How padel rackets are made: A peek behind the scenes

Ever wondered how your padel racket is made? From the design table to the padel court, it takes a lot of work and expertise. Let's take a closer look at the process, focusing particularly on a crucial part - the EVA core.

What is an EVA Core?

EVA stands for ethylene-vinyl acetate, a lightweight yet durable foam material that forms the core of a padel racket, giving it its feel and characteristics. EVA cores come in different densities, affecting the racket's feel and performance.

Step 1: Design and Material Selection

Before manufacturing begins, the racket's design is determined, and materials are chosen. Advanced design software is used to create the racket's appearance and characteristics, while careful research is done to select the best materials for each part.

Step 2: Core Manufacturing

The EVA core is the heart of the racket. It's made by mixing and shaping the foam to the desired density. Even compression and the right density are crucial for the racket's feel and performance.

Step 3: Layering and Lamination

Next, the outer layer of the racket is applied. This can be different materials depending on the racket's design and desired characteristics. Carbon fiber is common for its strength and lightness.

Step 4: Molding and Processing

Once all layers are applied, the racket is molded to the desired shape and size. This is usually done using presses and molds that give the racket its final appearance.

Step 5: Finishing and Quality Control

After molding, the racket is finished by adding the handle and any decorations or logos. Before leaving the factory, it undergoes thorough quality control to ensure it meets high standards.


Manufacturing a padel racket is a complex process that requires precision and expertise. By using high-quality materials and careful manufacturing, manufacturers can offer rackets of the highest quality to padel players worldwide.

And did you know? Starvie produces all of their rackets in their own factory, located in Azuqueca de Henares, Guadalajara, Spain. This assures quality through the whole process and a result of high end products for all hard games!

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