Pickleball’s booming popularity has led to a surge in paddle innovation. For businesses looking to manufacture paddles, understanding the production methods is crucial.
Two common techniques are cold press and thermoformed (or “hot press”) paddles. Each method impacts a paddle’s performance, durability, cost, and appeal. In this guide, we compare cold press and thermoformed pickleball paddles at a high level, helping your business choose the right manufacturing approach for your brand.
A cold press pickleball paddle is made by pressing together the paddle’s components at normal temperature (no additional heat). Manufacturers layer a face material (such as fiberglass or carbon fiber) over a polymer honeycomb core and compress them using pressure, with strong adhesives bonding the layers.
Cold press paddles typically use a polymer honeycomb core (often polypropylene) sandwiched between composite face sheets. Common face materials include fiberglass or raw carbon fiber (for a stiffer, more powerful feel).
In summary, a cold-pressed paddle generally consists of: a polymer core, three material face plates, glue bonding them, and an edge guard to protect the layers.
Cold press manufacturing offers several advantages for business. Key benefits include:
On the whole, cold press paddles are appreciated for their consistent performance and affordability. They’re a great choice if you want a dependable paddle that appeals to a broad market with solid playability and a friendly price point.
A thermoformed pickleball paddle is created using heat in addition to pressure to mold the paddle’s shape. In a thermoforming process (often considered a “hot press” method), the components are placed in a heated mold and pressed, causing the materials to fuse into a unified structure.
Essentially, the face material (often a plastic composite sheet) is heated until it becomes pliable, then wrapped or formed around the core under high pressure, resulting in a seamless, one-piece paddle shell. Thermoformed paddles also incorporate injected foam around the edges of the core during this molding process to reinforce the structure. This creates paddles with an enhanced sweet spot and a continuous feel from the center to the edge.
In summary, a thermoformed paddle’s manufacturing involves heat-molding the paddle in a precise mold, bonding the core and face together into a single piece to achieve a more uniform, molded shape.
Thermoformed paddles typically use advanced materials that can withstand the heat and pressure of the process. Most feature a polymer honeycomb core (often polypropylene) which augmented with foam injection in the perimeter cells or an internal foam frame for stability.
The surface material is usually high-grade carbon fiber. Carbon fiber (especially Toray T700 carbon, 3K, 18K etc) is popular in thermoformed designs for its strength-to-weight ratio and heat tolerance. Some high-end thermoformed paddles even use aramid fiber (Kevlar) layers or other advanced hybrids for the outer shell to boost strength and vibration dampening.
Thermoformed paddles represent the latest in paddle construction technology and come with several notable advantages:
For brands, having a thermoformed model in your lineup can signal premium quality and innovation, appealing to players willing to invest in top-tier equipment for performance gains. Despite typically higher production costs, the benefits above make thermoformed paddles attractive for high-end market segments.
In plain terms, thermoformed vs cold press isn’t about one being absolutely better – it’s about what’s better for your needs. Each method has strengths that align with different priorities:
Ultimately, "better" depends on what you want to prioritize, affordability and broad appeal (cold press) or high performance and premium appeal (thermoformed). Many successful brands offer both types in different product lines to cover both bases. For example, you might have an entry-level or club series using cold-press construction and a pro series featuring thermoformed paddles.
To decide between cold press and thermoformed (or to determine the mix), ask these questions about your brand positioning:
Who is your target customer?
If you cater to beginners and casual players, they value a paddle that is easy to play with, forgiving, and affordable. Cold press fits well here.
If you target advanced competitors or professionals, they might expect the latest tech and are willing to pay for performance; thermoformed is attractive to this group.
What price range are you aiming for?
For a value-oriented brand or a large retailer aiming for volume sales, cold press paddles allow you to hit lower price points while still delivering quality.
If your brand is premium or trying to establish a high-end image, a more expensive thermoformed paddle can justify a higher price due to its features and build.
What is your brand’s differentiation?
If your brand story emphasizes innovation, advanced materials, and “pro” equipment, thermoformed paddles reinforce that message. You’ll be offering something that not every competitor in the mid-range has.
If instead, your brand is about simplicity, reliability, or catering to grassroots players, sticking with a proven cold press construction might align better.
