FUNNER Surf’s up and it’s 3D printed

Surfer Eddie Rosenberg came to a life-changing realization in 2022 after a brand new surfboard suffered from pressure dings—a surfing term referring to compacted foam caused by the pressure from feet or knees. Reflecting on his frustration at the dinged-up board, he realized how incongruous it was to a) be so attached to an object made of foam and fiberglass and b) to be introducing these artificial and potentially polluting materials into the ocean, when surfing is really about being at one with the water. As he says on his website: “That question turned into an obsession with surfboard construction—exploring new methods to eliminate the toxic styrene foams and carcinogenic resins that dominate the surf world.” Thus, FUNNER Surf Craft was born.

The Oregon-based surfboard startup seeks to introduce new methods for producing surfboards that prioritize sustainability and performance: two things that matter to the surfing community. Traditionally, surfboards are made from a foam core coated in fiberglass and resin layers. Not only are these materials derived from non-renewable resources, but the production process, which involves sanding the resin and fiberglass coatings, generates particulate matter and harmful VOCs.

Rosenberg’s goal was, therefore, to find more sustainable processes and materials for constructing a surfboard just as sea-worthy as its foam counterpart. In just a few years since its founding, FUNNER Surf Craft has achieved this goal, using a combination of innovative production methods, like 3D printing and CNC machining, and sustainable materials to make a series of wave-friendly and affordable surfboards.

The key innovation developed by FUNNER Surf Craft is the Air Core, a hollow frame for the surfboard made using FDM 3D printing and recycled PETG. To make the board, this Air Core is encapsulated with renewable Paulownia wood decking, which is CNC machined to shape and internally laminated with natural basalt cloth and a bio-based epoxy, eliminating the need for fiberglass from the board’s construction. Finally, the external wood surfaces are infused with waterproof, plant-based oils with no VOCs.

Bringing 3D printing to surfing

After first hearing about FUNNER Surf Craft and its innovative Air Core approach, we were eager to learn more. After all, we always want to hear about the creative ways that additive manufacturing and sports intersect. Here is our conversation with founder Eddie Rosenberg about his company’s sustainable mission and how 3D printing has come to play an integral role in his surfboard production:

VoxelMatters: In your journey, at what point did 3D printing become a clear solution for constructing surfboards?  

Eddie Rosenberg: The surf industry has long relied on toxic materials like polyurethane foam and polyester resin, resulting in fragile boards with a heavy environmental impact. Seeking a better alternative, we turned to 3D printing. It allowed us to create hollow Air Cores from recycled polymers, eliminating toxic materials while enhancing strength,  buoyancy and sustainability.

VM: And what advantages does 3D printing offer compared to traditional surfboard production methods?  

ER: Our 3D printed Air Cores deliver a trifecta of benefits: performance, sustainability and manufacturing efficiency.

One of the biggest environmental breakthroughs is eliminating traditional fiberglassing.  Conventional boards rely on petroleum-based fiberglass and resin for durability and waterproofing—materials that emit toxins, create hazardous waste, and require intensive labor.

By integrating 3D printing, we eliminate the need for fiberglass encapsulation. This reduces our environmental impact, simplifies production, and results in stronger, more sustainable, and more cost-effective boards.

VM: Do you 3D print in-house?  

ER:  All design and manufacturing happen in-house. This ensures tight quality control, fosters continuous innovation and reduces transportation emissions and waste— aligning with our commitment to sustainability.

VM: Have you encountered any challenges in using 3D printing for this application?  

ER: Absolutely. Early on, we realized that fully 3D printing an entire surfboard wasn’t practical due to weight and print time. Traditional foam blanks are light, and while 3D printing offers precision and efficiency, printing a whole board, especially one strong enough to eliminate fiberglassing, would be too heavy and slow to manufacture.

Our solution was the Air Core design—a fusion of 3D printing and CNC woodworking.  Our 3D printed parabolic rail structure provides durability and precision, while CNC machined Paulownia wood skins, reinforced with basalt, flax and bio-epoxy, create a high-strength, lightweight outer shell.

By merging additive and subtractive manufacturing, we’ve streamlined board-building,  making it stronger, more sustainable and more efficient—without compromising quality.

VM: Do you use 3D printing for anything else in addition to the Air Cores?  

ER: Right now, our primary focus is Air Cores, but we’re actively exploring 3D printed fins, board racks and other accessories.

VM: How receptive has the surf world been to using new production methods like 3D printing?  

ER: The surf community increasingly embraces innovation, especially when sustainability and performance go hand in hand.

One reason for this adoption is our proprietary algorithm, which makes it seamless for shapers to work with us. Starting with industry-standard shaping programs like Shape3D, AKU Shaper and The Shaper Bay, we can instantly convert nearly any board design into our construction method. Shapers don’t need to learn new software or change their process—they shape, and we take care of the rest.

By making it easy to integrate our 3D printing technology, we’re ensuring that more boards are built in a way that’s better for surfers and the planet.

FUNNER Surf Craft and the future of surf

Ultimately, as the sport of surfing rises in popularity, particularly in the North West where FUNNER Surf is based, the company seems well-positioned to help surfers transition to more sustainable options without sacrificing—and even improving—the quality of their ride.