Falcon_Foil D/LAB 2024

The FULL CUSTOM CNC TECHNOLOGY is a full custom technology which is one hundred percent identical to high-end custom made boards.

Instead of using a mould to bring the EPS foam core into its final shape each EPS block gets CNC milled. This ensures maximum precision and saves weight. 

Same as with high-end custom board makers the major advantage lays in the processing. We call this SINGLE PROCESS TECHNOLOGY and it is the key to our industry-leading weight-strength ratio. Instead of combining working steps to save time and money every single step follows its individual process. So for example instead of joining the PVC sandwich with the EPS core in a single shot we vacuum-bag the top and bottom PVC shields with the EPS core separately. 

Also instead of using standard 3mm PVC elements for the entire board we use thicker and thinner PVC plates as well according to the stress areas which makes the board lighter yet stronger.

For all D/LAB boards we use our most sophisticated layup which consists of more than 60 individual parts and components (nearly 20% more parts than used for our PREMIUM SANDWICH CONSTRUCTION). 

On top we are using the most high-end composite materials available to-date. 

1. All carbon fibres used are a mix of high strength and high modulus carbon qualities depending on the individual requirements of each board section. Our high modulus carbon used can also be found on high-end products like aircraft’s, Formula One cars or our Platinum SLS masts, booms and extensions. 
2. Innegra is a high modulus Propylene with unbeatable tensile and ding resistance. It offers a similar tensile strength to Kevlar, but is significantly stiffer. In addition, Innegra is the best composite fibre to prevent dents.
3. We use our exclusive high performance S-glass fiber with an extra high silica content which offers much higher tensile strength as well as about 10-20% greater stiffness.
4. And finally we are using our exclusive DUOTONE SENTEX® resin impregnated with silicon nano-spheres which helps us to reduce the weight even further without sacrificing durability. 

Instead of using a similar layup on all boards we use a DISCIPLINE SPECIFIC FLEX CONSTRUCTION for all our D/LAB boards since demands on the different disciplines (wave, freestyle, freeride, racing) and conditions vary quite a lot.

1. Racing boards are e made to offer maximum performance (instant acceleration and V-max). Therefore these boards need be as stiff as possible. To achieve this no compromise stiffness we use a super high carbon content on all FALCON D/LAB layups.
2. On wave boards though a certain „give“ is essential since these boards are very short and might become too stiff thus uncontrollable using a full carbon layup. Therefore the GRIP D/LAB boards come with a higher Innegra and S_GLASS+ content. These high-tech composites have a much higher tensile strength avoiding breakages after high landings. To still achieve an outstanding "spring-back" characteristics which makes the board more reactive and has a tremendous effect on the acceleration we use unidirectional Carbon reinforcements in longitudinal direction. 

Last but not least even every single board size has an individual layup. That’s the final stage of individualisation in construction.

The result speaks for itself since the D/LAB boards are up to 500 grams lighter than our SLS boards and up to a full kilo lighter than other semi custom production boards. And it’s the first time that a production board can compete even with the lightest custom made boards out there. 

Yet all of this is achieved without any sacrifice in durability since we always follow our core motto LIGHT DONE RIGHT.

High quality closed cell neoprene for maximum longevity. Only black Lycra coating guarantees maximum comfort as well as maximum durability. The strap features measurement markings to allow you to quickly set up and replicate your individual size. Board specific attachments:

• All World Cup boards come equipped with double-screw plugs to prevent any twist and ensuring the most direct connection to the board
• All other boards come equipped with single-screw plugs to allow a faster repositioning of the straps plus a more comfortable ride due to a certain "give"

Vertical rail design to give the rider more leverage when canted over to windward and to increase righting moment plus forward drive

Ultra compact length for improved air flow and higher crosswind top speeds, whilst still maintaining a stable gybing area for the feet

Extensive Vee at the nose avoids catapults when touching down at full speed.

The 2 STEP CUT-OUTS reduce the wetted surface. This decreases the drag before take-off and accelerates the transition into flight mode.

Rocker line developed over decades that generates enough lift whilst still releasing drag, a key performance component of modern foil racing

Flatter deck shape for comfortable stance and maximum control during jibes. 

The recessed mast track area lowers the rig connection, boosting control and aerodynamics by “closing the gap”.

The recessed foil box area improves the tear-out strength and the power transmission to the foil and leads to a weight reduction of approx. 200g.