If you’ve been shopping for a new pickleball paddle, you’ve probably come across the term thermoformed—but what does it actually mean, and how does it compare to sandwich construction?
Thermoformed Paddles – These paddles are made by molding a single, continuous carbon fiber shell around the core. The edges are sealed, often with injected foam, to add stability and power. This factory-driven process makes mass production cheaper, but it also results in a stiff, uniform feel that can lack the natural feedback some players prefer. Additionally, since these paddles rely on a fully enclosed shell, once they start to break down, performance tends to decline quickly—and there’s no real way to repair them.
Sandwich Construction Paddles – This traditional method involves layering separate face materials onto a honeycomb core, which is then edge-glued and finished. This allows for a variety of face materials, including real wood, giving paddles:
✔ A More Natural Feel – Better vibration damping for a controlled, responsive playing experience.
✔ More Material Flexibility – Allows for different combinations of face materials, tuning the paddle for different play styles.
✔ Better Longevity – Unlike fully fused paddles, well-built sandwich paddles maintain their playability over time and can often be refinished or repaired if needed.
Which is More Cost-Effective for Mass Production?
Thermoformed paddles win on cost. Their mold-based process is highly automated, requiring less manual labor and allowing for faster, high-volume production. But this efficiency comes at a price—the trade-off is a paddle that prioritizes production speed over feel and longevity. Sandwich construction, while more labor-intensive, offers greater flexibility in materials and a more refined playing experience.
So, which one is better? It depends on what you value:
✔ Power & Pop? Thermoformed paddles deliver, but often at the cost of feel.
✔ Control & Longevity? Sandwich construction offers a more natural control a refined playing experience and often a longer paddle life.
At Brick House, we specialize in handcrafted, sandwich-constructed paddles that blend carbon fiber precision with the pure feel of real wood for what we believe is a better playing experience for players who value a more well rounded game.