Construction methods and materials
affect durability, weight, strength and cost.
Kayak Construction

Current Designs touring kayaks are produced using one of three manufacturing technologies, vacuum-bagged composite lamination, rotational molding, or our new Thermoformed Composite System (TCS™). Each of these methods provides unique benefits that influence factors including weight, strength, durability, and price.

Vacuum-bagged composite lamination
Vacuum-bagged composite lamination is the technology that Current Designs chose over twenty years ago for its superior properties. Originally developed by the aerospace industry to manufacture ultra-light, superbly strong components, Current Designs has been refining that same process ever since to deliver the lightest, strongest, and most durable kayaks available.

Today we are the recognized industry leader in this field. Vacuum-bagged composite lamination uses high pressures to eliminate any excess resin that would otherwise add weight and reduce strength of the finished kayak. This process also enables us to use specialized targeted reinforcements that offer superior structural benefits and to design in additional strength without adding substantial weight.

The result of our composite laminate construction is a kayak that is light-weight, extraordinarily tough and highly-durable. The exquisite finish of our vacuum-bagged composite kayaks gave rise to our tag line, "A work of art, made for life."

We offer three laminates -- fiberglass, Kevlar® and composite hybrid for some models. Each material offers unique benefits to the discriminating paddler.

Fiberglass laminate
Our vacuum-bagged fiberglass laminate is a notch above most other fiberglass products on the market. Vacuum-bagging allows us to select and place reinforcing materials to provide the optimal strength and stiffness properties without adding unnecessary weight. The result is a superbly crafted composite kayak that's impeccably finished inside and out.

Kevlar® laminate
We use only the best Kevlar® from Dupont, Kevlar® 49, to offer a kayak even lighter than fiberglass. You'll notice the lightness of our Kevlar® kayaks the first time you pick one up Ð and appreciate its easy lift on and off the car and its nimble feel on the water.

Hybrid laminate
We offer several models in fiberglass/ Kevlar¨ hybrid laminate for reduced weight at a lower cost.

Thermoformed Composite System (TCSª)
This is a breakthrough technology we've developed for our line of recreational touring kayaks. Our TCSª kayaks are made with high-performance thermoplastic sheets which, with the careful application of heat and vacuum, creates a kayak that outperforms most other plastic models. The sheets are made of co-extruded high impact acrylic over premium impact ABS. They feature the high gloss and light-weight of a traditional composite kayak, and the ruggedness of high impact plastic.

Compared to any polyethylene kayak, these hulls are stiffer, the material is three times harder, and has glossy, highly weatherable colors that resist fading. They also have higher heat resistance than polyethylene kayaks and will hold their shape, even in the hottest sun. TCS™ has terrific memory and readily springs back to its original shape after impacts (as with most plastics, temperatures approaching 0° F. will adversely affect its resiliency.) TCS™ kayaks are built with UV inhibitors and the deep gloss colors look great for years to come.

Rotational molding
Rotational molding uses high temperature to melt polyethylene powder in a closed rotating metal mold to produce a complete kayak hull and deck in a fraction of the time required for other construction methods. Our rotomolded polyethylene models offer paddlers the ability to enjoy many of the unique benefits of our designs at a economical price.

We've taken rotomolding to the next level with our own high-tech process controls to produce the lightest possible rotomolded kayaks. We use linear high density polyethylene in all of our rotomolded models to maximize stiffness without sacrificing impact strength. Our polyethylene maintains its integrity over a broad temperature range and has added stabilizers giving it increased protection from harmful ultraviolet rays.