A padel racket consists of far more than carbon and foam. Behind every model lies an elaborate manufacturing process in which materials, construction, and workmanship are precisely coordinated.
From the first carbon fabric to the finished racket, every model goes through numerous production steps. The goal is always the same: a racket that delivers exactly the playing feel on the court for which it was developed.
Let's take a look behind the scenes.
Step 1: Selecting the Materials
Every racket begins with the selection of its components.
Depending on the model, different materials are combined:
- Carbon fibers
- EVA core
- Frame construction
- Surface structure
- Grip system
Each model receives its own individual tuning.
A control-oriented racket requires different properties than a model designed for maximum power.
Step 2: Preparing the EVA Core
The heart of every racket is the EVA core.
Depending on the desired playing feel, different hardness levels are used:
- Soft EVA
- Medium EVA
- Hard EVA
The core later largely determines comfort, ball feel, and feedback on impact.
Already at this stage, it is decided whether a racket should play more comfortably, in a balanced way, or particularly directly.
Step 3: The Carbon Construction
The EVA core is then wrapped in several layers of carbon.
Depending on the model, different carbon fabrics are used:
- 3K Carbon
- 8K Carbon
- 12K Carbon
- 18K Carbon
The carbon layers are precisely positioned and later form the hitting surface as well as large parts of the racket structure.
This is where an important part of the final playing feel is created.
Step 4: Building the Frame
The frame forms the foundation of the racket.
It provides:
- Stability
- Durability
- Torsional stiffness
- Control
At this point the fundamental structure of the racket takes shape, which must later withstand the stresses of volleys, smashes, and fast exchanges.
Step 5: Molding Under Pressure and Heat
Once all components have been prepared, they are placed into special molds.
Under controlled pressure and high temperature, the following bond together:
- Carbon
- Resin
- EVA core
into a stable unit.
This step largely determines the later strength and quality of the racket.
Step 6: Drilling the Hitting Surface
After curing, the racket receives its characteristic hole pattern.
The holes influence:
- Weight
- Balance
- Aerodynamics
- Playing feel
Each model is individually tuned to its construction.
Step 7: Sanding and Finishing
Now the fine processing begins.
The surface is prepared and refined.
Depending on the model, the following finishes are created:
- Sandy Finish
- 3D structures
- Matte surfaces
In this step, each racket receives its own character and its final look.
Step 8: Painting and Design
Now the racket receives its appearance.
Colors, logos, and design elements are applied and sealed.
From the individual components, the finished product now emerges – the one that will later be used on the court.
Step 9: Assembling the Grip and Accessories
Finally, the following are assembled:
- Grip tape
- Wrist strap
- End cap
assembled.
Only now is the racket fully ready for use.
Step 10: Quality Control
Before a racket is shipped, a final inspection takes place.
Among the things checked are:
- Workmanship
- Surface
- Weight
- Appearance
- Overall impression
Only rackets that meet our requirements are then released for sale.
Why Every Detail Matters
Many players focus exclusively on individual features such as carbon or EVA when buying a racket.
In reality, however, the playing feel only arises through the interplay of all components:
- Shape
- Balance
- Carbon
- EVA core
- Surface
- Weight
That is why at Aurex we develop every racket as a coordinated overall package.
Because it is not a single technology that makes a great racket – but the right combination of all the details.
From Material to Playing Feel
Every Aurex racket is developed with one clear goal:
To give players exactly the playing feel that matches their style.
Whether control, versatility, or maximum power – behind every model lies a well-thought-out development and manufacturing process.
Because in the end it is not just about how a racket looks.
But how it feels at the very first ball contact.