The short answer is: honeycomb is usually better for pickleball paddles compared to a solid foam core, but it depends a little on what you’re prioritizing (like cost, feel, or durability).
Here’s a simple breakdown:
| Feature | Honeycomb Core | Foam Core |
|---|---|---|
| Common Materials | Polymer (plastic), Nomex (paper-based), Aluminum | EVA or PU foam |
| Feel | Crisp, controlled, predictable | Softer, mushier, less consistent |
| Power | Good balance of power and control | Often softer, can lack “pop” |
| Durability | High (especially polymer honeycomb) | Lower — foam can break down faster |
| Weight | Lightweight to medium | Very lightweight (sometimes too light) |
| Cost | Moderate to high | Usually lower |
| Sound | Thocky or poppy, depending on core material | Muted, dull sound |
In general:
- Honeycomb (especially polymer honeycomb) is the industry standard for a reason — it offers a great mix of durability, consistency, and performance.
- Foam cores can feel nice and soft for casual players, but they often break down faster, lose performance over time, and lack the consistent rebound that more serious players expect.
Why use a foam core?
More companies are using foam cores because it’s cheaper, faster to make, and can be marketed as “new tech” — even if it’s not always better for performance.
1. Lower Manufacturing Costs
- Foam cores (especially injection-molded ones like EVA or PU foam) are much cheaper to produce than precision-cut honeycomb cores.
- Foam also requires fewer steps — no layering or bonding sheets together like honeycomb needs. You mold it, cure it, and it’s ready.
- This makes paddles cheaper and faster to make, which is super attractive for companies trying to hit aggressive margins.
2. Easier to Shape and Customize
- Foam can be molded into exact shapes easily — edge-to-edge coverage, curves, different thickness zones.
- Honeycomb is a bit rigid — you have to cut and sandwich it into shapes, which is more limiting and costly.
- Foam allows companies to create paddles with different feels (thicker sweet spots, quieter paddles, edge foam extensions) without retooling a ton.
3. Marketing and “Innovation” Buzz
- Brands love to say “NEW FOAM TECH!” even if it’s not a true performance upgrade.
- Words like “thermoformed,” “molded,” or “sealed edge” sound high-tech, even when the main change is that the core is just solid foam.
- New players (and even some experienced ones) associate “new” with “better” — so marketing foam as innovative sells paddles.
4. Fits the Thermoforming Trend
- Thermoformed paddles (sealed edges, carbon fiber wraps) are trendy right now.
- Solid or semi-solid cores (like foam) make thermoforming easier because you don’t have to work around open honeycomb cells that can collapse under heat and pressure.
Bottom line:
Foam cores help companies make paddles faster, cheaper, and more profitably.
Foam cores let brands claim “new tech” even if performance isn’t better.
Foam cores feel softer, which some players like (especially casual or comfort-focused players).
Foam cores usually aren’t as durable and don’t give the crispness and control serious players look for.