If you’ve ever picked up a padel racket and wondered how something so solid, lightweight, and precise is actually made, you’re not alone. It’s a question many players ask once they start taking the game more seriously.
Unlike a strung tennis racket, a padel racket is a single, solid structure. Its performance comes not from strings, but from a carefully engineered combination of materials, layering, heat, pressure, and finishing work. Every stage of the manufacturing process plays a role in how the racket feels in your hand and performs on court.
Because we manufacture our own international padel federation-approved rackets at Raquex, we see this process from start to finish. What follows is a clear, behind-the-scenes look at how padel rackets are made, from raw materials to the finished product.
How Padel Rackets Are Made (At a Glance)
- An EVA foam core is shaped to define feel, comfort, and response
- Fiberglass or carbon fibre layers are built around the core
- Heat and pressure cure the racket into a solid structure
- Holes are drilled to refine aerodynamics and sweet spot behaviour
- The racket is finished, fitted with a handle, and quality checked
Each step influences how the racket performs; none of it is accidental.
Step 1: The EVA Foam Core (Comfort, Power & Feel)
Everything starts with the core. Often described as the “heart” of the racket, the core has a major influence on comfort, control, and power.
Most padel rackets use EVA (Ethylene Vinyl Acetate) foam. This rubber-like foam is cut into the exact shape of the racket head before any outer layers are applied.
The density of the EVA foam is critical. Softer EVA compresses more on impact, offering greater comfort and a larger sweet spot. Firmer EVA deforms less, delivering a more direct response that experienced players often associate with control and power.
Different rackets use different EVA densities depending on the type of player they’re designed for. This is one of the main reasons two rackets with similar shapes can feel completely different on court.
Step 2: Fiberglass vs Carbon Fibre Layers
Once the core is prepared, the racket’s structure is built by layering high-performance materials around it. These layers form both the frame and the face of the racket.
The two most common materials used are fiberglass and carbon fibre.
Fiberglass is more flexible and forgiving. It tends to offer a softer touch and a slightly higher trampoline effect, which can help generate power with less effort. Because of this, it’s often used in rackets aimed at beginner and intermediate players.
Carbon fibre is stiffer, lighter, and more durable. It provides a more precise response and greater stability, especially on fast or off-centre hits. Higher-end rackets may use different carbon weaves, such as 3K, 12K, or 18K carbon, to fine-tune stiffness and feel. The higher the “K” number, the more filaments per thread, resulting in a crisper response.
These material layers are impregnated with epoxy resin, which will later harden and bind everything together.
Step 3: Heat, Pressure & the Moulding Process
This stage is where the racket truly takes shape.
The layered structure, EVA core, fibre sheets, and resin, is placed into a steel mould shaped like the final racket. The mould is then subjected to carefully controlled heat and pressure.
During this curing process:
- The epoxy resin hardens, bonding all layers into a single structure
- The EVA foam compresses to its final working density
- The racket gains its strength, durability, and final shape
Precision here is essential. Too much heat or pressure can damage materials; too little can lead to weak bonding or inconsistent performance.
Step 4: Drilling, Finishing & Quality Control
After moulding, the racket is structurally complete but far from finished.
First, the holes are drilled into the face. These aren’t decorative; their placement affects aerodynamics, balance, and how the racket flexes across the sweet spot.
Next comes sanding and cosmetic finishing. The surface is smoothed, paint and graphics are applied, and a protective coating is added to improve durability.
The handle and grip are then fitted, along with the mandatory safety cord required for padel play.
Finally, each racket goes through quality control. Weight, balance, finish, and overall consistency are checked to ensure it meets performance standards before it ever reaches a court.
Why Manufacturing Quality Matters in Padel
Because padel rackets are solid, small variations in materials or construction have a big impact on performance. Manufacturing isn’t just about assembling parts, it’s about consistency.
This is why two rackets that look similar can feel completely different. The way the EVA foam is prepared, how layers are aligned, and how the racket is cured all influence durability, comfort, and playability.
What This Means for Your Game
When you choose a well-designed padel racket, you’re holding the result of a highly controlled manufacturing process. Every material choice and production step affects how the racket moves, feels, and responds on court.
The holes, the balance, the touch, none of it is accidental. Good racket design isn’t about one standout feature, but how everything works together.
Understanding how padel rackets are made makes it easier to appreciate why the right racket can elevate your game, and why quality construction really does matter.
Frequently Asked Questions About Padel Racket Manufacturing
What materials are padel rackets made from?
Most padel rackets use an EVA foam core combined with fiberglass or carbon fibre layers bonded with epoxy resin.
Are all padel rackets made the same way?
The overall process is similar, but materials, layer counts, carbon weaves, and curing methods vary significantly between rackets.
Is carbon fibre better than fiberglass?
Not necessarily. Carbon offers more stiffness and control, while fiberglass provides comfort and forgiveness. The “best” material depends on player level and preference.
Does manufacturing affect durability?
Yes. Proper curing, high-quality materials, and accurate drilling all play a major role in how long a racket lasts.
How long does it take to make a padel racket?
From core preparation to final inspection, the process typically spans multiple stages over several days.
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