When did it become an issue?
In recent years, the pickleball world has seen a surge of new paddle technologies—most notably thermoformed paddles and foam cores. As manufacturers strived to make paddles faster and more cost effectively serious issues became clear when trying to thermoform traditional honeycomb cores. These included core crush and delamination.
What Is Core Crush?
Core crush refers to the structural collapse of a paddle’s honeycomb core. This happens when excessive heat and pressure during the manufacturing process compromise the integrity of the core material, leaving it prone to breaking down during normal play. Once the core begins to crush, players often notice a “dead” feel in the paddle, reduced responsiveness, and in some cases, visible dents or soft spots.
When Did the Problem Start?
Core crush wasn’t an issue in earlier generations of honeycomb pickleball paddles. It began appearing with the rise of thermoforming, a manufacturing technique that bonds paddle layers together under extreme heat and pressure. Thermoforming can create a stiff, powerful paddle, but the high temperatures involved also place significant stress on the polypropylene honeycomb core cell and often lead to damaged and weakened cell walls right from the factory which lead to premature paddle failure.
Foam Cores: An Attempted Solution
As thermoformed paddles became more common, manufacturers began experimenting with foam-injected cores as a way to avoid core crush. While foam construction does eliminate the issue of honeycomb collapse, it comes with its own set of challenges:
- Delamination risk – Foam paddles are still prone to the surface layer separating from the core.
- Reduced long-term performance – Foam cores can break down or lose consistency more quickly than honeycomb.
- Different feel – Many players report that foam paddles lack the crisp responsiveness and touch of traditional honeycomb paddles.
In short, foam may solve the core crush issue, but it is not necessarily a better long-term solution for players nor does it produce a better performing paddle.
Why Cold-Pressed Honeycomb Paddles Still Matter
Traditional cold-press construction does not expose the honeycomb core to damaging heat or excessive pressure. Instead, the layers are bonded together under controlled conditions that preserve the core’s natural strength. Cold-pressed honeycomb paddles do not suffer from core crush, and they continue to deliver the lively, consistent responsiveness that players expect.
What This Means for Players
As paddle technology evolves, it’s important for players to look beyond marketing buzzwords and weigh the trade-offs. Thermoformed paddles deliver short-term performance but carry the risk of core crush if they use a honeycomb core. Foam paddles sidestep that issue but bring new problems of their own. Cold-pressed honeycomb paddles remain the most proven option for long-term playability, responsiveness, and durability.