3D-printed board cores
3D-printed board cores
Designed by shapers from the inside out.
What is a Swellcycle Core?
A Swellcycle core is a plant-based 3D-printed board blank, customized to your shape, engineered for performance, and made with sustainability in mind. Instead of cutting away foam, we build your board from the inside out using a precision additive process and responsible material.
Why use a Swellcycle Core?
Engineered from the Inside Out
Our printed lattice cores are designed for optimized flex, strength, and responsiveness -not just outer shape.
Parametric Customization
Dial in any dimension instantly. Adapt shapes for performance tweaks, different surfers, or new environments.
Micrometric Precision
3D printing delivers consistent, high-resolution accuracy - eliminating shaping inconsistencies.
Exact Replicas, Every Time
Effortlessly reproduce your best shapes for larger-scale production.
No Foam Waste
Our process produces no foam off-cuts or dust. What you design is what gets printed.
More Time to Create
Automated printing frees up time for design innovation and testing.
Cost-Effective
Reduce labor while increasing consistency and efficiency.
Designed from the inside-out
Inside every core is a unique lattice structure, custom-tuned to the board’s purpose and the shaper and surfer’s needs. This parametric approach allows us to:
- Dial in flex patterns
- Reduce weight while increasing strength
- Remove the need for traditional stringers
- Deliver consistency from print to print
What makes it sustainable?
BIO-BASED MATERIALS
Our cores are printed using a plant-based thermoplastic made from renewable resources like corn starch.
ADDITIVE MANUFACTURING
Instead of carving foam or cutting from blocks, we 3D print only what’s needed - no shaving, no cutting, no waste. The only byproduct is the printer support material, which we shred and repurpose into new products.
RETURN-READY CORES
When a board reaches the end of its life, the core can be upcycled into new products - closing the loop and extending the material’s life.
Want to try our tech on your shape?
Whether you're designing from scratch or scanning an old favorite, our process makes it easy to go from file to finished core fast, clean, and performance-ready.