Surfboard manufacturing has begun to utilise Expanded Polystyrene as a core material; however, surf literature relatively ignores this material. This manuscript investigates the mechanical behaviour of Expanded Polystyrene (EPS) sandwich composites. An epoxy resin matrix was used to manufacture ten sandwich-structured composite panels with varying fabric reinforcements (carbon fibre, glass fibre, PET) and two foam densities. The flexural, shear, fracture, and tensile properties were subsequently compared. Under common flexural loading, all composites failed via compression of the core, which is known in surfing terms as creasing. However, crack propagation tests indicated a sudden brittle failure in the E-glass and carbon fibre facings and progressive plastic deformation for the recycled polyethylene terephthalate facings. Testing showed that higher foam density increased the flex and fracture mechanical properties of composites. Overall, the plain weave carbon fibre presented the highest strength composite facing, while the single layer of E-glass was the lowest strength composite. Interestingly, the double-bias weave carbon fibre with a lower-density foam core presented similar stiffness behaviour to standard E-glass surfboard materials. The double-biased carbon also improved the flexural strength (+17%), material toughness (+107%), and fracture toughness (+156%) of the composite compared to E-glass. These findings indicate surfboard manufacturers can utilise this carbon weave pattern to produce surfboards with equal flex behaviour, lower weight and improved resistance to damage in regular loading.

Surfing is a popular sport, with the associated market forecast to reach 2.6 billion US dollars by 2027. In the published literature, there is a range of investigations into the performance of surfboard fins. Some studies model a single fin or review the performance of different fin layouts and surface designs. However, the effects of individual fin design features on flow dynamics are not well understood. This study provides numerical analysis into the thruster fin aspects (rake, depth, and base length) and resultant key performance indicators (i) lift and drag coefficients, and (ii) turbulent kinetic energy. The models were simulated in Ansys Fluent R19.1, solving steady Reynolds-averaged Navier–Stokes equations using the SST k−ω turbulence model at a velocity of 7 m/s. The results indicate the performance of fins varies more post-stall. The variations in rake showed the biggest impact on the turbulence intensity at an angle ≥20°. The variations in base length exhibited coefficient trends with greater lift at small angles but significant lift losses at high angles of attack. The variations in depth affected the forces on the fins rather than the performance indicators. Based on these simulations, a proposed fin set was developed that presented the lowest lift losses after the stall point.