The construction of a surfboard changes its weight, flex, durability and feel. Rusty offers three core approaches: traditional PU/polyester, EPoly and EPS/epoxy.
PU with polyester resin
Polyurethane foam is a proven closed-cell material used for decades. Paired with polyester resin, it creates the familiar feel many surfers know. It is cost-effective, straightforward to repair and available in different densities. Its predictable weight can also feel settled when conditions become choppy.
EPoly
EPoly combines a polyurethane blank with epoxy resin. The familiar PU core remains, but epoxy provides a stronger bond, better impact resistance and flex that lasts longer. The finished board can be lighter and less prone to yellowing than a traditional polyester build.
EPS with epoxy
Expanded polystyrene is made from fused beads and must be laminated with epoxy. It is usually lighter and more buoyant than PU, giving the board a lively feel and extra paddle efficiency. That energy is excellent in many conditions, although very light builds can feel nervous in wind or chop. A heavier glassing schedule can calm the ride.
EPS absorbs water faster after a ding, so leave the water and repair damage promptly. The best construction depends on the model, your surfing, local conditions and whether you value classic feel, lightness or maximum durability.
Adapted with permission from Rusty Surfboards USA.