Resource and Volume Considerations
Thermoforming typically requires more upfront investment. If you’re a newer brand with limited resources or you plan to produce many design variations quickly, cold press might be more feasible initially due to its flexibility and lower tooling costs. On the other hand, if you have the capital and you’re confident in the demand for a high-end paddle, investing in thermoformed manufacturing could pay off with a unique product in your lineup.
In many cases, brands find a hybrid strategy works: use cold press for one segment of paddles and thermoformed for another. For example, you can launch a cold-pressed carbon fiber paddle as your base model, and also have a top-of-the-line thermoformed carbon fiber paddle for your performance model. This way you cover both ends of the market.
In general, a thermoformed pickleball paddle can maintain good play performance for 1 to 3 years.
How long a paddle “lasts” can mean two things: how long until it physically breaks, and how long until its performance (pop, feel) degrades.
Even though thermoformed paddles are robust, the reality of intense play is that the core can fatigue and the surface can lose some of its initial pop over time. The advantage of thermoformed construction is that it minimizes risks like delamination, one of the common reasons paddles “die.”
One of the most exciting parts of creating your paddle line is designing how the paddles will look. Visual branding—colors, logos, and graphics—makes your brand recognizable and sets it apart on the court.
Your brand’s logo should feature prominently on the paddle face. Typically, logos are placed near the center of the face or slightly toward the top half, where they’ll be most visible but not distracting at the point of contact.
Choose a color scheme that aligns with your brand identity, whether that’s bold and bright or sleek and minimalist. Modern paddle printing techniques allow virtually any color or pattern. You might have a solid color background with your logo, or a full-face graphic design.
Keep in mind your audience: a vibrant, multicolor design might appeal to a younger, recreational crowd, while a simple two-tone design with carbon fiber weave showing might appeal to a high-end crowd (as it suggests a premium, material-focused aesthetic).
There are a few methods to get your graphics onto the paddle, and each has its advantages:
Discuss with us which printing/finishing method is best for your design. For instance, if your design has full-color gradients or photos, UV printing will handle that best. If your priority is a textured surface for performance, a simpler design that works with a sandblasted surface might be ideal. It’s possible to combine methods too, e.g., UV print the graphic and then add a spray sand for spin.
Beyond the face graphics, consider other custom elements that showcase your brand. You can often customize the logo on the grip or end cap of the handle. The edge guard can be made in different colors and have small logos or text printed on it. Also, little details like a logo on the paddle cover can enhance the overall presentation of your product line.
Overall, you want a great-looking paddle that represents your brand well, but also one that players will love to use. Be careful not to clutter the design; often a clean look with a standout logo works best, especially for a premium vibe.
When it comes to manufacturing your pickleball paddles, iAcesport stands out as a reliable partner for several compelling reasons. We understand that as a business, you need a manufacturer who can deliver on quality, cost, and customization.
With over 20 years in the sports equipment industry, you can trust that we understand what players and brands need, as evidenced by the many established brands that have partnered with us over the years. This experience allows us to offer valuable guidance to new brands on choosing materials, constructions, and designs that will succeed in the market.
Because we operate at scale and continuously optimize our processes, we offer very competitive OEM pricing. Even as a small or growing business, you’ll find our pricing flexible to different order sizes and transparently quoted with no hidden fees. Our goal is to help you maximize your margins.
We also have a relatively low MOQ, often as low as 100 pieces per design, so you don’t have to over-commit on inventory while starting out. This is ideal for testing the market or offering multiple designs without a massive upfront cost.
One of iAcesport’s biggest strengths is making your brand vision come to life. We offer a wide range of customization services. In essence, you get a paddle that is uniquely yours, not just a stock model with a logo slapped on.
Choosing iAcesport means choosing a manufacturer committed to quality, efficiency, and your success. We would be excited to help bring your cold press or thermoformed pickleball paddles to life and assist your brand in gaining a winning edge in the market.
CHIKOROKO is a professional pickleball paddle manufacturer with over 8 years of experiences in producing high-quality pickleball paddles for many brands. Specializing in both hot-press and cold-press manufacturing processes, we offer a wide range of customizable options for our clients. With more than 100 sets of molds available, we provide the flexibility to create custom pickleball paddles tailored to specific needs, from design to performance...[ Read More >>]
