Material Pre-treatment and Layup Design. Modern rackets primarily utilize carbon fiber. The process begins with a layup design where carbon fiber sheets are arranged in specific orientations (such as 0°, 45°, and 90°) and impregnated with resin. The specific layup configuration determines the racket's torsional rigidity, elasticity, and stability; this step is central to the structural design.
Molding and High-Temperature, High-Pressure Curing. Pre-impregnated carbon fiber materials are placed into a metal mold. Through a combination of heat and high pressure-akin to a "bake-and-press" process-the material cures and takes shape within the mold, forming the basic structure of the racket frame and shaft. This stage determines the racket's weight and uniformity, as well as the presence of any internal air bubbles or structural defects.
Trimming and Assembly. Once molded, the racket undergoes finishing processes such as edge trimming, sanding, and drilling, followed by the assembly of the frame, shaft, and grip. Finally, the racket undergoes painting, labeling, and quality inspections-including weight balance and tensile strength (string tension) tests-to ensure it meets factory standards.
The manufacturing process for badminton rackets is essentially a fusion of materials science and precision engineering; the more refined the process, the more reliable the racket becomes in terms of stability, consistency, and performance.