Foam Selection

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US Blanks offers 3 foam selections: Polyurethane, Block-Cut Expanded Polystyrene, and Superfused Expanded Polystyrene.

Polyurethane (PU)

US Blanks manufactures a water blown, Toluene Diisocyanate based polyester polyurethane blank. We feel this combination provides the best physical properties required by a surfboard, resulting in the strongest blank possible, and yields the best performance qualities. The quality, stability, and consistency of a TDI based polyurethane blank has long made it the choice of the majority of board builders.

While there are many formulations available for a TDI based blank, we believe our formulation provides the optimum strength while maintaining ease of shaping and maximum flex. We are continuously fine tuning our formulation to supply the shaper with a blank that exceeds industry standards for these characteristics.

To provide a truly custom polyurethane blank, we offer several densities for most blank sizes. Please reference our DENSITY SELECTION to learn more about weights available.

Expanded Polystyrene (EPS)

US Blanks offers 2 types of EPS foam; Superfused Molded and Block-Cut.

Superfused Molded blanks are available in 6 different sizes, 2 densities (1.5 pcf and 2.0 pcf), and several different thicknesses offering the shaper a wide variety of options. The molding process also provides tighter fusion and cell structure than traditional EPS blanks, although not as tight as traditional PU blanks.

Block-Cut EPS blanks are available in 2 stock densities (1.5 pcf and 2.0 pcf), with a 3rd (1.0 pcf) available via custom order. Block-Cut EPS blanks are available in any range and size up to 16’ long, 3′ tall, and 4’ wide. Every blank within our catalog is available as Block-Cut EPS. Custom cut files may be submitted in either Shape 3D or AKU Shaper formats.

Superfused EPS and Block-Cut EPS Comparison

Superfused EPS and Block-Cut EPS Comparison