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A 100% vacuum bagged glassing technology with polyester or epoxy resin


Varial has created a new patent-pending process for glassing boards, called Infused Glass. Drawing on our core competencies of adapting aerospace technologies for the advancement of surfboard performance, Varial has developed a revolutionary vacuum bagged glassing product.  The process, currently used to make large wind turbine blades and racing boat hulls, infuses polyester or epoxy resin into the fiberglass under vacuum pressure in one shot.  This produces a uniform laminate that’s tight to the shape with extremely low resin content.  We then have the ability to isolate and engineer specific characteristics into the skins of the surfboard for any desired performance attributes.


“What glass layup should I choose with on my Infused Glass™ board?”


“What’s the difference between epoxy and polyester?”


Wonder no more. We have data driven answers straight from the lab.

We put an end to buzz-word comparisons of strength and flex by getting down and dirty in the lab. Varial engineered flat panel samples to remove all the variables that get in the way of a true 1:1 comparison. We made them with all the most popular glass layups in both epoxy and polyester resin. See the data for yourself. Throw out the “magic” and use science and take the design of your Infused Glass™ board to the next level.



While you’re chewing on the data, here’s a few things we want to point out:


     • The myth of epoxy being stiffer than polyester is officially busted. Epoxy resin Infused Glass™ boards are up to 13% more flexible in bending. The more fiberglass you put on the board the less drastic the difference between the flex of polyester and epoxy boards.


     • We looked exclusively at deck buckling resistance in our study - that’s how boards usually break. If you want uniform strength everywhere on your board, stick to equal amounts of glass on the deck and hull.

Summary of the Bending Flexibility of Glassing Options



4 deck/4 bottom = baseline

4+4/4 = +18% stiffer

6/6 = +21%

6+4/6 = +37.8%


4 deck/4 bottom = +12.9% more flexible

4+4/4 = +13.1% stiffer

6/6 = +21.2%

6+4/6 = +34.9%

Summary of the Strength of Glassing Options



4 deck/4 hull = baseline

4+4/4 = +36.7% stronger

6/6 = +24%

6+4/6 = +62.8%


4 deck/4 hull = -3.4%

4+4/4 = +29.9% stronger

6/6 = +28%

6+4/6 = +66.2%

See what's in the lab    >


Surf Technology

1922 Palma Dr. Unit H

Ventura CA, 93003

(805) 288-3577