E10Roller line, wide

Ask for the test record on your run.

Open the brief Compliance