What is a Swellcycle Core?
A Swellcycle core is a plant-based 3D-printed surfboard 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. The result? A lightweight, high-strength structure that’s ready to glass the moment it leaves the printer.
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.
Lattice System
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:
- Reduce weight while increasing strength
- Dial in flex patterns
- 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.
The Future of Making
This is just the beginning. Our platform is evolving to support new shapes, new performance profiles, and more sustainable material options—all with circularity at its core.
