Development and manufacture of kites, kiteboards, foils and wings for water sports
CORE Kiteboarding GmbH
Fehmarn (Klausdorfer Weg 21a) · Fehmarn (Osterstraße 47, registered office)New on Amplifa
About CORE Kiteboarding
CORE Kiteboarding GmbH, based on Fehmarn, develops and manufactures water sports equipment for kitesurfing, wingfoiling and foiling. From the board brand CARVED, founded in 2001 and one of the first kiteboard manufacturers worldwide, the CORE brand emerged in 2007, under which premium kites, bars, boards and foils are developed and distributed. CARVED twintips are made from paulownia wood cores that are milled at 20,000 rpm, precisely measured and laminated with the exclusive Cartan 2 carbon using a vacuum infusion process; afterwards the boards are sanded, painted and assembled. Since 2019, series production of the twintips has taken place at sister company Elan in Slovenia, one of Europe's most modern ski and yacht production facilities, while development, testing and custom manufacturing remain on Fehmarn. Wings such as the Halo Pro 2 rely on Polyfusion technology, in which Exo-LT panels made of ALUULA 98 are thermally welded together. The products are developed and tested on site and used worldwide by the international pro team.
- Site
- Fehmarn
- Processes
- Milling (CNC milling of the undersides and deck profiles from paulownia wood cores, 20,000, Vacuum infusion process (carbon shell, significantly less resin than conventional processes), Laminating (carbon fibre shell around wood core), Sanding (including hand-sanded 3D rails), Painting, Shaping (board design/shape with specialist software), Insertion of inserts for fins, pads and grab handle, Quality inspection: precise measurement of the core, checking for unevenness, fibre residue and
- Materials
- Paulownia, Cartan 2 Carbon, Epoxy binder (epoxy resin), ALUULA™ 98 (Exo LT), Aluminium (CFS Aluminium Mast), ExoTex 3, ExoTex Light, CoreTex 2
- Founded
- 2001
- Industries
- Water sports, Kitesurfing, Wingfoiling
- 01
Shaping (board design with specialist software)
- 02
CNC milling of the paulownia wood cores
- 03
Quality inspection: precise measurement of the core
- 04
Insertion of the inserts for fins, pads and grab handle
- 05
Vacuum infusion and laminating of the Cartan 2 carbon shell
- 06
Sanding including hand-sanded 3D rails
- 07
Painting
- 08
Final inspection and assembly
Materials and Processes
Paulownia
Wood core for the milled undersides and deck profiles of the kiteboards
Cartan 2 Carbon
Carbon weave with minimal epoxy binders for the shell of the boards
Epoxy resin
Binder in the vacuum infusion process, significantly less resin than with conventional processes
Aluminium
Mast material of the CFS Aluminium Mast for foil setups
ALUULA 98 (Exo LT)
Ultra-lightweight high-performance composite for welded wing panels
CoreTex 2 / CoreTex Power Matrix / ExoTex 3 / ExoTex Light
Weight-optimised kite fabrics for NXS and Halo Pro 2
Tectanium 2
Line material of the Sensor 4S Pro with immediate impulse transmission
Locations
Fehmarn, Klausdorfer Weg 21a
DEDevelopment, custom board manufacturing and testing
- Lot size
- Prototype to one-off (custom)
- Materials
- Paulownia, Cartan 2 Carbon, epoxy resin
- CNC milling machine (20,000 rpm)
- Vacuum infusion system
Fehmarn, Osterstraße 47
DERegistered office and administration
Products
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Milling (CNC milling of the undersides and deck profiles from paulownia wood cores, 20,000Machining | – | – | – | – | Paulownia wood |
| Vacuum infusion process (carbon shell, significantly less resin than conventional processes)Plastics | – | – | – | – | Cartan 2 Carbon, Epoxy resin |
| Laminating (carbon fibre shell around wood core)Plastics | – | – | – | – | Cartan 2 Carbon, Epoxy resin, Paulownia wood |
| Sanding (including hand-sanded 3D rails)Surface | – | – | – | – | – |
| PaintingSurface | – | – | – | – | – |
| Shaping (board design/shape with specialist software)Engineering | – | – | – | – | – |
| Insertion of inserts for fins, pads and grab handleAssembly | – | – | – | – | – |
| Quality inspection: precise measurement of the core, checking for unevenness, fibre residue andTesting | – | – | – | – | – |
| Polyfusion® technology (thermal welding of the Exo LT panels made of ALUULA™ 98 under highJoining | – | – | – | – | ALUULA™ 98 (Exo LT) |
| Handcrafted custom board manufacturing (kiteboard manufactory)Plastics | – | – | – | 1 | Paulownia wood, Cartan carbon |
Additional services
History
- 2001
Founding of CARVED in a garage on Fehmarn; first custom board 'Imperator'; one of the first kiteboard manufacturers worldwide
- 2007
Launch of the CORE brand: development and distribution of premium kites, bars, boards and foils
- 2019
CARVED twintips have been manufactured at Elan in Slovenia since 2019