Production process
How your racket is made
From carbon weave to the final coat of lacquer: this is how a MerchPadel racket comes to life. First what we do with your design, then every step in the factory. Your design is only printed once you have approved the print proof.
In short
- A 3K, 12K or 18K carbon face with an EVA foam core: medium on the 3K, hard on the 12K and 18K.
- 52 holes of 12 mm, drilled before printing. That is why they are on your print proof.
- Your design: full-colour digital UV print on both faces, under a protective clear coat.
- Finish of your choice: matte, gloss or gloss with a sand texture, at no extra cost.
- Print proof within 1 working day. Nothing is printed until you approve it.
- From approval to your door: 3 to 5 weeks.
What we do before the factory starts
The most important work on your racket happens before anything is printed: making sure the design is right.
Your design
You design it yourself in the editor, with the print area and the holes in view. Or you send your logo or idea and our designer makes it for you.
Print proof within 1 working day
We put your design on the racket and email you a digital print proof within 1 working day, with all 52 holes drawn in. So you can see exactly whether a hole falls through a letter or a logo.
Your approval
Only when you approve the proof does your order go to the factory. Want something changed? We adjust it and send you a new proof.
Check against the template
We place the approved file on the factory template one more time. If anything is off, you hear it from us before anything is printed.
In the factory: eight steps
The racket itself is made by our regular production partner: a factory that makes carbon padel rackets, for other brands as well. The first steps make the racket; from printing onwards it becomes your racket.
- Step 1
Preparing the materials
The carbon weave, the EVA foam core and the epoxy resin are prepared. The 3K gets a medium core, the 12K and 18K a hard one. The number stands for the fibres per yarn in the weave, 3,000, 12,000 or 18,000: the higher, the coarser the weave.
- Step 2
Building it up layer by layer
The carbon is laid in layers around the EVA core, following a fixed build for each model. The resin will bond the layers into one piece. This build largely decides how the racket feels.
- Step 3
Shaping in the mould
The layers go into a closed mould in the shape of the racket: the teardrop with the closed throat. There the resin cures and the racket becomes one solid piece. After demoulding, a first check for visible faults follows.
- Step 4
Deburring, sanding and painting
Excess material along the mould seam is removed. The racket is sanded, small imperfections are filled and it is wet sanded. Then come the primer and the base colour: the smooth surface for your design.
- Step 5
Drilling the holes
52 holes of 12 mm are drilled in the face, in a straight grid of 22 mm centre to centre: rows of 4, 6, 8, 8, 8, 8, 6 and 4. The holes and the surface are then cleaned. So the holes are already there when your design is printed.
Render - Step 6
Your design goes on
Now it becomes your racket. Your design is printed in full colour with UV ink, on both faces. UV light cures the ink instantly. Where there is a hole, there is no ink: exactly as you saw on the proof.
Render - Step 7
The finishing coat
A clear coat goes over the print to protect your design. It also decides how the racket looks and feels: matte, gloss, or gloss with a sand texture, a fine rough grain for more spin. All three at no extra cost.
Render - Step 8
Grip, inspection and packing
The grip is wrapped around the octagonal handle. The racket is then checked for size, weight, finish, the holes and the print, among other things. Only then is it packed and shipped.
Render
What is inside your racket
A cross-section of the head. Both sides have the same build, so your design can go on the front and the back.
- Finish: matte, gloss or sand
- Your design (UV print)
- Primer and base colour
- Carbon: 3K, 12K or 18K
- EVA foam core
- 12 mm hole
And then to you
Shipping
The racket is packed well and sent to you. What shipping costs and how it works is on the shipping page.
How long it takes
From your approval of the proof to your door: 3 to 5 weeks. Express delivery is faster, at an extra cost.
Questions about how it is made
- Who makes my racket?
- Our regular production partner: a factory that makes carbon padel rackets, for other brands as well. We handle the design, the proof and the check against the template; the factory makes and prints the racket.
- Why are the holes on my print proof?
- Because they are already there when your design is printed. The factory drills the 52 holes before printing, and no ink lands there. So the proof shows exactly what will be visible of your design, and you can still move a text or logo.
- Can I see my racket before it is made?
- Yes. Within 1 working day you get a digital print proof with the holes drawn in. Nothing is printed until you approve it; until then you can still make changes.
- What is the difference between 3K, 12K and 18K?
- The number stands for the fibres per yarn in the carbon weave: 3,000, 12,000 or 18,000. The higher, the coarser the weave. The biggest difference in feel comes from the core: the 3K has a medium EVA core, the 12K and 18K a hard one.
- Does the print stand up to play?
- The print sits under a clear coat that protects it. A hard knock against the wall or the ground can damage the lacquer and the print, as with any printed racket.