MSL Fusion Construction

Monocoque Structural Laminate (MSL) fusion construction is the industry leader when it comes to manufacturing process'. It is used as the construction method of choice for premium inflatable stand up paddle boards. Boards made with this advanced technology and manufacturing process have the best of both worlds when it comes to durability and performance.

Starting from the drop stitching, how the PVC is added is what makes up the different construction methods. Basic single layer boards are made by hand applying a layer of soft PVC to coat the drop stitch core. This construction is generally seen in lower end boards as it requires the least amount of material and specialized equipment. Due to only relying on one layer of soft PVC to keep the drop stitching core airtight, they can be less durable. Single layer boards will also have more flex to them and don’t perform as well.

Double layer boards are made by gluing an additional layer of more rigid PVC on top of that first layer, coating the entire paddle board a second time. This results in a board that is far more rigid and durable, however much heavier. It also can introduce air pockets and cosmetic flaws during the gluing process and is vulnerable to delamination as the adhesives break down. 

This brings us to MSL Fusion construction that provides the best of both worlds. MSL fusion does away with hand applying the first layer of soft PVC. Instead, the drop stitch core is covered in a strong adhesive to act as the first layer. That is followed by a second layer of strong rigid PVC. This is much like the PVC used in the second layer of traditional dual layer boards, however it is machine laminated and fused onto the board. This eliminates any potential imperfections of the hand gluing process and gives the board a perfect cosmetic finish and look. Just like double layer construction, rigidity, strength and durability is drastically increased over single layer boards by adding a layer of strong and rigid PVC. At the same time the board is kept far lighter by using the machine lamination and eliminating the need to first coat the board in a soft layer of PVC. Due to the layer of rigid PVC, this soft PVC layer is redundant and does not serve much purpose on dual layer boards.

For the ultimate in long lasting lightweight durability, Solstice paddle boards is proud to make MSL fusion our premium construction method of choice. It strikes the perfect mix between maintaining a lightweight construction similar to single layer boards, while providing the strength, durability and rigidity of dual layer boards.

Why We Love MSL Fusion

Durability - Having the added layer of hardened PVC laminated to the board increases durability without the need for redundant layers and adhesives. This ensures your board will perform great and maintain a flawless cosmetic finish for a long time to come.

Lightweight - The fusion process cuts out the excess weight to keep your board light for packing in, while maintaining high performance rigidity and durability.

Rigidity - With the added hardened PVC layer machine laminated to the board, it gives a hardboard like feel for performance you can rely on.



1 - Nylon Drop Stitch: The key to inflatable boards that deliver hardboard-like stiffness. Tens of thousands of threads woven together that lock in place, allowing the board to be inflated to rock hard pressure and maintain the perfect desired shape

2 - Base Cloth: This layer contains the nylon drop stitching that makes up the core of the board

3 - Adhesive Coating: This helps prep the base cloth for the additional PVC layer

4 - Hardened PVC Layer: PVC layer that becomes fused with the board during the lamination process

5 - Inner Side Rail: Heat pressed seam to create an airtight and waterproof seal along the side edge of the board

6 - Outer Side Rail: Second side layer that provides added protection against UV rays and scratches

7 - Large EVA Deck Pad: 5mm EVA deck pad. Great comfort and cushion underfoot that’s non-abrasive and extremely durable