A pickleball paddle is an absolute requirement to play the sport of pickleball. But have you ever wondered how pickleball paddles are made?

Too many players don't know what exactly goes into the pickleball paddle manufacturing process as they are only concerned about purchasing the best paddle that money can buy. However, you must know everything you can about this sport in order to play it well, including how a pickleball paddle is made.

The pickleball paddle manufacturing process usually consists of four steps. The first step is selecting the core and face material, the second is attaching the grip and cap, the third is assembling the rim and finalizing the paddle, and the last is shipping it out to the customer.

While the manufacturing process sounds relatively simple, a lot goes behind the scenes that make it complicated. For instance, unique foam-type material is wrapped around the pickleball paddle handle to provide a non-slip grip for the player to hang on to. This prevents the paddle from slipping from their hands. Furthermore, the face material is attached on both sides of the core, providing the pickleball paddle with characteristics like ball control, spin, and precision.

Of course, the material type is not the only thing that goes into the entire pickleball paddle manufacturing process. We have studied the pickleball paddle manufacturing process for quite some time and are experts in this field. Here, we will share all the steps behind the pickleball paddle manufacturing process and why knowing this can benefit you as a pickleball player.

How Do You Make a Pickleball Paddle?

Step 1: Selecting The Materials for The Core And Face

The body of a pickleball paddle had two sections - the core and the face. The face is a layer that covers the core on both sides of the paddle to help prevent damage while adding particular attributes. The core is typically around three to four centimeters thick. This is one of the first steps when discussing how pickleball paddles are made.

All pickleball paddle cores are given a honeycomb design similar to those on Boeing Aircraft panels.

The Core

The core of a pickleball paddle is typically manufactured using the three materials mentioned below;

Aluminum

Aluminum is one of the cheapest materials used to manufacture pickleball paddle core. However, paddles with an aluminum core are best if you're looking for better control. However, they have a less powerful shot than paddles made from polymer or Nomex.

Polymer

Polymer is a material that contains a blend of different types of plastics. Paddles with a polymer core are softer, providing you more shot power but sacrificing control. Plus, they are extremely quiet.

Nomex

Nomex is the most common material used to manufacture pickleball paddle cores. It has characteristics that are similar to cardboard. Hence, it's very lightweight. That said, paddles with a Nomex core offer exceptional control and durability. However, they are noisier than paddles with a polymer core.

That being said, many pickleball paddle manufacturers are experimenting with different core materials to solve particular problems that pickleball players may encounter with their paddle. For example, paddle manufacturers such as Engage have their own patented technology known as ProPolyCore. This material enables them to design and manufacture pickleball paddles with all the control of a thinner, lightweight paddle and the shot power of a thicker paddle.

The Face

As far as the face of the pickleball paddle goes, you have a choice of three materials. This material is then used to cover the core of the paddle.

Carbon Fiber

Carbon is one of the sturdiest and toughest materials around. It is used to manufacture sports car chassis, Aircraft panels, medical appliances, etc. It is also used to manufacture the face of the pickleball paddle. Paddles with a carbon fiber face are lightweight and offer much more control and durability but sacrifice shot power.

Graphite

Graphite is one of the most cost-effective materials for manufacturing paddle faces. Just like carbon fiber, graphite is a sturdy material, perfect for manufacturing pickleball paddle faces. In fact, paddles with a graphite face are similar to carbon fiber in durability but are difficult to find these days.

Fiberglass

Lastly, fiberglass is the most common material as far as designing paddle faces is concerned. Paddles with a fiberglass face are perfect for control. But you might have to give up shot power with this type of material.

Furthermore, various companies are coming up with newer composite materials such as polypropylene to offer more control and durability to pickleball players.

After selecting the facing material and applying it to the paddle's core, the pickleball paddle manufacturer applies another layer to the face to make the paddle more appealing. However, the USAPA forces paddle manufacturers to follow strict rules and guidelines, as adding an extra layer on the face of the paddle can add more spin.

Step 2: Attaching The Grip And Cap

The pickleball paddle's head is manufactured using industrial equipment and follows a similar process used to make badminton and tennis rackets. In addition, however, the paddle's head is extended toward the bottom to create the handle (made from similar material as the head).

When the head and handle are carved out, the assembly of the paddle begins with the grip. Firstly, a cap is attached to the bottom of the paddle's handle. This cap has a circumference that is a little larger than the handle itself.

After attaching the cap, paddle manufacturers utilize specialized, high-quality foam and tightly wrap it around the handle to form the grip. The grip is the most critical part of the pickleball paddle as it allows players to hold onto the paddle properly, avoiding slippage during games.

Step 3: Assembling Rim

Once the grip is attached to the paddle's handle, the rim is attached by hand. The purpose of the rim is to expose the honeycomb design and hold the pickleball paddle together. Furthermore, it also protects the paddle from damage when used during the game.

Typically, most pickleball players are prone to dropping their paddles every now and then. Therefore, the rim adds an extra layer of protection while allowing players to grip the paddle perfectly.

Step 4: Shipping Out The Paddle

Once the entire pickleball paddle is assembled, the last step is to ship it out to paying customers. Top pickleball paddle manufacturers such as Paddletek and Selkirk bundle a warranty car with each paddle sold. This allows customers the protection they need if their pickleball paddle is shipped with defects or dead spots.