The manufacturing method of thermally formed pickleball racket involves first cutting the honeycomb carbon fiber fabric core and surface layer into desired shapes. Some resources claim that the foam around the edges of the honeycomb board is "injected" around the edges after thermal forming, but it is likely to be placed around the honeycomb carbon fiber fabric core before thermal forming to provide mechanical support for the surface layer and keep its curvature consistent with the foam during the thermal forming process.
The honeycomb carbon fiber board is sandwiched between the top and bottom panels, and then the entire assembly is placed in a mold. The racket preform is heated and pressurized to cross-link the adhesive, bonding the top and bottom panels to the honeycomb board. After cooling, the racket is removed from the mold.
The fiber is imported from Japan and made fabric by ourselves.
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