The manufacturing process starts with a molded expanded polystrene (E.P.S.) core. This foam core is extremely light and represents less than 10% of the weight of the finished board or approximately one-third the core weight of traditional surfboards. As a result of the weight saved in the core, additional layers of fiberglass can be applied to the board to create a thicker load-bearing surface skin.

The core is hand-detailed and hand-wrapped with multiple layers and varying weights and weaves of fiberglass fabric. Applying the fiberglass at this stage enables the board to be seamless, reducing the likelihood of the surfboard splitting along a seam upon impact. This technique is unique to the construction process of newsurproject boards.

After wrapping the core with fiberglass fabric, the board is saturated with epoxy resin and then place it in finish molds. These finish molds contain thermoformed (P.V.T.) top sheet material. The top sheet has been screen-printed with the board’s graphics on the underside so that when the graphics are applied, they appear underneath the top sheet and cannot be scuffed off. The molds are closed, placed into hydraulic presses and heated to cure the epoxy resin.

When the boards are popped out of the molds, there is a mid-rail seam created by the joining of the top and bottom of the top sheet material. This seam is cut back and coated with a thin layer of polyester fairing compound. This compound is then sanded and the rail is coated with urethane-based paint.

Finishing details are added to the surfboards such as mini-Tuttle flange boxes and traction pads on smaller models. After that, the boards are ready to ride

Prices range from £180 - £280 (approximately). Used NPS' range from £100 - £220 (approximately)