The Right Pickleball Paddle Construction Will Change Your Game: Cold Pressed vs. Thermoformed and More
When choosing a pickleball paddle one of the most important and least understood aspects is how the paddle is constructed.
The manufacturing process behind a paddle impacts its power, durability, feel, and performance consistency. In this guide, we’ll break down four of the most common paddle construction methods. Each has its own pros, cons, and role in the modern paddle market.
Table of Contents
Why Paddle Construction Matters
How a paddle is built determines how well its layers bond together, how energy transfers through the face, and how long it holds up under pressure. In many ways, the construction method is the foundation of paddle performance.
A poorly made paddle might feel great for a few games, but break down quickly or become inconsistent. A well-built paddle delivers reliable performance, shot after shot.
Coldpressed Paddles
Coldpressing involves bonding the face and core of a paddle at room temperature using high pressure. This method has been around for years and is commonly used in traditional paddle manufacturing.
Key Characteristics:
- Paddles are pressed without heat
- Creates a consistent and predictable feel
- Internal layers may be bonded together with glue
Pros:
- Reliable performance with solid control and feel
- More affordable than thermoformed options
Cons:
- May lack the power boost found in thermoformed paddles
- Lower durability compared to seamless thermoformed designs
- Edges and layers may separate over time under heavy use which is called delamination
Best For: Players prioritizing control, affordability, and consistency over raw power.
Thermoformed Paddles
Thermoforming uses heat and pressure to fuse the paddle’s components into a single, cohesive structure. This newer manufacturing technique is especially popular among high-performance paddles, especially those made with raw carbon fiber faces.
Key Characteristics:
- Heat softens materials so they can be molded into one seamless piece
- Paddle edges are often foam-injected for added stability and sweet spot
- Provides improved power and durability
Pros:
- Stronger bonds between layers mean better structural integrity
- Enhanced power due to a stiffer, more reactive face
- Uniform feel across the entire hitting surface and tends to have a larger sweet spot
Cons:
- More expensive to produce
- Stiffer feel may reduce touch or soft game finesse
Best For: Players looking to improve power and paddle longevity, especially in high-speed play.
Internal Pressure Molded Paddles
Internal Pressure Molding is an advanced construction process where the paddle is formed inside a mold with both heat and internal pressure applied. This technique produces paddles with perfect structural uniformity, eliminating weak points and increasing longevity.
Key Characteristics:
- Heat and pressure are applied from inside the mold
- Creates a true one-piece paddle with no glue seams or edge separation
Pros:
- Maximum durability and structural consistency
- Reduces chances of delamination or breakage
- Delivers uniform response across the paddle face
Cons:
- Typically the most expensive construction method
- Still relatively new, with fewer paddles using this technique
- Can feel firmer or stiffer than traditional builds
Best For: Players who want long-term durability with minimal risk of paddle breakdown.
Crushed Thermoformed Paddles
Crushed thermoforming isn’t a manufacturing method by design, it’s what happens when a paddle is over-compressed during the thermoforming process, often unintentionally.
This compression can collapse the internal honeycomb structure, resulting in a trampoline effect that dramatically increases power output. Often referred to as a “pop” or “springy” feel.
Key Characteristics:
- Caused by excessive pressure during manufacturing
- Increases power, but sacrifices feel and consistency
- Can lead to durability issues and may violate tournament regulations
Pros:
- Enhanced shot speed and power
- Favored by some players who like a springy paddle
Cons:
- Paddle may feel unstable or overly reactive
- Poor durability and higher chance of internal breakdown
- May be non-compliant with USAPA or tournament guidelines due to excessive trampoline effect
Best For: Players chasing raw power but willing to sacrifice control, reliability, and the ability to play in tournaments.
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Paddle Break-In Periods and Delamination: What to Know
Break-In Period: What to Expect from a New Paddle
Most modern paddles especially those made with thermoformed construction have a short break-in period. This is the time it takes for the paddle to settle and reach its optimal feel after a few hours of play.
During break-in:
- The paddle may slightly soften or have improved dwell time causing you to gain more spin and power
- Sweet spot responsiveness can improve as the materials stabilize
- The overall feel becomes more predictable and consistent
Typically, a paddle feels its best after 5 to 10 hours of play. However, break-in should not drastically alter how the paddle performs. If it does, it may be a sign of structural issues rather than normal wear.
What Is Delamination?
Delamination occurs when the bonded layers of a paddle begin to separate or come apart and is common in coldpressed paddles. This is a serious manufacturing defect or result of wear, and it significantly affects how the paddle performs.
Signs of delamination:
- A hollow or clicking sound when hitting the ball
- Inconsistent bounce or “dead spots” on the paddle face
- A visible gap between the surface layer and the core
- Sudden loss of control or power, or unusual vibrations
Delaminated paddles are considered damaged and non-compliant for tournament play. In some cases, delamination can occur prematurely due to:
- Over-compression during thermoforming or crushed cores
- Poor quality control during cold-pressed or glued paddle production
- Extreme heat exposure (like leaving a paddle in a hot car)
Final Thoughts: Why Construction Should Guide Your Paddle Choice
Pickleball paddle construction is one of the most underrated but important factors in performance and paddle lifespan. It influences how your paddle feels on every shot and how long it lasts before breaking down.
- Coldpressed paddles are best for players focused on control and reliability
- Thermoformed paddles are ideal for those seeking power and durability
- Internal pressure molded paddles offer the highest structural quality
- Crushed thermoformed paddles deliver explosive power but come with significant trade-offs in control and longevity
Understanding the differences in construction helps you make a smarter investment. One that aligns with your game goals and playing style.