STAGE 6 - CIRCLE SURF PROJECT DEVELOPMENT

In the second half of 2025, the project will enter a particularly demanding phase of functional validation, focusing on the pilot production of cork-based PADs, the application of the fastening system, and its testing in a real-world usage context.

NIn the first stage, 30 units are produced using a formulation of 50% cork and 50% resin, protected with a surface coating and fitted with 3M double-sided tape. Upon receipt of the parts, NOMADS SURFING reports persistent adhesion issues at the interface between the PAD and the fixing system’s adhesive, with detachments observed, particularly in the kicker area, even after careful application and pre-heating.

In view of this non-conformity, a systematic technical analysis was initiated, involving the collection of the parts, the complete removal of the adhesive, a new inspection, re-machining, the repetition of bonding tests and consultation with 3M. The tests indicate that the problem stems not only from the adhesive application process, but also from the geometry and stiffness of the part, particularly its difficulty in following the curvature of the board in the kicker area, generating additional stresses on the PAD–adhesive–support–adhesive–board interface.

Based on this evidence, a redesign of the PAD is now being considered, based on dividing it into three parts and redefining various geometric parameters, including the kicker profile, the height of the relief, the effective length of the part and the fillet radii at the cut-off zones. This phase involves intensive technical development work between JCConsulting, NOMADS SURFING, the 3D designer and industrial partners, leading to the decision to proceed with a new mould.

The new mould will be completed in August 2025 and, following coating, will enter the industrial trial phase in September. The tests show a significant reduction in the total mass of the PAD, to values in the range of 165 to 167 g, and validate the viability of the new three-piece solution, although they also highlight the need for auxiliary pre-compression tools to improve filling and compaction in critical areas of the mould.

At the end of the period, new assemblies are produced and sent to NOMADS SURFING, now featuring 3M mesh tape; however, sea trials once again reveal difficulties at the interface between the PAD and the adhesive, with the adhesion problem persisting at the first level of the fastening system. In light of this result, the project embarks on a new phase of work focused specifically on this critical interface, with direct involvement from 3M and the dispatch of parts for laboratory analysis in Madrid.

This stage thus marks an important transition in the project: the central issue is no longer solely the formulation and geometry of the PAD, but now includes, as a critical element, the reliability of the PAD–adhesive interface as an indispensable condition for the final validation of the product.